NHTSA Complaint #10423261 — 2009 HARLEY-DAVIDSON FLHTCU

REAR BRAKE LIGHT PRESSURE SWITCH FAILURE. THE SWITCH WHICH TRIGGERS THE REAR BRAKE LIGHT TO TOGGLE ON WHEN THE REAR BRAKE LEVER IS DEPRESSED IS A HYDRAULIC PRESSURE SWITCH. THIS SWITCH FAILED ALLOWING BRAKE FLUID TO PASS THROUGH THE SWITCH AND SPRAY OUT THE END WHERE THE TERMINALS ARE ATTACHED. THIS SPRAYING FLUID CAUGHT FIRE DUE TO THE HEAT OF THE EXHAUST PIPE WHICH IS CLOSE BY. BIKE WAS SITTING AT A LIGHT WHEN I SMELLED SOMETHING BURNING. A RIDING BUDDY NOTICED A SMALL FIRE LOCATED JUST BELOW THE RIGHT SIDE PASSENGER FLOORBOARD. I WAS STOPPED AT THE TIME WAITING FOR THE LIGHT TO CHANGE. NOTICING THE FIRE WE SAFELY PULLED OVER TO A SIDE-STREET AND I EXTINGUISHED THE FIRE WITH A BOTTLE OF WATER I WAS CARRYING. I NOTICED WHAT THE PROBLEM WAS WITH THE SWITCH BY GENTLY DEPRESSING THE BRAKE LEVER WITH MY HAND AND FLUID DRIPPED OUT. I ALSO NOTICED WHEN I WAS PULLING THE BIKE OVER TO A SAFER LOCATION THAT I HAD LOST THE REAR BRAKE COMPLETELY; THIS, DUE TO A BREACH IN THE OTHERWISE CLOSED BRAKE SYSTEM. THE FIRE BURNED THE WIRES WHICH ATTACH TO THIS PRESSURE SWITCH. I WAS ABLE TO MOTOR UP TO AN AUTO PARTS STORE, REMOVE THE SWITCH (1/8" NPT THREAD) AND PUT A PLUG IN SO I COULD RIDE WITH TWO BRAKES. THERE WAS NO HARLEY DEALER CLOSE BY TO MY LOCATION. *TR