2002 Harley-Davidson Flhpi

Defect. ON CERTAIN TOURING AND POLICE MODEL MOTORCYCLES, THE 40 AMP MAIN CIRCUIT BREAKER CAN "OPEN" FOR REASONS OTHER THAN WHICH IT WAS DESIGNED, CAUSING AN UNEXPECTED INTERRUPTION OF ALL ELECTRICAL POWER TO THE MOTORCYCLE.

Risk. THIS CONDITION COULD CAUSE THE MOTORCYCLE TO STALL, WHICH COULD RESULT IN A CRASH.

Remedy. DEALERS WILL REPLACE THE CIRCUIT BREAKER. OWNER NOTIFICATION BEGAN APRIL 23, 2004. OWNERS SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-343-4056.

Defect. ON CERTAIN MOTORCYCLES, THE CLIPS THAT RETAIN THE WIRING FOR THE FRONT FENDER TIP LIGHT CAN BECOME DETACHED FROM THE FENDER, CAUSING THE WIRES TO FRAY AND SHORT.

Risk. THIS COULD CAUSE THE LIGHTING SYSTEM FUSE TO BLOW, LEAVING THE VEHICLE WITHOUT AN OPERATIONAL FRONT FENDER TIP LIGHT, HEADLIGHT, TAILLIGHT, RUNNING LIGHTS, AND PASSING LAMPS (IF EQUIPPED).

Remedy. DEALERS WILL REPLACE THE FENDER TIP LIGHT WIRING HARNESS RETENTION CLIPS, AND INSPECT AND REPLACE, IF NECESSARY, ANY DAMAGED WIRING HARNESSES. OWNER NOTIFICATION BEGAN JANUARY 9, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-342-4680.

WHILE OPERATING MY MOTORCYCLE, THE ENGINE BEGAN SPUTTERING AND THE ODOR OF GASOINE FUMES BECAME OVERWHELMING. I LOOKED DOWN AT THE AIR INTAKE AND NOTICED GASOLINE SPRAYING ON THE ENGINE AND PAST THE AIR INTAKE. IT WAS QUITE FORTUNATE THAT THIS DID NOT RESULT IN A FIRE! THE FUEL LINE HAD SEPARATED FROM THE CONNECTOR ON THE FUEL RAIL AND THE FUEL PUMP WAS SUPPLYING FUEL AT THE FULL DELIVERY RATE. INSPECTION OF THE FUEL LINE SHOWED THAT THE FUEL LINE WAS A HARDENED PLASTIC LINE (COVERED BY A PLASTIC CORREGATED HEAT SHIELD) THAT WAS HELD IN PLACE BY FRICTION ONLY, THERE WERE NO CLAMPS USED. BECAUSE THE FUEL LINE WAS A HARDENED MATERIAL, WITHOUT ELASTICITY OR RETAINING HARDWARE, THE VIBRATION OF THE ENGINE (AND MOST LIKELY THE HEAT AS WELL) DETERIORATED THE ADHESION OF THE CONNECTION RESULTING IN THE SEPARATION. THIS WAS A USED MOTORCYCLE, BUT IT ONLY HAD 638 MILES AND NO EVIDENCE OR RECORD OF MAINTENANCE IN THIS AREA. THE PROBLEM WAS FIXED BY THE DEALER USING HARLEY-DAVIDSON'S PART LIST WHICH INDICATED 1/4" RUBBER FUEL LINE PROTECTED BY A CORREGATED PLASTIC COVERING FOR HEAT ISOLATION, AND TWO CRIMPED HOSE CLAMPS FOR RETENTION, ONE ON EACH END. I HAVE THE ORIGINAL FUEL LINE FOR INSPECTION.*AK