2005 HARLEY-DAVIDSON TOURING Recalls, Complaints & Safety

FUEL SYSTEM, GASOLINE:CARBURETOR SYSTEM

CERTAIN MOTORCYCLES MAY HAVE BEEN PRODUCED WITH DEFECTIVE FUEL SHUT-OFF VALVES. THE FUNCTIONALITY OF THE 'ON' POSITION AND THE 'RESERVE' POSITION OF THE VALVE MAY HAVE BEEN REVERSED.

Remedy: DEALERS WILL INSPECT THE FUEL VALVE AND REPLACE IT, IF NECESSARY. THE RECALL BEGAN FEBRUARY 7, 2005. OWNERS SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-342-4080.

9,501 vehicles affected

FUEL SYSTEM, GASOLINE:CARBURETOR SYSTEM

CERTAIN FUEL SHUT-OFF VALVES USED AS REPLACEMENT EQUIPMENT, P/NOS 61338-02, 62169-02A, 61338-94D, AND 62169-95C FOR USE ON CERTAIN 2005 CARBURETED SPORTSTERS, DYNA, SOFTAIL, AND TOURING MODEL MOTORCYCLES. THESE VALVES MAY HAVE BEEN PRODUCED WITH THE FUNCTIONALITY OF THE 'ON' POSITION AND THE 'RESERVE' POSITION OF THE VALVE MAY HAVE BEEN REVERSED.

Remedy: DEALERS WILL INSPECT THE FUEL VALVE AND REPLACE IT, IF NECESSARY. THE RECALL BEGAN JANUARY 27, 2005. OWNERS SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-342-4080. IF YOU HAVE HAD OR INSTALLED A REPLACEMENT FUEL SHUT-OFF VALVE IN YOUR MOTORCYCLE, PLEASE TAKE YOUR VEHICLE TO YOUR DEALER TO HAVE THE VALVE INSPECTED FOR PROPER OPERATION AS SOON AS POSSIBLE.

364 vehicles affected

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

ON CERTAIN MOTORCYCLES, A CONDITION OCCURS THAT COULD ALLOW PRESSURE TO BUILD UP IN THE FUEL TANK. ON FUEL INJECTED VEHICLES, THIS CONDITION COULD CAUSE FUEL TO SPRAY OUT UNEXPECTEDLY WHEN THE FUEL CAP IS REMOVED. ON CARBURETED VEHICLES, EXCESSIVE FUEL COULD BE TRANSFERRED TO THE CARBURETOR, WHICH WOULD EVENTUALLY ALLOW FUEL TO DRIP FROM THE AIR CLEANER.

Remedy: DEALERS WILL TEST EACH CANISTER FOR BLOCKAGE, THEN REPLACE AS NECESSARY. THE RECALL BEGAN NOVEMBER 4, 2004. OWNERS SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-343-4056.

2,828 vehicles affected

THE HORN ON MY 2005 HARLEY DAVIDSON FLHTCUI DOES NOT WORK PROPERLY. THE HORN IS VERY MUFFLED AND IS ONLY AUDIBLE FOR APPROX 50 FEET. *8NM

FAULTY HORN ON HARLEY DAVIDSON MOTORCYCLES(FLHT),SAFETY HAZARD,WORKS INTERMITTENTLY. *JB

HORN CONTINUALLY FAILS TO OPERATE. HAVE TAKEN IT TO THE DEALER MULTIPLE TIMES ONLY TO BE TOLD THAT IT IS A CHRONIC PROBLEM WITH 2005 HARLEY DAVIDSON MOTORCYCLES AND THERE IS NO FIX.*JB

THE HORN ON MY BRAND NEW 2005 HARLEY-DAVIDSON ULTRA CLASSIC HAS NOT WORKED PROPERLY SINCE I HAVE HAD THE BIKE AND THE DEALERSHIP WHERE I PURCHASED THE BIKE TOLD ME THAT THEY CANNOT REPAIR THE HORN. *NM

THE HORN ON MY 05 HARLEY DAVIDSON MOTORCYLE DOES NOT WORK. THE DEALERSHIP AND ALL THE OTHER DEALERSHIPS THAT SERVICE HARLEY DAVIDSON'S IN THE AREA KNOW OF NO FIX FOR THE PROBLEM. THEY SAY ALL THE NEW BIKES HAVE DISFUNCTIONAL HORNS AND THE REPLACEMENT PARTS ARE JUST AS BAD. IT IS VERY IMPORTANT TO HAVE A FUNCTIONAL HORN ON A MOTORCYCLE BECAUSE PEOPLE SIMPLY DON'T ALWAYS SEE US AND WE NEED TO LET THEM KNOW WE'RE IN THE LANE THEY ARE TRYING TO OCCUPY. ESPECIALLY IN DC TRAFFIC. *NM

DT: THE CONSUMER STATED WHILE RIDING HIS BIKE, THE CONNECTION PIN CAME OUT OF THE MOUNTING BRACKET AND THE SADDLE BAG DRAGGED ON THE GROUND. HE WAS TRAVELING AT 60 MPH. HE SAYS THERE WAS NO WARNING. THE DEALERS FIRST RESPONSE WAS THIS COULD NOT HAPPEN. THE DEALER WAS ABLE TO DUPLICATE THE PROBLEM. DEALER AND MANUFACTURER WERE CALLED AND HE IS WAITING FOR THEM TO GET BACK TO HIM. HE SAID IT APPEARS THEY ARE NOT COOPERATING WITH EACH OTHER TO RESOLVE THE PROBLEM.*JB UPDATED 11/2/2005 - THE DEALER/MANUFACTURER HAVE SINCE REPLACED THE DAMAGED BAG UNDER WARRANTY. THE CONSUMER WAS UNABLE TO DETERMINE IF THE DEALER INSTALLED THE PIN IMPROPERLY OR IF THE PIN WAS DEFECTIVE. *NM

MOTORCYCLE DEVELOPED A HIGH SPEED WOBBLE,WAS TRAVELING IN NEVADA IR15 AT APPROXIMATELY 90 MPH,HANDLEBARS WENT VIOLENTLY RIGHT AND LEFT. COULD NOT STOP THEM FROM MOVING BACK AND FORTH. MOTORCYCLE FORCED ME TO THE ROAD,FIRST IMPACT WAS THE RIGHT SIDE OF MOTORCYCLE. THE MOTORCYCLE FORCED ME TO THE GROUND. *NM

Crash 1 injured

WHILE DRIVING ON THE INTERSTATE AT APPROXIMATELY 60 MPH THE CRUISE CONTROL STARTED TO ACCELERATE T ON ITS OWN. I COULD NOT GET IT TO TURN OFF UNTIL IT HIT 85 MPH. AFTER THAT THE CRUISE CONTROL WAS INOPERABLE UNTIL THE POWER WAS TURNED OFF. *NM

DT: WHILE TRAVELING ON THE HIGHWAY LOST ALL ELECTRICAL POWER. THEN, POWER RESTORED IN A SHORT PERIOD OF TIME. THIS HAPPENED 3 TIMES. DISCOVERED THAT A GROUNDED WIRING LEADING TO THE FRONT FENDER RUNNING LIGHT RUBBED AGAINST THE TIRE REMOVING THE INSULATION, WHICH RESULTED IN THE FAILURE. TOOK VEHICLE TO DEALER TO DETERMINE WHY VEHICLE LOST ELECTRICAL POWER. WAS UNABLE TO OBTAIN COMPUTER CODES DIAGNOSTICIANS. TOOK VEHICLE HOME, AND THERE DISCOVERED THE WIRING PROBLEM. THERE WAS A RUBBING SOUND AT LOW SPEEDS, INDICATING A WIRING PROBLEM. THERE WAS A PREVIOUS NHTSA RECALL 02V002000 REPAIRS FOR THE SAME REASON AN 2001, HARLEY, BUT RECALL DID NOT APPLY TO 2005 MODEL. 2005. CONSUMER MADE REPAIRS AT HOME. HAD NOT CONTACTED HARLEY DAVIDSON. *AK

BOUGHT VEHICLE BRAND NEW ON 04/08/05. VEHICLE ENGINE PINGS AT NORMAL OPERATING RPM, TOOK VEHICLE TO DEALER, DEALER WAS ABLE TO HEAR NOISE BUT DID NOT KNOW HOW TO FIX, DEALER CONTACTED MANUFACTURE, THEY SENT A REPRESENTATIVE TO DRIVE THE VEHICLE, THE FACTORY REP. SAID THE SOUND WAS NORMAL DUE TO EMISSIONS. I HAVE 2 FRIENDS WHO HAVE SAME YEAR AND MODEL BIKES AND THERE BIKES DO NOT PING. I CONTACTED THE GENERAL MANAGER OF THE DEALERSHIP AND HARLEY DAVIDSON CUSTOMER SERVICE, THEIR RESPONSES WERE IF THE REP. SAID IT WAS NORMAL THEN IT WAS NORMAL. IF NORMAL, WHY DO OTHER BIKES NOT DO THIS, AND I KNOW THAT PINGING IS NOT GOOD FOR A ENGINE. I WOULD NEVER BE ABLE TO SELL THIS MACHINE IN THE FUTURE WITH IT PINGING LIKE THIS, I AM VERY UNHAPPY WITH THIS ANSWER, THE DEALER AND THE MANUFACTURE, I FEEL LIKE I MADE A VERY BAD DECISION IN PURCHASING THIS VEHICLE. IF THE DEALER OFFERED TEST RIDES (WHICH THEY DON'T), I NEVER WOULD HAVE BOUGHT THIS BIKE MAKING THIS NOISE.

2005 HARLEY DAVIDSON SCREAMING EAGLE ELECTRAGLIDE, MOTORCYCLE HAS A HIGH SPEED WOBBLE. ( 70+MPH) EXHIBITED PROBLEM SINCE DELIVERY. MOTORCYCLE HAS AT TIMES TAKEN TWO FULL TRAFFIC LANES TO GET UNDER CONTROL. INVESTIGATION SHOWED STEERING HEAD BEARINGS IMPROPERLY ADJUSTED FROM FACTORY. DEALER HAS NOT BEEN ABLE TO PROPERLY ADJUST. DEALER ACKNOWLEDGES PROBLEM, FACTORY REP DOES NOT SO DEALER REFUSES TO WORK ON THE BIKE WITHOUT FACTORY AUTHORIZATION. LETTERS TO HARLEY DAVIDSON CEO & PRESIDENT GO UNANSWERED.

DT: NEW HARLEY DAVIDSON WHILE DRAINING THE TRANSMISSION FOR SERVICE A PIECE WAS FOUND. TOOK TO DEALER AND DEALER CALLED MANUFACTURER. THE MANUFACTURER SAID THEY WOULD NOT PAY FOR TO FIND OUT WHAT IS WRONG WITH MOTOR CYCLE, AND THEY SAID TO DRIVE IT A FEW MORE THOUSAND MILES TO SEE WHAT HAPPENS. THE MOTOR CYCLE IS STILL UNDER WARRANTY. *NM

DT: WHILE CROSSING AN INTERSECTION (TURNING LEFT) THE CONSUMER LET OUT THE CLUTCH, AND WHILE MOVING FORWARD, THE MOTORCYCLE STALLED AND FELL OVER. PREVIOUSLY, ON ANOTHER, MORE GRADUAL LEFT TURN, THE MOTORCYCLE SIMPLY "COUGHED" AND KEPT GOING. *NM

1 injured

I PURCHASED THIS NEW 2005 HARLEY DAVIDSON ON 1/20/2005. WHILE RIDING ON THE INTERSTATE FREEWAY I ENGAGED THE CRUISE CONTROL. I ATTEMPTED TO DISENGAGE IT SO I COULD ADJUST MY SPEED. THE CONTROLS DID NOT DISENGAGE IT. I USED MY BRAKES, THOSE DID NOT DISENGAGE IT. I PULLED THE CLUTCH, THAT DID NOT DISENGAGE IT BUT THE ENGINE SPEED JUMP UP TO 6500 RPM. WHEN I RELEASED THE CLUTCH MY SPEED INCREASED TO AROUND 85 MPH. I TURNED OFF THE DASH SWITCH AND THAT DID NOT HAVE ANY EFFECT. I TURNED OFF THE MOTORCYCLE AND COASTED TO AN OFF RAMP. I RESTARTED THE MOTORCYCLE AND RODE TO THE DEALER. THE DEALER MECHANIC PUT THE MOTORCYCLE ON TEST EQUIPMENT AND COULD FIND NOTHING WRONG. THEN HE TOOK IT FOR A TEST RIDE. THE CRUISE LOCKED ON FOR HIM ALSO. WHEN HE GOT BACK HE WORKED ON IT SOME MORE UNTIL I NEEDED TO LEAVE AND GET BACK TO WORK. HE DISCONNECTED THE CRUISE AND I RODE HOME. I TOOK IT BACK TO THEM THE NEXT WEEK AND THEY COULD NOT FIND ANYTHING WRONG. THEY HOOKED EVERYTHING BACK UP AND SENT ME AWAY. IF I HAD BEEN IN HEAVIER TRAFFIC WHEN THIS HAPPENED IT COULD HAVE BEEN VERY SERIOUS.