Harley-Davidson touring motorcycle recall
Maverick - Dec 13, 2009

In accordance with National Highway Traffic Safety Administration’s defect reporting regulations, Harley-Davidson Motor Company, Inc. reported a defect – buckling of the front mounting brackets in a direction that is trying to tear the bracket away from the fuel tank tunnel in the area of the weld – discovered while performing a 30 MPH, 90 degree barrier impact test with a 2010 FLHTK motorcycle on May 28, 2009.  

The identified issue involves 111,569 motorcycles for 2009 and 2010 model year motorcycles manufactured between June 6, 2008 and November 19, 2009. 

The makes/models/model years subject to recall are: H-D/FLHP/2009; 2010 H-D/FLHPE/2009; 2010 H-D/FLHR/2009; 2010 H-D/FLHR SHRINE/2009-2010; H-D/FLHRC/2009-2010; H-D/FLHT/2009-2010; H-D/FLHTC/2009-2010; H-D/FLHTCU/2009-2010; H-D/FLHTCU SHRINE/2009-2010; H-D/FLHTCU W/SC/2009-2010; H-D/FLHTCU4-CVO/2009; H-D/FLHTCUSE4/2009; H-D/FLHTCUSE5/2010; H-D/FLHTCUTG/2009-2010; H-D/FLHTK/2010; and H-D/FLHTP/2009-2010.

During the post-test evaluation, the vehicle did not meet Harley-Davidson’s internal requirement for fuel containment. Further investigation of the vehicle showed some small tears in the sheet metal of the fuel tank tunnel adjacent to a weld attaching the front fuel tank mounts to the tank.

In June of 2009, for additional analysis, Harley-Davidson retrieved three similar vehicles that had been barrier crash tested. While the reports on the results of these three barrier crash tests did not show any fuel leakage, close study showed similar damage on 2 of the 3 fuel tanks.

During July and August of 2009, Harley-Davidson continued to investigate the nature, scope, and safety consequences of this issue. The company developed a bench test and an analytical model to simulate this failure mode to better analyze the condition observed in the full-vehicle barrier test. This testing and analysis revealed how the buckling and sheet metal tears were the result of frame distortion in a frontal impact, and how the fuel tank reacts to this frame distortion.

As a consequence of sheet metal tear and fuel leak during an accident, a spark provided by an ignition source may result in a fire, which could lead to injury or death to the rider.

From September through early-November, Harley-Davidson conducted further analysis to understand the correlation between the Harley-Davidson 90-degree barrier crash test and real world performance. To date, Harley-Davidson has not received any reports of fire, injuries, or fatalities related to this issue. 

On November 19, 2009, based on the information and analysis developed and provided by the Recall Investigation Committee, Harley-Davidson’s executive management determined that a safety related defect exists on the subject motorcycles and declared a recall to remedy the issue.

Remedy:  Dealers will install a left and a right brace, which are intended to reduce front mount distortion during certain crash conditions. This repair will be performed free of charge. The safety recall is expected to begin on or about December 14, 2009. Motorcycle owners may contact Harley-Davidson at 1-414-343-4056 for further information .