NHTSA Complaint #10386382 — 2007 HARLEY-DAVIDSON FXDB

REAR WHEEL LOCKED UP WHEN ACCELERATING FROM STOP AT TRAFFIC LIGHT. MOTORCYCLE STALLED AND I COULD NOT GET IT TO MOVE FORWARD. THOUGHT BRAKE WAS STUCK, BUT AFTER VISUAL INSPECTION NOTICED ALL THE BOLTS (5) IN THE REAR SPROCKET HAD SHEARED OFF. IT DOES NOT APPEAR THAT THE BOLTS BACKED OUT OF THE WHEEL HUB, BECAUSE PART OF THE BOLTS REMAINED IN THE BOTTOM OF THE THREADED PORTION OF THE HUB. AFTER REMOVING THE WHEEL AND INSPECTING THE DAMAGE IT APPEARS THAT THE STAINLESS BOLTS, ALUMINUM HUB AND LOOSE FITTING HOLES IN THE SPROCKET ALL PLAYED A ROLE IN THE FAILURE. NOTE: TO THE BEST OF MY KNOWLEDGE ALL PARTS ARE STOCK PARTS AND AS INSTALLED BY THE FACTORY. AN INTERNET SEARCH REVEALED NUMEROUS FORUMS ON HARLEY MOTORCYCLES WITH OWNERS COMPLAINING ABOUT THIS FAILURE. I READ FORUM POST FROM 2003 TO FEBRUARY 2011 DISCUSSING THE SHEARED SPROCKET BOLTS, AND REFUSAL FROM HARLEY TO ADDRESS THIS ISSUE. I BELIEVE THIS IS A VERY SERIOUS SAFETY PROBLEM THAT DEMANDS THE ATTENTION FROM NHTSA TO PROTECT THE SAFETY OF THE PUBLIC. I WORK IN THE POWER INDUSTRY AND HAVE WITNESSED ROOT CAUSE FAILURES DUE TO CORROSION OF DISSIMILAR METALS - ALUMINUM AND STEEL, STRESS CRACK CORROSION CAUSED BY HIGH MOISTURE, AND STRESS RISERS CAUSED AT THREADS FROM LOOSE FITTING PARTS FLEXING WHEN TORQUE. ALL OF THESE CONDITIONS EXISTS IN THE DESIGN AND INSTALLATION OF THE SPROCKET AT THE REAR WHEEL INSTALLED ON THIS MOTORCYCLE. I HAVE THE PARTS AVAILABLE FOR INSPECTION AND ANALYSIS IF REQUESTED BY NHTSA AND OR HARLEY DAVIDSON COMPANY. *TR