MotorDeets

Harley-Davidson FLHPI problems & recalls

NHTSA records for 1999–2007: 6 recall campaigns and 14 owner complaints. Pick a model year.

199920002001200220032004200520062007

By year

YearRecallsComplaints
199922
200013
200124
200221
200322
200401
200521
200610
200710

What owners complain about (all years)

Engine And Engine Cooling3
Electrical System3
Service Brakes, Hydraulic3
Tires2
Fuel/Propulsion System1
Fuel System, Other1
Exterior Lighting1

Recent recalls

Service Brakes, Hydraulic #08V090000 · 2008 · 5,947 units

Problem: Harley-davidson is recalling 5,947 my 2005-2007 flhp, flhpi, flhtp, flhtpi, flhpe and flhpei police and escort motorcycles equipped with anti-lock brake systems (abs). inconsistencies in the routing of the brake lines can cause abrasion of the brake lines and hoses. in some cases, this condition has caused brake fluid leaks.

Risk: Loss of brake fluid could lead to loss of brake function, which could lead to a crash resulting in injury or death.

Fix: Dealers will inspect and replace the brake lines, if necessary. brake line retention and clutch cable positioning devices will also be installed to prevent future abrasion to the brake lines. the recall began on february 29, 2008. owners may contact harley-davidson at 1-414-342-4680.

Service Brakes, Hydraulic #05V293000 · 2005 · 1,552 units

Problem: On certain police and escort motorcycles, the anti-lock brake system (abs) lines may have been reversed during installation procedures.

Risk: This could cause the front brake to lock up if an abs event is triggered, which could result in a crash,

Fix: Dealers will inspect and re-route the abs brake lines free of charge. the recall began on june 24, 2005. owners may contact harley davidson at 1-414-343-4056.

Exterior Lighting #04V218000 · 2004 · 31,070 units

Problem: On certain dyna, xl, and touring motorcycles, the tail light bulb can fall out of the socket.

Risk: The tail light and the brake light become inoperative, which could lead to a crash.

Fix: Dealers will replace the bulbs. owner notification began on june 3, 2004. owners should contact harley-davidson at 1-414-342-4680.

Electrical System #04V134000 · 2004 · 81,496 units

Problem: On certain touring and police model motorcycles, the 40 amp main circuit breaker can "open" for reasons other than which it was designed, causing an unexpected interruption of all electrical power to the motorcycle.

Risk: This condition could cause the motorcycle to stall, which could result in a crash.

Fix: Dealers will replace the circuit breaker. owner notification began april 23, 2004. owners should contact harley-davidson at 1-414-343-4056.

Exterior Lighting #02V002000 · 2002 · 28,949 units

Problem: On certain motorcycles, the clips that retain the wiring for the front fender tip light can become detached from the fender, causing the wires to fray and short.

Risk: This could cause the lighting system fuse to blow, leaving the vehicle without an operational front fender tip light, headlight, taillight, running lights, and passing lamps (if equipped).

Fix: Dealers will replace the fender tip light wiring harness retention clips, and inspect and replace, if necessary, any damaged wiring harnesses. owner notification began january 9, 2002. owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact harley-davidson at 1-414-342-4680.

Engine And Engine Cooling #99V003000 · 1999 · 14,211 units

Problem: Vehicle description: motorcycles. the engine cam bolt can lose its clamp load and/or break.

Risk: This condition can cause the engine to quit running with or without prior warning. in some instances, the engine could run erratically before quitting.

Fix: Dealers will replace the engine cam bolts and washers.

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 FLHPI.

Clymer Print or online manual

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

Check FLHPI manual
Haynes Print book or online

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

Check FLHPI manual
eManualOnline Download (PDF), keep forever

Downloadable service manuals. Pay once, keep it.

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