NHTSA Complaint #10280058 — 2009 HARLEY-DAVIDSON FXDL

DURING ROUTINE OPERATION OF NEW MOTORCYCLE, NORMAL APPLICATION OF FRONT BRAKE RESULTS IN BRAKE FLUID LEAK AT JUNCTION OF FRONT BRAKE MASTER CYLINDER AND FRONT BRAKE MASTER CYLINDER COVER. BRAKE FLUID ERODES PAINTED SURFACES AT JUNCTION OF MASTER CYLINDER AND MASTER CYLINDER COVER, RESULTING IN FURTHER DEGRADATION OF SEAL. CONSEQUENCES INCLUDE: (A) POTENTIAL LOSS OF ABILITY TO TIMELY AND SAFELY STOP VEHICLE DUE TO INEFFECTIVE FRONT BRAKE; (B) POTENTIAL LOSS OF ABILITY TO TIMELY AND SAFELY STOP VEHICLE DUE TO BRAKE FLUID DRIPPING ON TO FRONT BRAKE DISC; (C) POTENTIAL LOSS OF ABILITY TO PROPERLY CONTROL VEHICLE DUE TO BRAKE FLUID DRIPPING ON TO FRONT OR REAR TIRES; (D) POTENTIAL LOSS OF ABILITY TO CONTROL VEHICLE DUE TO BRAKE FLUID DRIPPING ONTO ROAD SURFACES; AND (E) POTENTIAL FIRE HAZARD DUE TO CONTACT BETWEEN LEAKING BRAKE FLUID AND HOT MOTORCYCLE SURFACES (EXHAUST PIPES, CYLINDER HEADS, ETC.). BRAKE FLUID IS RETAINED BY RUBBER GASKET BETWEEN MASTER CYLINDER AND MASTER CYLINDER COVER. MASTER CYLINDER COVER IS SECURED BY TWO PHILLIPS-HEAD SCREWS THAT COMPRESS RUBBER GASKET. PROPER TORQUE SETTING IS DIFFICULT TO MAINTAIN ON SCREWS. AS SCREWS LOOSEN DUE TO VIBRATION DURING NORMAL OPERATION, THE FLUID LEAK OCCURS. HOWEVER, RETIGHTENING SCREWS COMPRESSES GASKET AND MAY INCREASE AMOUNT OF FLUID LEAK. LEAK IS RELATIVELY SMALL AT PRESENT. I INTEND TO HAVE MASTER CYLINDER, GASKET AND COVER REPLACED BY MANUFACTURER UNDER WARRANTY. *TR