NHTSA Complaint #10038985 — 2002 HARLEY-DAVIDSON ELECTRA GLIDE

I OWN A 2002 HARLEY DAVIDSON FLHTCI MOTORCYCLE. THE BRAKE LIGHT SWITCH HAS FAILED TWICE SINCE I PURCHASED THE VEHICLE IN APRIL OF 2002. THE FAILURE OF THE SWITCH CAUSES THE BRAKE LIGHTS TO STAY ON. AS A RESULT, ANYONE FOLLOWING ME HAS NO WAY OF KNOWING WHEN I HAVE APPLIED THE BRAKES. AFTER THE SECOND FAILURE I REPLACED THE SWITCH AND OPENED THE DEFECTIVE SWITCH UP TO SEE WHAT HAD FAILED. WHAT I FOUND WAS THE MECHANICAL BOD OF THE EXTERNAL CONTACT AND THE INTERNAL SWITCH MOVING CONTACT WAS RESISTIVE. THE RESULTANT HEAT FROM THIS RESTIVE CONTACT HEATED AND WARPED THE INSULATOR DISK. THE DISK WARPED IN SUCH A MANNER AS TO ACTIVATE THE SWITCH. I FOUND OUT FROM THE LOCAL DEALER THAT THEY HAVE SOLD OVER 50 OF THESE SWITCHES SINCE JULY 1ST. THIS IS A VERY HIGH NUMBER EVEN TAKING INTO ACCOUNT THE NUMBER OF RIDERS IN THE AREA FOR THE STURGIS MOTORCYCLE RALLY. I KNOW OF TWO OWNERS WHO HAVE HAD SWITCH FAILURE IN THE PAST YEAR. EVERY FAILURE HAD THE BRAKE LIGHT ON ALL THE TIME. THIS IS A POTENTIALLY VERY DANGEROUS SITUATION, ESPECIALLY ON A MOTORCYCLE. *JB