NHTSA Complaint #10407511 — 2009 BUELL 1125R

REF 2009 BUELL 1125R AND CR COMPONENT: ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR THE STATOR & REGULATOR/RECTIFIER ASSEMBLIES ON THE 2009 BUELL 1125R AND 2009 BUELL 1125CR MOTORCYCLES CREATE A UNCONTROLLED BUILD UP OF ELECTRICAL HEAT THAT CAN CAUSE THESE COMPONENTS TO FAIL. THE STATOR ASSEMBLIES HAVE INSUFFICIENT THERMAL PROTECTION TO HANDLE THE HEAT GENERATED BY THE CHARGING SYSTEM. THIS CAUSES THE ELECTRICAL INSULATION TO MELT TO A POINT WHERE A SHORT CIRCUIT SITUATION IS CREATED AND THE STATOR FAILS. THE REGULATOR/RECTIFIER WAS PRODUCED WITH INSUFFICIENT ABILITY TO DISSIPATE HEAT GENERATED BY THE CHARGING SYSTEM. THIS CONDITION CAUSES EXCESSIVE HEAT WITHIN THE CHARGING SYSTEM AND UNCONTROLLED ELECTRIC CURRENT OUTPUT WHICH CAN RESULT IN INSUFFICIENT CHARGING CURRENT BEING PROVIDED TO THE MOTORCYCLE BATTERY. THIS CAN CAUSE THE DISCHARGE OF THE BUELL MOTORCYCLE'S BATTERY, WHICH CAN LEAD TO STALLING OR A NON-START CONDITION; IF THE MOTORCYCLE'S ENGINE STALLS, IT COULD INCREASE THE RISK OF A CRASH. *TT