2003 HARLEY-DAVIDSON FLHRI

POST-RECALL 25V274 ( & EA25007, EA25001) EXHAUST INTRUSION WITH CARBON MONOXIDE POISONING HAZARD Following the complete engine replacement under GM recall N252494000, my vehicle has developed a severe and persistent exhaust intrusion that allows toxic exhaust fumes, including carbon monoxide (CO), t... o enter the passenger cabin. CO levels have measured a peak of 83 PPM and consistent reading between 20-37 over multiple tests. PATTERN OF POST-RECALL EXHAUST SYSTEM FAILURES Vehicle has been in for service 6 times, over 100 days, as part of the engine replacement plus (metal found in the oil pan). Since recall, the vehicle has had an exhaust smell and noise rattle issue with the following exhaust system components deemed failed and been replaced: 1. Radiator cap (leaking onto exhaust) 2. Exhaust muffler (replaced TWICE - June 2025 and August 2025) 3. Exhaust clamps (leaking) 4. Left exhaust manifold (warped) Critical Finding: Despite replacement of virtually the entire exhaust system, the defect persists. This suggests a fundamental design or installation defect related to the engine replacement procedure, NOT isolated component failures. Documented Carbon Monoxide Levels: Between January 30 and February 3, 2026, I conducted 15+ tests using a professional-grade Klein Tools ET180 Carbon Monoxide Meter. Results: • Peak reading: 83 PPM • Multiple readings: 40-72 PPM sustained for 6+ minutes directly at my [XXX] daughter's car seat position • Testing method: Vehicle started via remote start, CO meter placed in cabin, readings recorded over 10-15 minute periods Health Impacts to Family: • Wife and [XXX] daughter consistently experience dizziness, headaches, and nausea when riding in vehicle • Daughter now refuses to ride in vehicle because it makes her feel sick • Symptoms consistent with carbon monoxide poisoning Independent service station verification on January 30th confirmed "vehicle is dangerous to operate with children inside and needs immediate service." INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMARead more

HARLEY DAVIDSON 2003 FLHRI TOURING MOTORCYCLE. NOTICED FLUID ALONG FRAME NEAR FLOORBOARD MOUNT FOR SOMETIME, WAS NOT SURE WERE IT WAS COMING FROM. ON A RIDE AND BRAKE PETAL WENT ALL THE WAY DOWN, REAR BRAKE FAILURE. BROUGHT BIKE HOME. I REMOVED THE EAR BRAKE LINE TO FIND IT HAD BEEN RUBBING AGAINST ... THE FRAME. HARLEY PUT A THIN PLASTIC SLEEVE IN THE AREA OF THE FRAME WHERE FLOORBOARD MOUNT IS. THE PROBLEM WAS LINE IS ROUTED AGAINST THIS AREA AND RUBBED RIGHT THROUGH METAL BRAKE LINE. BROUGHT TO AMERICAN HARLEY IN LEOMINSTER MASS. GOT NEW LINE AND IT HAD BEEN TOTALLY REDESIGNED. THE NEW LINE IS RUBBER WERE THE ORIGINAL WAS METAL COMING OUT OF MASTER CYLINDER BACK TO JUNCTION BEFORE CALIPER. I RECENTLY CHANGED THE OIL ON MY FRIENDS FLHCI ROAD KING AND HER BIKE HAS BRAKE FLUID ALL OVER THE PLACE IN SAME AREA WHERE THE LINE COMES IN CONTACT WITH FRAME AT FLOORBOARD MOUNTS. HARLEY KNOWS THIS IS A PROBLEM THAT IS WHY PART HAS BEEN TOTALLY CHANGED. I ALMOST LOST MY LIFE ON THIS DAYNOT BEING ABLE TO STOP AT THE END OF WILLIAMS STREET IN UPTON BECAUSE OF SUDDEN BRAKE FAILURE. I HAVE OLD BRAKE LINE AND I PLAN ON CHANGING MY FRIENDS LINE AND COMPARE BOTH. SHE HAS A 2004 TOURING. I INTEND TO MAKE SURE THIS IS ADDRESSED BEFORE SOMEONE IS KILLED. PLEASE TAKE THIS SERIOUSLY . IT IS NOT AN ISOLATED INCIDENT. THANKYOU. *TRRead more

TRAVELING ALONG ON MY 2003 HARLEY DAVIDSON ROAD KING MOTOR CYCLE, LET OFF ON THE GAS AND IMMEDIATLY WENT INTO A SPEED WOBBLE. I LOST CONTROL AND CRASHED. *JB