Harley-Davidson XL problems & recalls

Problem: 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.

Risk: These situations could cause serious personal injury or create a fire hazard for persons or property on or near the motorcycle.

Fix: 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.

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.

Problem: A short circuit could develop due to possible chafing where the battery cable is close to the evaporative emissions control system.

Risk: Battery cable might overheat and result in a fire.

Fix: Replace battery cable and other appropriate parts.

Problem: Wireform that secures rubber grommets, which serve as a routing guide for the positive battery cable, may not meet specifications.

Risk: Wireforms could chafe the positive battery cable andcause a short circuit to the motorcycle chassis during operation.

Fix: Replace positive battery cable wireform with wireform that that meets specifications.