Harley-Davidson FL problems & recalls
NHTSA records for 1990–2001: 6 recall campaigns and 8 owner complaints. Pick a model year.
By year
What owners complain about (all years)
Recent recalls
Service Brakes, Hydraulic #97V227000 · 1997 · 2,012 units
Problem: Vehicle description: motorcycles. the rear brake pedal assembly may have an inadequate weld.
Risk: This condition can allow the lever hub to separate from the master cylinder lever which would affect rear brake performance.
Fix: Dealers will perform the recall service on these vehicles.
Fuel System, Gasoline #96V204000 · 1996 · 176,515 units
Problem: The effects of reformulated gasoline along with certain usage of the fuel supply valve affects the supply of gasoline to the carburetor. this condition requires two factors: (1) the use of reformulated fuels containing mbte and (2) starting the motorcycle with the fuel valve handle in the off position.
Risk: This condition can cause the fuel flow to be unpredictable thus causing the engine to shut down increasing the risk of a motorcycle accident.
Fix: Dealers the replace the diaphragm in the fuel valve.
Service Brakes, Hydraulic #96V103000 · 1996 · 251 units
Problem: The seal on the rear master cylinder piston can move out of position.
Risk: This condition can result in a loss of rear braking performance increasing the potential for a vehicle accident.
Fix: Dealers will inspect and, if necessary, replace the rear brake master cylinder.
Fuel System, Gasoline #92V173000 · 1992 · 66,046 units
Problem: The fuel inlet needle does not seal properly against the fuel inlet seat.
Risk: The fuel overflow system allows fuel to leak onto theground, which could result in a fire if exposed to a source of ignition.
Fix: Replace the fuel inlet needle.
Electrical System #92V125000 · 1992 · 6,838 units
Problem: The positive battery cables installed as part of harley- davidson's previous recall 077 (nhtsa recall 92v011000) can fail in service.
Risk: Failure of the positive battery cable results in loss ofelectrical system functions of ignition, lights, and accessories.
Fix: Install new replacement battery cables.
Electrical System #92V011000 · 1992 · 34,693 units
Problem: The positive battery cable can chafe because of its proximity to the oil tank, causing a short circuit if the cable should ground.
Risk: The heat from a short circuit could result in a vehiclefire.
Fix: Replace the postive battery cable.
Want the full repair deets? Get the service manual.
Recall and complaint data tells you what goes wrong. A service manual tells you how to fix it: torque specs, wiring diagrams, fluid capacities and step-by-step procedures for the FL.
Motorcycle-specific service manuals with step-by-step procedures (Clymer is part of Haynes).
Step-by-step photos written from a real teardown. Great for first-timers.
Downloadable service manuals. Pay once, keep it.
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