MotorDeets

Harley-Davidson FL problems & recalls

NHTSA records for 1990–2001: 6 recall campaigns and 8 owner complaints. Pick a model year.

199019911994199519961997199820002001

By year

YearRecallsComplaints
199030
199110
199411
199511
199623
199710
199810
200001
200102

What owners complain about (all years)

Electrical System4
Fuel System, Gasoline2
Equipment1
Engine And Engine Cooling1

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.

Clymer Print or online manual

Motorcycle-specific service manuals with step-by-step procedures (Clymer is part of Haynes).

Check FL manual
Haynes Print book or online

Step-by-step photos written from a real teardown. Great for first-timers.

Check FL manual
eManualOnline Download (PDF), keep forever

Downloadable service manuals. Pay once, keep it.

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