NHTSA Complaint #10410524 — 2009 BUELL 1125R

THERE IS A DESIGN FLAW IN THE CHARGING SYSTEM OF THE '09 BUELL 1125R AND 1125CR MOTORCYCLES. THE ELECTRICAL STATOR PRODUCES MORE HEAT THAN CAN BE MANAGED AND WILL EVENTUALLY OVER HEAT AND FAIL. THIS FAILURE HAS OCCURRED ON A LARGE PERCENTAGE OF '09 BUELL 1125R AND 1125CR MOTORCYCLES. THE REPLACEMENT PARTS FROM HARLEY DAVIDSON (BUELL'S PARENT) HAVE BEEN BACKORDERED ON MULTIPLE OCCASIONS AS SUPPLY CANNOT KEEP UP WITH THE SUBSTANTIAL AMOUNT OF FAILURES. THERE ARE SAFETY CONSIDERATIONS. WHEN THE FAILURE OCCURS, HEADLIGHTS AND TURN SIGNALS FAIL TO WORK. THE MOTORCYCLE MAY STALL INCREASING THE RISK OF A CRASH. HARLEY HAS ISSUED A 'FIX' IN THE FORM OF A RELAY THAT SHUTS OFF 1/3 OF THE CHARGING SYSTEM. IRONICALLY THE 'FIX' SEEMS TO HAVE INCREASED THE NUMBER OF CHARGING SYSTEM FAILURES. WITH THE 'FIX' IN PLACE THE MOTORCYCLE IS STARVED FOR ELECTRICAL POWER. THERE IS NOT SIGNIFICANT POWER TO KEEP THE BATTERY CHARGED. BRIGHT HEADLIGHT CANNOT BE USED WITHOUT FURTHER DRAINING OF MOTORCYCLE'S BATTERY, ETC. MANY, MANY CASES OF STATOR FAILURES CAN BE FOUND HERE: HTTP://WWW.BADWEATHERBIKERS.COM/BUELL/MESSAGES/290431/290431.HTML?1309888179 PLEASE LAUNCH A DEFECT INVESTIGATION TO DETERMINE THE SERIOUSNESS OF THESE SAFETY CONCERNS. *KB