2009 Buell 1125R

TL* THE CONTACT OWNS A 2009 BUELL 1125R MOTORCYCLE. THE CONTACT WAS EXPERIENCING A RECURRING FAILURE WITH THE STATOR AND VOLTAGE REGULATORS OVERHEATING. WHILE DRIVING 50 MPH, THE BATTERY WARNING LIGHT ILLUMINATED AND THERE WAS A REDUCTION OF ALL POWER. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE STATOR AND VOLTAGE REGULATOR WERE REPLACED. THE COMPONENTS HAD BEEN REPLACED THREE TIMES AS A RESULT OF THE STATOR AND VOLTAGE REGULATOR OVERHEATING. THE FAILURE DID NOT BEGIN UNTIL THE SYSTEM WAS UPGRADED BY A PREVIOUS DEALER. THE CONTACT DID NOT FEEL SAFE OPERATING THE VEHICLE. THE FAILURE MILEAGE WAS 11,777.

THERE IS A DESIGN FLAW IN THE CHARGING SYSTEM OF THE '09 BUELL 1125R AND 1125CR MOTORCYCLES. THE ELECTRICAL STATOR PRODUCES MORE HEAT THAN CAN BE MANAGED AND WILL EVENTUALLY OVER HEAT AND FAIL. THIS FAILURE HAS OCCURRED ON A LARGE PERCENTAGE OF '09 BUELL 1125R AND 1125CR MOTORCYCLES. THE REPLACEMENT PARTS FROM HARLEY DAVIDSON (BUELL'S PARENT) HAVE BEEN BACKORDERED ON MULTIPLE OCCASIONS AS SUPPLY CANNOT KEEP UP WITH THE SUBSTANTIAL AMOUNT OF FAILURES. THERE ARE SAFETY CONSIDERATIONS. WHEN THE FAILURE OCCURS, HEADLIGHTS AND TURN SIGNALS FAIL TO WORK. THE MOTORCYCLE MAY STALL INCREASING THE RISK OF A CRASH. HARLEY HAS ISSUED A 'FIX' IN THE FORM OF A RELAY THAT SHUTS OFF 1/3 OF THE CHARGING SYSTEM. IRONICALLY THE 'FIX' SEEMS TO HAVE INCREASED THE NUMBER OF CHARGING SYSTEM FAILURES. WITH THE 'FIX' IN PLACE THE MOTORCYCLE IS STARVED FOR ELECTRICAL POWER. THERE IS NOT SIGNIFICANT POWER TO KEEP THE BATTERY CHARGED. BRIGHT HEADLIGHT CANNOT BE USED WITHOUT FURTHER DRAINING OF MOTORCYCLE'S BATTERY, ETC. MANY, MANY CASES OF STATOR FAILURES CAN BE FOUND HERE: HTTP://WWW.BADWEATHERBIKERS.COM/BUELL/MESSAGES/290431/290431.HTML?1309888179 PLEASE LAUNCH A DEFECT INVESTIGATION TO DETERMINE THE SERIOUSNESS OF THESE SAFETY CONCERNS. *KB

THE CHARGING SYSTEM ON THE 2009 BUELL 1125R AND 1125CR HAS A DESIGN DEFECT. WHILE IDLING IN TRAFFIC, THE CHARGING SYSTEM WILL OVERHEAT AND THE STATOR WILL BURN OUT AND FAIL, CAUSING THE MOTORCYCLE TO STALL AND CANNOT BE RESTARTED DUE TO THE BATTERY BEING DRAINED. THIS DEFECT AFFECTS ALL 2009 BUELL 1125R AND 1125CR MOTORCYCLES. HARLEY DAVIDSON (BUELL'S PARENT COMPANY) IS AWARE OF THE DESIGN DEFECT AND IN MARCH, 2010 RELEASED A 'FIX' IN THE FORM OF A CHARGING HARNESS UPGRADE. THIS 'FIX' WAS INSTALLED ON MY MOTORCYCLE AT 1,456 MILES. MY CHARGING SYSTEM COMPLETELY FAILED AT 3,706 MILES. THE 'FIX' ISSUED BY HARLEY DAVIDSON SHUTS OFF 1/3 OF THE STATOR LEAVING THE MOTORCYCLE ONLY 2/3 OF THE POWER LISTED IN THE SPECIFICATION. THIS IS ULTIMATELY NOT ENOUGH POWER TO OPERATE ALL THE ELECTRICAL COMPONENTS ON THE MOTORCYCLE. BRIGHT HEADLIGHTS CANNOT BE USED WITHOUT CAUSING THE BATTERY LIGHT TO ILLUMINATE AND ULTIMATELY DRAINING THE BATTERY. AT IDLE, THE CHARGING SYSTEM CANNOT PRODUCE ENOUGH POWER TO KEEP THE BATTERY CHARGED. SEVERAL MINUTES OF IDLING WILL CAUSE THE BATTERY LIGHT TO ILLUMINATE, THEN A 'SYSTEM VOLTAGE ERROR' WILL APPEAR ON THE INSTRUMENT CLUSTER, THEN THE HEADLIGHTS & TURN SIGNALS WILL STOP WORKING, FINALLY THE MOTORCYCLE WILL STALL. MY ENTIRE CHARGING SYSTEM HAS BEEN REPLACED (STATOR, VOLTAGE REGULATOR, BATTERY), AND HAS BEEN INSPECTED SEVERAL TIMES BY A HARLEY DAVIDSON DEALER AND BY A REPRESENTATIVE FROM HARLEY DAVIDSON CORPORATE. THE SITUATION HAS NOT IMPROVED. HARLEY DAVIDSON IS EITHER INCAPABLE OR UNWILLING TO SOLVE THIS ISSUE. *TR

REF 2009 BUELL 1125R AND CR COMPONENT: ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR THE STATOR & REGULATOR/RECTIFIER ASSEMBLIES ON THE 2009 BUELL 1125R AND 2009 BUELL 1125CR MOTORCYCLES CREATE A UNCONTROLLED BUILD UP OF ELECTRICAL HEAT THAT CAN CAUSE THESE COMPONENTS TO FAIL. THE STATOR ASSEMBLIES HAVE INSUFFICIENT THERMAL PROTECTION TO HANDLE THE HEAT GENERATED BY THE CHARGING SYSTEM. THIS CAUSES THE ELECTRICAL INSULATION TO MELT TO A POINT WHERE A SHORT CIRCUIT SITUATION IS CREATED AND THE STATOR FAILS. THE REGULATOR/RECTIFIER WAS PRODUCED WITH INSUFFICIENT ABILITY TO DISSIPATE HEAT GENERATED BY THE CHARGING SYSTEM. THIS CONDITION CAUSES EXCESSIVE HEAT WITHIN THE CHARGING SYSTEM AND UNCONTROLLED ELECTRIC CURRENT OUTPUT WHICH CAN RESULT IN INSUFFICIENT CHARGING CURRENT BEING PROVIDED TO THE MOTORCYCLE BATTERY. THIS CAN CAUSE THE DISCHARGE OF THE BUELL MOTORCYCLE'S BATTERY, WHICH CAN LEAD TO STALLING OR A NON-START CONDITION; IF THE MOTORCYCLE'S ENGINE STALLS, IT COULD INCREASE THE RISK OF A CRASH. *TT

2009 BUELL 1125R WAS RIDING ON FREEWAY WHEN BATTERY LIGHT CAME ON AND VOLTAGE STARTED TO DROP. INTENSE HEAT TO FRAME BURNING LEGS THROUGH HEAVY RIDING GEAR, SMOKE POURING FROM UNDER THE SEAT. VEHICLE ENGINE CUT OUT SUDDENLY AS I APPROACHED HOME AND LUCKILY I HAD THE CLUTCH PULLED IN. VEHICLE WOULD NOT RESTART AND IGNITION IS DEAD.. VERY COMMON ISSUE WITH 2009 1125'S AND LUCKILY IT FAILED ON A RESIDENTIAL STREET OR I WOULD HAVE BEEN SERIOUSLY INJURED. VOLTAGE REGULATOR, STATOR FAILED PARTS ON BACKORDER DUE TO THE AMOUNT OF FAILURES. *TR

CHARGING SYSTEM STATOR FAILS RESULTING IN LOW SYSTEM VOLTAGE AND EVENTUALLY ENGINE WILL QUIT RUNNING OR STALL. I HAD THREE FAILURES IN THE FIRST 12,000 MILES OF OWNERSHIP. THE LAST FAILURE I INSTALLED THE PREVIOUS MODEL YEAR('08) COMPONENTS (ROTOR AND STATOR) THAT HAVE A LOWER ELECTRICAL OUTPUT, AT MY OWN EXPENSE TO RESOLVE THE ISSUE. DEALER UNDER WARRANTY WOULD ONLY REPLACE THE STATOR WITH THE SAME (09) PART THAT KEEPS FAILING. *TR

COMPONENT: ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR THE STATOR & REGULATOR/RECTIFIER ASSEMBLIES ON THE 2009 BUELL 1125R AND 2009 BUELL 1125R MOTORCYCLES CREATE A UNCONTROLLED BUILD UP OF ELECTRICAL HEAT THAT CAN CAUSE THESE COMPONENTS TO FAIL. THE STATOR ASSEMBLIES HAVE INSUFFICIENT THERMAL PROTECTION TO HANDLE THE HEAT GENERATED BY THE CHARGING SYSTEM. THIS CAUSES THE ELECTRICAL INSULATION TO MELT TO A POINT WHERE A SHORT CIRCUIT SITUATION IS CREATED AND THE STATOR FAILS. THE REGULATOR/RECTIFIER WAS PRODUCED WITH INSUFFICIENT ABILITY TO DISSIPATE HEAT GENERATED BY THE CHARGING SYSTEM. THIS CONDITION CAUSES EXCESSIVE HEAT WITHIN THE CHARGING SYSTEM AND UNCONTROLLED ELECTRIC CURRENT OUTPUT WHICH CAN RESULT IN INSUFFICIENT CHARGING CURRENT BEING PROVIDED TO THE MOTORCYCLE BATTERY. THIS CAN CAUSE THE DISCHARGE OF THE BUELL MOTORCYCLE'S BATTERY, WHICH CAN LEAD TO STALLING OR A NON-START CONDITION; IF THE MOTORCYCLE'S ENGINE STALLS, IT COULD INCREASE THE RISK OF A CRASH. *TR

1. RIDING UNDER NORMAL CONDITIONS 40-90 DEGREES OUT OF THE BLUE I GET A SYSTEM-VOLTAGE ACROSS MY SPEEDOMETER SCREEN. 2. WHEN THE SYSTEM VOLTAGE COMES ON I HAVE NO IDEA HOW FAST I AM GOING, I HAVE NO GAUGES, AND MOST IMPORTANT I HAVE NO TURN-SIGNALS. THIS HAS HAPPENED TO ME 8 TIMES IN ONE YEAR. DARING THESE 8 TIMES MY SPEEDOMETER AND TURN SIGNALS HAVE BEEN RENDERED USELESS. I HAVE ABOUT BEEN HIT 3OF THE 8 TIMES DUE TO SCENARIOS LIKE THIS ONE WHICH I WAS ABOUT KILLED. I PUT MY ARM UP TO TURN RIGHT, THE CAR BEHIND ME WAS BEING PASSED AND SOON AS HE GOT AN OPENING, THE CAR BEHIND ME MADE A FAST SWERVE AROUND ME LEAVING THE CAR RIDDING HIS BUMPER WITH LITTLE TO NO REACTION TIME WHILE HE WAS LOCKING UP HIS BREAKS MADE ME ALTER MY PLAN. AFTER I ALTERED MY PLAN THE DRIVER WHO ABOUT HIT ME BECAUSE OF NO TURN SIGNAL SWERVES AT ME WHILE YELLING USE YOUR TURN-SIGNAL AND FLIPPING ME OFF. THIS ALL HAPPENED WHILE TRYING TO AVOID A POT-HOLE, AND SAND MAKING ME TAKE MY LEFT ARM DOWN FOR A SECOND. "SEC. 2.5. A MOTORCYCLE MANUFACTURED ON JANUARY 1, 1956, OR AFTER THIS DATE IS REQUIRED TO BE EQUIPPED WITH THE FOLLOWING DEVICES: (1) A REAR VIEW MIRROR. (2) A SPEEDOMETER.(3) MECHANICAL OR ELECTRIC TURN SIGNALS."(INDIANA MOTORCYCLE LAW) 3.ALL WORK DONE BY HARLEY DAVIDSON. SYSTEM VOLTAGE CAME ON IN THE BEGGING OF FEB. 2010 NEW CHARGING SUB-HARNESS WAS PUT ON FEB 2010 TO FIX THE CHARGING SYSTEM PROBLEM RECALL BY NHTSA(WHICH CAUSES SYSTEM VOLTAGE). SYSTEM VOLTAGE CAME ON IN JUNE 2010, JULY 2010 I TOOK THE BIKE IN AND NO PROBLEM WAS FOUND. MORE TIME?S UNTIL AUG. 2010 THE CHARGING SYSTEM BURNT SOME WIRE AND THE STATOR WENT BAD. AUG. 2010 REPLACED; STATOR, SUB-HARNESS, VOLTAGE REGULATOR. SYSTEM VOLTAGE OCT 2010, JAN. 2011 SYSTEM VOLTAGE DO I HAVE TO LOSE MY LIFE BEFORE HARLEY DAVIDSON BUELL FIXES A KNOWN PROBLEM? *TR

MY 2009 BUELL 1125R MOTORCYCLE USES A HYDRAULICALLY ACTUATED CLUTCH. THE CLUTCH FLUID BEGAN TO LEAK OUT OF THE ENGINE COVER, EMANATING A DROP OF FLUID FOR EACH TIME THE CLUTCH WAS DISENGAGED. THERE IS A LIMITED AMOUNT OF CLUTCH FLUID IN THE RESERVOIR, AND THE LEAKAGE WILL EVENTUALLY DEPLETE THE RESERVOIR. WITHOUT FLUID IN THE RESERVOIR, THE RIDER'S ABILITY TO DISENGAGE THE CLUTCH IS ELIMINATED. THIS COULD RESULT IN A CRASH. THE DEALERSHIP ORDERED NEW PARTS THAT ARE DESIGNED TO REPAIR THE PROBLEM. HOWEVER, THE NEW PARTS DID NOT REPAIR THE LEAK. IN ADDITION TO THE POTENTIAL LOSS OF CLUTCH CONTROL, THE FLUID ITSELF IS DOT4 BRAKE FLUID. WHILE RIDING, THE LEAKED FLUID SPRAYS BACK ONTO THE RIGHT HAND SIDE OF THE MOTORCYCLE. THE FLUID IS VERY SLIPPERY, AND IF IT SPRAYS ONTO CERTAIN COMPONENTS IT MAY CAUSE THE REAR BRAKE TO FAIL TO OPERATE, OR THE REAR TIRE TO LOSE TRACTION. I DID NOT CRASH AS A RESULT OF THE CLUTCH FLUID LEAKAGE, BUT A LESS ATTENTIVE RIDER MAY NOT NOTICE THE LEAK UNTIL THEY LOSE CONTROL OF THE MOTORCYCLE'S CLUTCH. *TR