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October 18, 2022 NHTSA CAMPAIGN NUMBER: 22V781000
Unintended Brake Light Illumination/FMVSS 108
Unintended illumination of the brake lights may confuse other drivers, increasing the risk of a crash.
NHTSA Campaign Number: 22V781
Manufacturer Harley-Davidson Motor Company
Components EXTERIOR LIGHTING
Potential Number of Units Affected 199,419
Summary
Harley-Davidson Motor Company (Harley-Davidson) is recalling certain 2019-2022 Trike and CVO Trike and 2020-2022 Touring and CVO Touring motorcycles. Please refer to Addendum A for specific vehicle model details. The brake lights may illuminate without the rider applying the brakes. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 108, “Lamps, Reflective Devices, and Associated Equipment.”
Remedy
Dealers will update the software on Touring and CVO Touring motorcycles. On Trike and CVO Trike motorcycles, a new pressure switch will also be installed. All repairs will be performed free of charge. Owner notification letters were mailed November 2, 2022. Owners may contact Harley-Davidson customer service at 1-800-258-2464. Harley-Davidson’s number for this recall is 0635.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
Check for Harley-Davidson Recalls
M1568
2023-04-05
M1568 (REV D): RECALL 0635 – TOURING AND TRIKE BRAKE LIGHT ACTIVATION
Purpose for Service Bulletin
This bulletin informs dealers that Harley-Davidson has decided that certain model year 2019-2022 Trike/CVO Trike vehicles (all models) and 2020-2022 Touring/Police Touring/CVO Touring vehicles (all models) vehicles may fail to conform to: Federal Motor Vehicle Safety Standard No. 108; Lamps, Reflective Devices, and Associated Equipment.
Motorcycles Affected
2019 to 2022 Trike and CVO Trike built on or before June 23, 2022.
2020 to 2022 Touring, Police Touring, and CVO Touring built on or before June 23, 2022.
NOTE
Touring, Police Touring, and CVO Touring affected vehicles require a Body Control Module (BCM) reflash ONLY and do NOT require the installation of a recall kit.
Trike and CVO Trike affected vehicles require a BCM reflash as well as the installation of a recall kit.
Markets Affected
All markets are affected.
Part Numbers
Refer to Table 2.
Table 2. Recall Kit Part Number
Item Description | New Part No. |
Kit, Recall, 0635, Signal, Brake Light | 91500112 |
Table 3. DOT 4 Brake Fluid
Description | Part Number Regions |
DOT 4 Brake Fluid | 41800770
U.S., Mexico, South America |
91500091
Canada |
|
41800772
Asia Pacific |
|
41800773
EMEA |
|
41800774
Russia |
Full Service Bulletin bellow in PDF
Chronology :
6/10/2021 – 10/28/2021 – Harley-Davidson’s Technical Subcommittee (TSC) investigated reports of brake lamps remaining illuminated on some MY20 Touring motorcycles. The TSC requested parts back from the field, engaged the suppliers and requested support in the investigation, and enlisted the support of H-D Engineering. Warranty and Customer Contact records were reviewed and analyzed. Based upon the information and data available (including the low frequency of known incidents and the fact that this condition can correct itself based on riding patterns/behavior), the TSC decided to close its investigation.
5/12/2022 – The TSC reopened its investigation after receiving reports that indicated a higher occurrence rate of this potential issue.
5/13/2022 – 8/24/2022 – The TSC reviewed updated Warranty and Customer Contact records. A software change was implemented at H-D assembly plants that eliminated this potential issue on future production. The TSC elected to monitor this issue monthly.
9/2/2022 – 9/13/2022 – After reviewing field data while in monitor status, the TSC moved this issue back to Active status. An updated search and analysis of warranty and customer contacts data was performed. The TSC escalated this issue to H-D’s Field Action Committee (FAC).
9/20/2022 – The FAC reviewed the TSC’s findings and analysis and escalated the matter to H-D’s Executive Decision Authority (EDA).
9/21/2022 – 10/10/2022 – The EDA met two times to discuss and review the information available. In addition, H-D reached out to NHTSA’s Office of Defect Investigation to discuss the circumstances associated with this issue.
10/11/2022 – Based upon the information developed during the investigation, the EDA authorized a voluntary recall to address this condition.
55 Affected Products
Vehicles
MAKE | MODEL | YEAR |
HARLEY-DAVIDSON | FLH | 2021 |
HARLEY-DAVIDSON | FLHP | 2020-2022 |
HARLEY-DAVIDSON | FLHR | 2020-2022 |
HARLEY-DAVIDSON | FLHRXS | 2020-2022 |
HARLEY-DAVIDSON | FLHT | 2020-2022 |
HARLEY-DAVIDSON | FLHTCUTG | 2019-2022 |
HARLEY-DAVIDSON | FLHTCUTGSE | 2020-2022 |
HARLEY-DAVIDSON | FLHTK | 2020-2022 |
HARLEY-DAVIDSON | FLHTK SHRINE | 2021-2022 |
HARLEY-DAVIDSON | FLHTKSE | 2020-2021 |
HARLEY-DAVIDSON | FLHX | 2020-2022 |
HARLEY-DAVIDSON | FLHXS | 2020-2022 |
HARLEY-DAVIDSON | FLHXSE | 2020-2022 |
HARLEY-DAVIDSON | FLHXST | 2022 |
HARLEY-DAVIDSON | FLRT | 2019-2022 |
HARLEY-DAVIDSON | FLTRK | 2020-2022 |
HARLEY-DAVIDSON | FLTRKSE | 2022 |
HARLEY-DAVIDSON | FLTRX | 2020-2022 |
HARLEY-DAVIDSON | FLTRXS | 2020-2022 |
HARLEY-DAVIDSON | FLTRXSE | 2020-2022 |
HARLEY-DAVIDSON | FLTRXST | 2022 |
14 Associated Documents
Addendum A – Vehicle Information
RMISC-22V781-0145.pdf 110.817KB
Noncompliance Notice 573 Report
RCLRPT-22V781-2876.PDF 216.771KB
Recall Acknowledgement
RCAK-22V781-9375.pdf 646.962KB
Recall 573 Report – Amendment 1
RCLRPT-22V781-4161.PDF 216.774KB
Remedy Instructions and TSB
RCRIT-22V781-4737.pdf 921.054KB
Remedy Instructions and TSB
RCRIT-22V781-9561.pdf 123.302KB
Recall 573 Report – October 29, 2022
RCLRPT-22V781-1496.PDF 216.814KB
ISSUED Owner Notification Letter(Part 577)
RCONL-22V781-6395.pdf 203.972KB
Recall 573 Report – November 29, 2022
RCLRPT-22V781-4929.PDF 216.958KB
Remedy Instructions and TSB
RCRIT-22V781-1135.pdf 1000.043KB
Recall Quarterly Report #1, 2022-4
RCLQRT-22V781-6743.PDF 211.16KB
Recall Quarterly Report #2, 2023-1
RCLQRT-22V781-1198.PDF 211.262KB
Remedy Instructions and TSB
RCRIT-22V781-8111.pdf 1000.653KB
Recall Quarterly Report #3, 2023-2
RCLQRT-22V781-8027.PDF 211.351KB
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For the Latest and Most Recent Recalls Information Visit the link below…
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V781&docType=RCL
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SEOCONTENT-START
Addendum A Harley-Davidson Part 573 Defect Information Report Recall No. 22V781 (Oct. 21, 2022) This recall covers all Touring/CVO Touring and Trike/CVO models produced during the stated production ranges. These models have the following H-D model designations: Model Year Touring / CVO Touring Models Production Range: 07/02/2019 – 06/23/2022 ONLY Trike / CVO Trike Models Production Range: 07/06/2018 – 06/23/2022 ONLY 2019 FLHTCUTG, FLRT 2020 FLHP, FLHR, FLHRXS, FLHT, FLHTK, FLHTKSE, FLHTKSHRINE, FLHTP, FLHX, FLHXS, FLHXSE, FLTRK, FLTRX, FLTRXS, FLTRXSE FLHTCUTG, FLRT, FLHTCUTGSE 2021 FLH, FLHP, FLHR, FLHRXS, FLHT, FLHTK, FLHTKSE, FLHTKSHRINE, FLHTP, FLHX, FLHXS, FLHXSE, FLTRK, FLTRX, FLTRXS, FLTRXSE FLHTCUTG, FLRT, FLHTCUTGSE 2022 FLHP, FLHR, FLHRXS, FLHT, FLHTK, FLHTKSHRINE, FLHTP, FLHX, FLHXS, FLHXSE, FLHXST, FLTRK, FLTRKSE, FLTRX, FLTRXS, FLTRXSE, FLTRXST FLHTCUTG, FLRT, FLHTCUTGSEE
**************************************************************************************************************
IMPORTANT RECALL INFORMATION Regulatory Non-Compliance Recall Campaign 0635 Touring, CVO Touring, Trike and CVO Trike Brake Light May Remain On To: Worldwide Dealers Roles: Dealer Operator, General Manager, All P&A Roles, All Service Roles, Vehicle Sales Manager October 24, 2022 Dear Dealer: Harley-Davidson Motor Company, Inc. has learned that certain model year 2019 – 2022 Trike/CVO Trike motorcycles and certain model year 2020 – 2022 Touring/CVO Touring motorcycles may fail to conform to Federal Motor Vehicle Safety Standard/Canadian Motor Vehicle Safety Standard No. 108, Lamps, reflective devices, and associated equipment. The subject motorcycles may exhibit a condition that can result in the brake lamp(s) remaining illuminated regardless of whether the brakes are being applied. We have voluntarily declared that this condition constitutes a regulatory non-compliance which allows us to formally recall (Campaign 0635) all affected motorcycles. The remedy is to first confirm that the motorcycles are covered by this recall. If covered, perform the recommended recall update per Service Bulletin M1568 (the “Bulletin”). The Bulletin outlines the repair and credit procedures for the recall repair and additional relevant information. In the interest of our customers’ satisfaction, and as required by federal law, you may sell but not deliver any affected motorcycles until the recall remedy is complete. Please refer to H-Dnet / My Toolbox / Warranty Campaign Center. Select “Safety Campaign Open VIN list,” then select “0635” Campaign to view the VIN list. In accordance with federal regulations administered by the National Highway Traffic Safety Administration (NHTSA) and other appropriate market-specific government agencies, Harley-Davidson or authorized Harley-Davidson dealers will provide notice to all owners of record of affected products with direction to arrange for the recall service. If you have any questions related to this recall, you can contact us at: • U.S. dealers: Call 800-664-7762 and select the appropriate prompts • International dealers: Contact their regional office We take pride in the quality standards and controls we employ in our drive to lead the industry and deliver the world’s most desirable motorcycles. Thank you for your cooperation. Sincerely, Harley-Davidson Motor Company, Inc. Recall 0635 Key Dates: • On or about 10/28/2022: Service Bulletin posts. • On or about 10/31/2022: Owner notification letters begin mailing. • On or about 11/21/2022: Recall kits will be available to order.
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M1568 2023-04-05 M1568 (REV D): RECALL 0635 – TOURING AND TRIKE BRAKE LIGHT ACTIVATION Reason for Revision Refer to Table 1. Table 1. Document History Date Rev Revision (Rev) Description 2023-04-05 D Kit ordering information updated. * Updated Kit Ordering Information. Added and edited tables. 2022-12-14 C Updated Part Numbers and Credit * Procedure. 2022-11-17 B Added note. * Updated Motorcycles Affected. Added Techlink 3 (TL-3) Information. 2022-11-07 A Updated Credit Procedure. Updated Required Dealer Action and * Credit Procedure. 2022-10-26 – Initial release Purpose for Service Bulletin This bulletin informs dealers that Harley-Davidson has decided that certain model year 2019-2022 Trike/CVO Trike vehicles (all models) and 2020-2022 Touring/Police Touring/CVO Touring vehicles (all models) vehicles may fail to conform to: Federal Motor Vehicle Safety Standard No. 108; Lamps, Reflective Devices, and Associated Equipment. Motorcycles Affected 2019 to 2022 Trike and CVO Trike built on or before June 23, 2022. 2020 to 2022 Touring, Police Touring, and CVO Touring built on or before June 23, 2022. NOTE Touring, Police Touring, and CVO Touring affected vehicles require a Body Control Module (BCM) reflash ONLY and do NOT require the installation of a recall kit. Trike and CVO Trike affected vehicles require a BCM reflash as well as the installation of a recall kit. Markets Affected All markets are affected. Part Numbers Refer to Table 2. Table 2. Recall Kit Part Number Item Description New Part No. Kit, Recall, 0635, Signal, Brake 91500112 Light Table 3. DOT 4 Brake Fluid Part Number Description Regions 41800770 U.S., Mexico, South America DOT 4 Brake Fluid 91500091 Canada 41800772 Asia Pacific 41800773 EMEA 41800774 Russia Kit Ordering Information NOTE As of April 4 2023, wave shipments for the Recall Kit have ended. Dealers can now place orders for the kit. Required Dealer Action Table 4. Action Resolution Required Actionable: Any vehicle, component or software related issues must be performed per service bulletin procedure. NO YES 1. 1. Verify that vehicle is part of Recall 0635. a. a. See H-Dnet.com. 2. Select: Favorites > Warranty Campaign Center. 3. Select: Safety Campaign Open Vehicle Identification Number (VIN) list. NOTE In the interest of preserving customer safety and satisfaction, always check for outstanding recalls whenever any motorcycle is brought into your dealership for either maintenance or service. LEADTECHNICIAN TECHNICIAN NO. 1 TECHNICIAN NO. 2 TECHNICIAN NO. 3 RETURN THIS TO WARRANTY PROCESS MANAGER SERVICE SALES MANAGER PARTS MANAGER ROUTING MANAGER INITIAL HERE NOTE If the vehicle does not appear on the VIN list in your Warranty Campaign Center, refer to Vehicle Information link to verify if the vehicle is included in the recall. 4. Select: Campaign number 0635. NOTE Make sure that software version V22.6 or later is installed on Digital Technician II (DT II). NOTE See Figure 1. External power adapter must be plugged into TL-3 for Electronic Control Module (ECM) reflash procedure to prevent unrecoverable lockups. • See Figure 2. The external power adapter must have an output of at least 12 V and 1.2 A. This includes the power adapter included with the TL-3 or the adapter for the DT II. • The vehicle battery should be fully charged prior doing the software update. • Have a battery tender connected to the battery while performing software update. 1 1 1 Special-case halo options: Standard Callout For busy background instances 1610770 Figure 1. External Power Adapter 1 1 1 Special-case halo options: Standard Callout For busy background instances 1 1610771 1. 12 V and 1.2A Minimum Output Figure 2. 12 V and 1.2A Output Touring, Police Touring and CVO Touring 1. Update BCM using DT II. a. DT II Software version: v22.8.4 or later. b. BCM Software version: 28794018 YM0 or later. Trike and CVO Trike NOTE Trike and CVO Trike vehicles require the installation of Recall Kit (Part No. 91500112) in addition to a BCM software update. Follow the Hydraulic and Electrical steps for the brake switch and wiring installation prior to completing the BCM software update. Hydraulic Portion of Trike Brake Switch Rework 1. Remove left and right side covers. See service manual. 2. Remove rear master cylinder to Electro Hydraulic Control Unit (EHCU) banjo bolt. Discard gaskets. 3. See Figure 3. Install rear brake switch (1) banjo bolt (Part No. 72025-06B). a. Install two new gaskets (2) (Part No. 41751-06A). Torque: 25.5–28.5 N·m (19–21 ft-lbs) Rear Brake Switch Banjo Bolt 4. Bleed brake system using special tool. Special Tool: DIGITAL TECHNICIAN II (HD-48650) 1 2 1760994 1. Brake switch 2. Gasket (2) Figure 3. Brake Switch Electrical Portion of Trike Brake Switch Rework 1. Remove left and right side covers. See service manual. 2. Remove main fuse. 2 / 5 M1568 3. Remove battery. See service manual. a. Gain access to left ground stud and main harness. 4. See Figure 4. Install jumper terminal (Part No. 69203239) into cavity (F3) of the BCM connector. a. See Figure 5. Using cable strap (2) secure jumper harness (1) to main harness. 5. See Figure 6. Route and install jumper ring terminal to left side ground stud. a. Using cable strap (2) secure jumper harness (3) to main harness. 6. Route jumper harness (3) behind EHCU assembly and secure using cable straps (2). 7. See Figure 7. Install flag terminals (1) to new brake switch. 8. Install battery. See service manual. 9. Install main fuse. See service manual. 10. Install BCM calibration using special tool. Special Tool: DIGITAL TECHNICIAN II (HD-48650) a. DT II Software version: v22.8.4 or later. b. BCM Software version: 28794018 YM0 or later. 11. Install left and right side covers. See service manual. 1760990 Figure 4. BCM Pin Location 1 2 1760991 1. Jumper harness 2. Cable strap Figure 5. Jumper Harness BCM Connector 2 2 2 1 3 1760992 1. Jumper harness routing 2. Cable strap (3) 3. Jumper harness Figure 6. Jumper Harness Routing M1568 3 / 5 2 2 1 2 3 1760993 1. Flag terminal (2) 2. Cable strap (3) 3. Jumper harness routing Figure 7. Brake Switch Trike External Brake Switch DTII NOTE New brake switch must be installed and brake system bleeding has been performed. DT II Software version: v22.8.4 or later. 1. Option for configuration found under Vehicle Setup. 2. Select: Trike Configuration a. Follow steps in DT II. b. Update Vehicle. c. Answer external brake switch question. d. Start brake pedal operation. 3. Monitor countdown. a. If functioning correctly the BCM will notice the brake switch input at pin F3. b. The count down will then be automatically stopped and be continued to the next screen. 4. Did the stop lamp illuminate while depressing rear brake pedal? a. You will need to visually confirm that the brake lights did in fact turn on when the brake pedal was pushed. b. If you did not notice during the previous step you can recheck again now. c. Verify brake switch operation and confirm. Troubleshooting Conditions for a failed configuration: 1. BCM software needs a reflash to the latest version. 2. Rear brake switch input not being received at BCM. a. Incorrect install. b. Brakes not bled so there is no pressure at the switch. c. Switch not functioning. d. Open in wire harness. e. Brake pedal was not pressed twice. 3. When asked if vehicle is equipped with external brake switch and was answered NO. Credit Procedure Talon/h-dnet.com Warranty Claim System Users-Touring Models. For each vehicle involved in this recall (involvement of VIN has been verified on h-dnet.com), submit a recall claim per Table 5. NOTE Enter bulletin number into comment section of claim. Table 5. Talon/h-dnet.com Warranty Claim System Users- Touring Models. ITEM DATA Claim Type SRC Problem Part Number 41000341F Quantity Leave Blank Primary Labor Code 2817 (1) Time 0.2 hours Customer Concern Code 0635 Condition Code 9981 (1) Download may be required Upon submission of the properly completed claim, you will be credited for 0.2 hours of labor time for performing the procedure, plus appropriate administrative time. Submit campaign events on their own warranty claim. Do not mix them with other warranty events. Table 6. GDP/SAP System Users-Touring Models. ITEM DATA Claim Type Recall Claim Fix ID-Found in Recall Number R Problem Part Number 41000341F Customer Concern Code 0635 Condition Code 9981 Talon/h-dnet.com Warranty Claim System Users-Trike Models. For each vehicle involved in this recall (involvement of VIN has been verified on h-dnet.com). Submit a recall claim per Table 7. NOTE Enter bulletin number into comment section of claim. 4 / 5 M1568 Table 7. Talon/h-dnet.com Warranty Claim System Users- Trike Models. ITEM DATA Claim Type SRC Problem Part Number 41000341F Quantity Leave Blank Primary Labor Code 2818 (1) Time 1.8 hours Customer Concern Code 0635 Condition Code 9982 91500112 and Replacement Part Number 41800770 Quantity 1 (1) Download may be required Talon/h-dnet.com Warranty Claim System Users-Trike Models. Upon submission of the properly completed claim, you will be credited for 1.8 hours of labor time for performing the procedure, plus appropriate administrative time. Credit will also be issued for the recall kit (U.S. only). Submit campaign events on their own warranty claim. Do not mix them with other warranty events. Table 8. GDP/SAP System Users-Trike Models. ITEM DATA Claim Type Recall Claim Fix ID-Found in Recall Number C Problem Part Number 41000341F Customer Concern Code 0635 Condition Code 9982 M1568 5 / 5
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M1568 2022-10-26 M1568: RECALL 0635 – TOURING AND TRIKE BRAKE LIGHT ACTIVATION Reason for Revision Refer to Table 1. Table 1. Document History Date Revision Description 2022-10-26 Initial release Purpose for Service Bulletin This bulletin informs dealers that Harley-Davidson has decided that certain model year 2019-2022 Trike/CVO Trike vehicles (all models) and 2020-2022 Touring/Police Touring/CVO Touring vehicles (all models) vehicles may fail to conform to: Federal Motor Vehicle Safety Standard No. 108; Lamps, Reflective Devices, and Associated Equipment. Motorcycles Affected 2019 to 2022 Trike and CVO Trike on or before June 23, 2022. 2020 to 2022 Touring, Police Touring, and CVO Touring built on or before June 23, 2022. Markets Affected All markets are affected. Part Numbers Refer to Table 2. Table 2. Recall Kit Part Number Item Description New Part No. Kit, Recall, 0635, Signal, Brake 91500112 Light Kit Ordering Information NOTE Kits will not be available for order at launch of this recall. Dealers will be provided kits via wave shipments. Required Dealer Action Table 3. Action Resolution Required Actionable: Any vehicle, component or software related issues must be performed per service bulletin procedure. NO YES 1. 1. Verify that vehicle is part of Recall 0635. a. a. See H-Dnet.com. 2. Select: Favorites > Warranty Campaign Center. 3. Select: Safety Campaign Open Vehicle Identification Number (VIN) list. NOTE If the vehicle does not appear on the VIN list in your Warranty Campaign Center, refer to Vehicle Information link to verify if the vehicle is included in the recall. 4. Select: Campaign number 0635. Touring, Police Touring and CVO Touring 1. Update Body Control Module (BCM) using Digital Technician II (DT II). a. DT II Software version: v22.8.4 or later. b. BCM Software version: 28794018 YM0 or later. Trike and CVO Trike NOTE Trike and CVO Trike vehicles require the installation of Recall Kit (Part No. 91500112) in addition to a BCM software update. Follow the Hydraulic and Electrical steps for the brake switch and wiring installation prior to completing the BCM software update. Hydraulic Portion of Trike Brake Switch Rework 1. Remove left and right side covers. See service manual. NOTE In the interest of preserving customer safety and satisfaction, always check for outstanding recalls whenever any motorcycle is brought into your dealership for either maintenance or service. LEADTECHNICIAN TECHNICIAN NO. 1 TECHNICIAN NO. 2 TECHNICIAN NO. 3 RETURN THIS TO WARRANTY PROCESS MANAGER SERVICE SALES MANAGER PARTS MANAGER ROUTING MANAGER INITIAL HERE 2. Remove rear master cylinder to Electro Hydraulic Control Unit (EHCU) banjo bolt. Discard gaskets. 3. See Figure 1. Install rear brake switch (1) banjo bolt (Part No. 72025-06B). a. Install two new gaskets (2) (Part No. 41751-06A). Torque: 25.5–28.5 N·m (19–21 ft-lbs) Rear Brake Switch Banjo Bolt 4. Bleed brake system using special tool. Special Tool: DIGITAL TECHNICIAN II (HD-48650) 1 2 1760994 1. Brake switch 2. Gasket (2) Figure 1. Brake Switch Electrical Portion of Trike Brake Switch Rework 1. Remove left and right side covers. See service manual. 2. Remove main fuse. 3. Remove battery. See service manual. a. Gain access to left ground stud and main harness. 4. See Figure 2. Install jumper terminal (Part No. 69203239) into cavity (F3) of the BCM connector. a. See Figure 3. Using cable strap (2) secure jumper harness (1) to main harness. 5. See Figure 4. Route and install jumper ring terminal to left side ground stud. a. Using cable strap (2) secure jumper harness (3) to main harness. 6. Route jumper harness (3) behind EHCU assembly and secure using cable straps (2). 7. See Figure 5. Install flag terminals (1) to new brake switch. 8. Install battery. See service manual. 9. Install main fuse. See service manual. 10. Install BCM calibration using special tool. Special Tool: DIGITAL TECHNICIAN II (HD-48650) a. DT II Software version: v22.8.4 or later. b. BCM Software version: 28794018 YM0 or later. 11. Install left and right side covers. See service manual. 1760990 Figure 2. BCM Pin Location 1 2 1760991 1. Jumper harness 2. Cable strap Figure 3. Jumper Harness BCM Connector 2 / 4 M1568 2 2 2 1 3 1760992 1. Jumper harness routing 2. Cable strap (3) 3. Jumper harness Figure 4. Jumper Harness Routing 2 2 1 2 3 1760993 1. Flag terminal (2) 2. Cable strap (3) 3. Jumper harness routing Figure 5. Brake Switch Trike External Brake Switch DTII NOTE New brake switch must be installed and brake system bleeding has been performed. DT II Software version: v22.8.4 or later. 1. Option for configuration found under Vehicle Setup. 2. Select: Trike Configuration a. Follow steps in DT II. b. Update Vehicle. c. Answer external brake switch question. d. Start brake pedal operation. 3. Monitor countdown. a. If functioning correctly the BCM will notice the brake switch input at pin F3. b. The count down will then be automatically stopped and be continued to the next screen. 4. Did the stop lamp illuminate while depressing rear brake pedal? a. You will need to visually confirm that the brake lights did in fact turn on when the brake pedal was pushed. b. If you did not notice during the previous step you can recheck again now. c. Verify brake switch operation and confirm. Troubleshooting Conditions for a failed configuration: 1. BCM software needs a reflash to the latest version. 2. Rear brake switch input not being received at BCM. a. Incorrect install. b. Brakes not bled so there is no pressure at the switch. c. Switch not functioning. d. Open in wire harness. e. Brake pedal was not pressed twice. 3. When asked if vehicle is equipped with external brake switch and was answered NO. Credit Procedure Talon/h-dnet.com Warranty Claim System Users-Touring Models. For each vehicle involved in this recall (involvement of VIN has been verified on h-dnet.com), submit a recall claim per Table 4. NOTE Enter bulletin number into comment section of claim. Table 4. Talon/h-dnet.com Warranty Claim System Users- Touring Models. ITEM DATA Claim Type SRC Problem Part Number 41000341F Quantity Leave Blank Primary Labor Code 2817 (1) Time 0.2 h Customer Concern Code 0635 Condition Code 9981 (1) Download may be required Upon submission of the properly completed claim, you will be credited for 0.2 hours of labor time for performing the procedure, plus appropriate administrative time. Submit campaign events M1568 3 / 4 on their own warranty claim. Do not mix them with other warranty events. Submit a warranty claim per Table 5. Table 5. GDP/SAP System Users-Touring Models. ITEM DATA Claim Type Recall Claim Fix ID-Found in Recall Number R Problem Part Number 41000341F Primary Labor Code 2817 Condition Code 9981 Talon/h-dnet.com Warranty Claim System Users-Trike Models. For each vehicle involved in this recall (involvement of VIN has been verified on h-dnet.com), submit a recall claim per Table 6. NOTE Enter bulletin number into comment section of claim. Table 6. Talon/h-dnet.com Warranty Claim System Users- Trike Models. ITEM DATA Claim Type SRC Problem Part Number 41000341F Quantity Leave Blank Primary Labor Code 2818 (1) Time 1.8 h Customer Concern Code 0635 Condition Code 9982 Replacement Part Number 91500112 Quantity 1 (1) Download may be required Talon/h-dnet.com Warranty Claim System Users-Trike Models. Upon submission of the properly completed claim, you will be credited for 1.8 hours of labor time for performing the procedure, plus appropriate administrative time. Credit will also be issued for the recall kit (U.S. only). Submit campaign events on their own warranty claim. Do not mix them with other warranty events. Submit a recall claim per Table 7. Table 7. GDP/SAP System Users-Trike Models. ITEM DATA Claim Type Recall Claim Fix ID-Found in Recall Number C Problem Part Number 41000341F Customer Concern Code 0635 (1) Condition Code 9982 (1) Download may be required 4 / 4 M1568
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M1568 2022-12-14 M1568: RECALL 0635 – TOURING AND TRIKE BRAKE LIGHT ACTIVATION Reason for Revision Refer to Table 1. Table 1. Document History Date Revision Description Added and edited tables. 2022-12-14 Updated Part Numbers and Credit Proced* ure. 2022-11-17 Added note. * Updated Motorcycles Affected. Added Techlink 3 (TL-3) Information. Updated 2022-11-07 Credit Procedure. Updated Required Dealer Action and Credit * Procedure. 2022-10-26 Initial release Purpose for Service Bulletin This bulletin informs dealers that Harley-Davidson has decided that certain model year 2019-2022 Trike/CVO Trike vehicles (all models) and 2020-2022 Touring/Police Touring/CVO Touring vehicles (all models) vehicles may fail to conform to: Federal Motor Vehicle Safety Standard No. 108; Lamps, Reflective Devices, and Associated Equipment. Motorcycles Affected 2019 to 2022 Trike and CVO Trike built on or before June 23, 2022. 2020 to 2022 Touring, Police Touring, and CVO Touring built on or before June 23, 2022. NOTE Touring, Police Touring, and CVO Touring affected vehicles require a Body Control Module (BCM) reflash ONLY and do NOT require the installation of a recall kit. Trike and CVO Trike affected vehicles require a BCM reflash as well as the installation of a recall kit. Markets Affected All markets are affected. Part Numbers Refer to Table 2. Table 2. Recall Kit Part Number Item Description New Part No. Kit, Recall, 0635, Signal, Brake 91500112 Light Table 3. DOT 4 Brake Fluid Part Number Description Regions 41800770 U.S., Mexico, South America DOT 4 Brake Fluid 91500091 Canada 41800772 Asia Pacific 41800773 EMEA 41800774 Russia Kit Ordering Information NOTE Kits will not be available for order at launch of this recall. Dealers will be provided kits via wave shipments. Required Dealer Action Table 4. Action Resolution Required Actionable: Any vehicle, component or software related issues must be performed per service bulletin procedure. NO YES 1. 1. Verify that vehicle is part of Recall 0635. a. a. See H-Dnet.com. 2. Select: Favorites > Warranty Campaign Center. 3. Select: Safety Campaign Open Vehicle Identification Number (VIN) list. NOTE If the vehicle does not appear on the VIN list in your Warranty Campaign Center, refer to Vehicle Information link to verify if the vehicle is included in the recall. NOTE In the interest of preserving customer safety and satisfaction, always check for outstanding recalls whenever any motorcycle is brought into your dealership for either maintenance or service. LEADTECHNICIAN TECHNICIAN NO. 1 TECHNICIAN NO. 2 TECHNICIAN NO. 3 RETURN THIS TO WARRANTY PROCESS MANAGER SERVICE SALES MANAGER PARTS MANAGER ROUTING MANAGER INITIAL HERE 4. Select: Campaign number 0635. NOTE Make sure that software version V22.6 or later is installed on Digital Technician II (DT II). NOTE See Figure 1. External power adapter must be plugged into TL-3 for Electronic Control Module (ECM) reflash procedure to prevent unrecoverable lockups. • See Figure 2. The external power adapter must have an output of at least 12 V and 1.2 A. This includes the power adapter included with the TL-3 or the adapter for the DT II. • The vehicle battery should be fully charged prior doing the software update. • Have a battery tender connected to the battery while performing software update. 1 1 1 Special-case halo options: Standard Callout For busy background instances 1610770 Figure 1. External Power Adapter 1 1 1 Special-case halo options: Standard Callout For busy background instances 1 1610771 1. 12 V and 1.2A Minimum Output Figure 2. 12 V and 1.2A Output Touring, Police Touring and CVO Touring 1. Update BCM using DT II. a. DT II Software version: v22.8.4 or later. b. BCM Software version: 28794018 YM0 or later. Trike and CVO Trike NOTE Trike and CVO Trike vehicles require the installation of Recall Kit (Part No. 91500112) in addition to a BCM software update. Follow the Hydraulic and Electrical steps for the brake switch and wiring installation prior to completing the BCM software update. Hydraulic Portion of Trike Brake Switch Rework 1. Remove left and right side covers. See service manual. 2. Remove rear master cylinder to Electro Hydraulic Control Unit (EHCU) banjo bolt. Discard gaskets. 3. See Figure 3. Install rear brake switch (1) banjo bolt (Part No. 72025-06B). a. Install two new gaskets (2) (Part No. 41751-06A). Torque: 19–21 ft-lbs (25.5–28.5 N·m) Rear Brake Switch Banjo Bolt 4. Bleed brake system using special tool. Special Tool: DIGITAL TECHNICIAN II (HD-48650) 1 2 1760994 1. Brake switch 2. Gasket (2) Figure 3. Brake Switch Electrical Portion of Trike Brake Switch Rework 1. Remove left and right side covers. See service manual. 2. Remove main fuse. 3. Remove battery. See service manual. a. Gain access to left ground stud and main harness. 2 / 5 M1568 4. See Figure 4. Install jumper terminal (Part No. 69203239) into cavity (F3) of the BCM connector. a. See Figure 5. Using cable strap (2) secure jumper harness (1) to main harness. 5. See Figure 6. Route and install jumper ring terminal to left side ground stud. a. Using cable strap (2) secure jumper harness (3) to main harness. 6. Route jumper harness (3) behind EHCU assembly and secure using cable straps (2). 7. See Figure 7. Install flag terminals (1) to new brake switch. 8. Install battery. See service manual. 9. Install main fuse. See service manual. 10. Install BCM calibration using special tool. Special Tool: DIGITAL TECHNICIAN II (HD-48650) a. DT II Software version: v22.8.4 or later. b. BCM Software version: 28794018 YM0 or later. 11. Install left and right side covers. See service manual. 1760990 Figure 4. BCM Pin Location 1 2 1760991 1. Jumper harness 2. Cable strap Figure 5. Jumper Harness BCM Connector 2 2 2 1 3 1760992 1. Jumper harness routing 2. Cable strap (3) 3. Jumper harness Figure 6. Jumper Harness Routing M1568 3 / 5 2 2 1 2 3 1760993 1. Flag terminal (2) 2. Cable strap (3) 3. Jumper harness routing Figure 7. Brake Switch Trike External Brake Switch DTII NOTE New brake switch must be installed and brake system bleeding has been performed. DT II Software version: v22.8.4 or later. 1. Option for configuration found under Vehicle Setup. 2. Select: Trike Configuration a. Follow steps in DT II. b. Update Vehicle. c. Answer external brake switch question. d. Start brake pedal operation. 3. Monitor countdown. a. If functioning correctly the BCM will notice the brake switch input at pin F3. b. The count down will then be automatically stopped and be continued to the next screen. 4. Did the stop lamp illuminate while depressing rear brake pedal? a. You will need to visually confirm that the brake lights did in fact turn on when the brake pedal was pushed. b. If you did not notice during the previous step you can recheck again now. c. Verify brake switch operation and confirm. Troubleshooting Conditions for a failed configuration: 1. BCM software needs a reflash to the latest version. 2. Rear brake switch input not being received at BCM. a. Incorrect install. b. Brakes not bled so there is no pressure at the switch. c. Switch not functioning. d. Open in wire harness. e. Brake pedal was not pressed twice. 3. When asked if vehicle is equipped with external brake switch and was answered NO. Credit Procedure Talon/h-dnet.com Warranty Claim System Users-Touring Models. For each vehicle involved in this recall (involvement of VIN has been verified on h-dnet.com), submit a recall claim per Table 5. NOTE Enter bulletin number into comment section of claim. Table 5. Talon/h-dnet.com Warranty Claim System Users- Touring Models. ITEM DATA Claim Type SRC Problem Part Number 41000341F Quantity Leave Blank Primary Labor Code 2817 (1) Time 0.2 h Customer Concern Code 0635 Condition Code 9981 (1) Download may be required Upon submission of the properly completed claim, you will be credited for 0.2 hours of labor time for performing the procedure, plus appropriate administrative time. Submit campaign events on their own warranty claim. Do not mix them with other warranty events. Table 6. GDP/SAP System Users-Touring Models. ITEM DATA Claim Type Recall Claim Fix ID-Found in Recall Number R Problem Part Number 41000341F Customer Concern Code 0635 Condition Code 9981 Talon/h-dnet.com Warranty Claim System Users-Trike Models. For each vehicle involved in this recall (involvement of VIN has been verified on h-dnet.com). Submit a recall claim per Table 7. NOTE Enter bulletin number into comment section of claim. 4 / 5 M1568 Table 7. Talon/h-dnet.com Warranty Claim System Users- Trike Models. ITEM DATA Claim Type SRC Problem Part Number 41000341F Quantity Leave Blank Primary Labor Code 2818 (1) Time 1.8 h Customer Concern Code 0635 Condition Code 9982 91500112 and Replacement Part Number 41800770 Quantity 1 (1) Download may be required Talon/h-dnet.com Warranty Claim System Users-Trike Models. Upon submission of the properly completed claim, you will be credited for 1.8 hours of labor time for performing the procedure, plus appropriate administrative time. Credit will also be issued for the recall kit (U.S. only). Submit campaign events on their own warranty claim. Do not mix them with other warranty events. Table 8. GDP/SAP System Users-Trike Models. ITEM DATA Claim Type Recall Claim Fix ID-Found in Recall Number C Problem Part Number 41000341F Customer Concern Code 0635 Condition Code 9982 M1568 5 / 5
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Harley-Davidson Motor Company, 3700 West Juneau Ave., PO Box 653, Milwaukee, WI 53201 414/342-4680 IMPORTANT SAFETY RECALL Owner Notification This notice applies to your vehicle, VIN # 1HD1ACL15NB November 2nd, 2022 Harley-Davidson Recall No. 0635 NHTSA Recall No. 22V781 Dear Harley-Davidson® Motorcycle Owner: This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Harley-Davidson Motor Company, Inc. has decided that certain model year 2019 – 2022 Trike/ CVO Trike motorcycles (see table below) and certain model year 2020 – 2022 Touring/CVO Touring motorcycles (see table below) fail to conform to Federal Motor Vehicle Safety Standard No. 108, Lamps, reflective devices, and associated equipment. We are notifying you because our records indicate that you may own one of these motorcycles. What is the Issue? The brake light(s) may illuminate regardless of whether the rider applies the brakes. If the brake lights(s) remain on, this may confuse other drivers, and increase the risk of a crash. What Should You Do? Please contact your authorized Harley-Davidson motorcycle dealer and arrange an appointment to have your motorcycle repaired. • For Touring and CVO Touring models, the remedy involves a software update only. This update should take less than 30 minutes. • For Trike and CVO Trike models, the remedy involves a software update and installation of a new brake switch. The recall kits are expected to begin shipping to authorized Harley-Davidson dealers in early December 2022. This repair should take approximately 2 hours. FAFATDFAATDDDAFFAAFADATFFTFDDDAFFFDFATTAFAFTFDFFADTADDDTDFAAADDFF 1HD1ACL15NB623373 ************AUTO**SCH 5-DIGIT 03032 P1 C1 ## 0635 To schedule an appointment to have your motorcycle repaired, please contact your Harley-Davidson dealer. The repair will be performed at no cost to you. Due to scheduling, the dealer may require your motorcycle for a longer period. Once the service has been completed, your dealer will ask you to sign a recall claim. If you have previously paid to have this condition addressed, you may be eligible for reimbursement. For more information, please contact us at the number below. If you have sold your motorcycle and have an address for the current owner, it is important that you forward this notice to the new owner. Alternatively, you may contact us at the Harley- Davidson phone numbers listed below and provide us with the new contact information so that we may notify the new owner of this recall. Also, federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten (10) days. What If You Have Additional Questions or Concerns? For more information, or if you take your motorcycle to your dealer on a mutually agreed upon date and they are unable to perform the required service to your satisfaction, please contact Harley-Davidson Motor Company, Inc. for immediate assistance at 1-800-258-2464 in the U.S. or 1-414-343-4056 world-wide. If you are still having difficulty getting your vehicle serviced in a reasonable time or without charge, you may write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington, DC 20590; or call the toll-free Auto Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. We regret any inconvenience this may cause you, but we are initiating this action in the interest of your personal safety and satisfaction with our products. Thank you for your cooperation. Sincerely, Harley-Davidson Motor Company, Inc. Recall 0635 Model Year Models Touring / CVO Touring Models Production Range: 07/02/2019 – 06/23/2022 ONLY Trike / CVO Trike Models Production Range: 07/06/2018 – 06/23/2022 ONLY 2019 FLHTCUTG, FLRT 2020 FLHP, FLHR, FLHRXS, FLHT, FLHTK, FLHTKSE, FLHTKSHRINE, FLHTP, FLHX, FLHXS, FLHXSE, FLTRK, FLTRX, FLTRXS, FLTRXSE FLHTCUTG, FLRT, FLHTCUTGSE 2021 FLH, FLHP, FLHR, FLHRXS, FLHT, FLHTK, FLHTKSE, FLHTKSHRINE, FLHTP, FLHX, FLHXS, FLHXSE, FLTRK, FLTRX, FLTRXS, FLTRXSE FLHTCUTG, FLRT, FLHTCUTGSE 2022 FLHP, FLHR, FLHRXS, FLHT, FLHTK, FLHTKSHRINE, FLHTP, FLHX, FLHXS, FLHXSE, FLHXST, FLTRK, FLTRKSE, FLTRX, FLTRXS, FLTRXSE, FLTRXST FLHTCUTG, FLRT, FLHTCUTGSE
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-781 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Harley-Davidson Motor Company Submission Date : NOV 29, 2022 NHTSA Recall No. : 22V-781 Manufacturer Recall No. : 0635 Manufacturer Information : Manufacturer Name : Harley-Davidson Motor Company Address : 3700 W. Juneau Avenue Milwaukee WI 53201-0653 Company phone : (414) 343-4056 Population : Number of potentially involved : 199,419 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2020-2022 Harley-Davidson Touring and CVO Touring (See Addendum A) Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : This recall includes a total of 167,847 MY 2020 – 2022 Touring and CVO Touring motorcycles that were manufactured with software that determines if/when the brake lamp(s) should be illuminated. Motorcycles produced after 06/24/2022 are equipped with a software calibration update that addresses the potential concern. Production Dates : JUL 02, 2019 – JUN 23, 2022 VIN Range 1 : Begin : 1HD1KRP18LB600080 End : 1HD1FMP11NB645226 ✔ Not sequential Vehicle 2 : 2019-2022 Harley-Davidson Trike and CVO Trike (See Addendum A) Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : This recall includes a total of 31,572 MY 2019 – 2022 Trike and CVO Trike motorcycles that were manufactured with software that determines if/when the brake lamp(s) should be illuminated. Motorcycles produced after 06/24/2022 are equipped with a new pressure switch and a software calibration update that addresses the potential concern. Production Dates : JUL 06, 2018 – JUN 23, 2022 VIN Range 1 : Begin : 1HD1MAF14KB850024 End : 1HD1MCP19NB854018 ✔ Not sequential Part 573 Safety Recall Report 22V-781 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Noncompliance : Description of the Noncompliance : Certain Touring, CVO Touring, Trike and CVO Trike motorcycles may exhibit a condition due to a system interaction between modules that determines when/ if the brake lamp should be illuminated that can result in the brake lamp(s) remaining illuminated regardless of whether the service brakes are applied. This condition may constitute a non-compliance with FMVSS 108, S7.3.5 and Table 1-c. FMVSS 1 : 108 – Lamps, reflective devices, and assoc. Equipment FMVSS 2 : NR Description of the Safety Risk : If the brake lamp(s) remain on, this may increase the risk of a rear end collision by a following vehicle. Description of the Cause : Certain motorcycles in the identified population motorcycles may exhibit a condition that may result in the brake lamp(s) remaining illuminated. Identification of Any Warning that can Occur : A rider may detect that the brake lamp(s) is illuminated during the pre-ride inspection. Involved Components : Component Name 1 : Body Control Software Component Description : Body Control Software Component Part Number : NR Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : 6/10/2021 – 10/28/2021: Harley-Davidson’s Technical Subcommittee (TSC) investigated reports of brake lamps remaining illuminated on some MY20 Touring motorcycles. The TSC requested parts back from the field, engaged the suppliers and requested support in the investigation, and enlisted the support of H-D Engineering. Warranty and Customer Contact records were reviewed and analyzed. Based upon the information and data available (including the low frequency of known incidents and the fact that this condition can correct itself Part 573 Safety Recall Report 22V-781 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 based on riding patterns/behavior), the TSC decided to close its investigation. 5/12/2022: The TSC reopened its investigation after receiving reports indicating a higher occurrence rate of this potential issue. 5/13/2022 – 8/24/2022: The TSC reviewed updated Warranty and Customer Contact records. A software change was implemented at H-D assembly plants that eliminated this potential issue on future production. The TSC elected to monitor this issue monthly. 9/2/2022 – 9/13/2022: After reviewing field data while in monitor status, the TSC moved this issue back to Active status. An updated search and analysis of warranty and customer contacts data was performed. The TSC escalated this issue to H-D’s Field Action Committee (FAC). There have been 287 claims related to this issue beginning as early as 09/20/2019 through 09/08/2022. Harley-Davidson is not aware of any allegations of “brake light remains on” tied to any accidents or injuries. 9/20/2022: The FAC reviewed the TSC’s findings and analysis and escalated the matter to H-D’s Executive Decision Authority (EDA). 9/21/2022 – 10/10/2022: The EDA met twice to discuss and review the information available. In addition, H-D reached out to NHTSA’s Office of Defect Investigation to discuss the circumstances associated with this issue. 10/11/2022: Based upon the information developed during the investigation, the EDA authorized a voluntary recall to address this condition. Description of Remedy : Description of Remedy Program : Owners of affected motorcycles will be advised to arrange service with an authorized Harley-Davidson dealer, who will perform the remedy at no charge to the customer. Dealers will apply a software update to affected Touring and CVO Touring vehicles. Dealers will apply a software update and install a new pressure switch on affected Trike and CVO Trike vehicles. How Remedy Component Differs from Recalled Component : Updated software will address this condition on Touring and CVO Touring models. Updated software and a new pressure switch will address this condition on Trike and CVO Trike models. Identify How/When Recall Condition was Corrected in Production : Production motorcycles beginning on 06/24/2022 have been updated and are not subject to the recall condition. Recall Schedule : Description of Recall Schedule : Harley-Davidson will notify the dealer network between 10/21/2022 and 10/28/2022. Owner notification letters will be sent between 10/26/2022 and 11/02/2022. Planned Dealer Notification Date : OCT 21, 2022 – OCT 28, 2022 Planned Owner Notification Date : OCT 26, 2022 – NOV 02, 2022 Part 573 Safety Recall Report 22V-781 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-781 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Harley-Davidson Motor Company Submission Date : OCT 21, 2022 NHTSA Recall No. : 22V-781 Manufacturer Recall No. : 0635 Manufacturer Information : Manufacturer Name : Harley-Davidson Motor Company Address : 3700 W. Juneau Avenue Milwaukee WI 53201-0653 Company phone : (414) 343-4056 Population : Number of potentially involved : 199,419 Estimated percentage with defect : NR Vehicle Information : Vehicle 1 : 2019-2022 Harley-Davidson Trike and CVO Trike (See Addendum A) Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : This recall includes a total of 31,572 MY 2019 – 2022 Trike and CVO Trike motorcycles that were manufactured with software that determines if/when the brake lamp(s) should be illuminated. Motorcycles produced after 06/24/2022 are equipped with a new pressure switch and a software calibration update that addresses the potential concern. Production Dates : JUL 06, 2018 – JUN 23, 2022 VIN Range 1 : Begin : 1HD1MAF14KB850024 End : 1HD1MCP19NB854018 ✔ Not sequential Vehicle 2 : 2020-2022 Harley-Davidson Touring and CVO Touring (See Addendum A) Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : This recall includes a total of 167,847 MY 2020 – 2022 Touring and CVO Touring motorcycles that were manufactured with software that determines if/when the brake lamp(s) should be illuminated. Motorcycles produced after 06/24/2022 are equipped with a software calibration update that addresses the potential concern. Production Dates : JUL 02, 2019 – JUN 23, 2022 VIN Range 1 : Begin : 1HD1KRP18LB600080 End : 1HD1FMP11NB645226 ✔ Not sequential Part 573 Safety Recall Report 22V-781 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Noncompliance : Description of the Noncompliance : Certain Touring, CVO Touring, Trike and CVO Trike motorcycles may exhibit a condition that can result in the brake lamp(s) remaining illuminated regardless of whether the service brakes are applied. This condition may constitute a noncompliance with FMVSS 108, S7.3.5 and Table 1-c. FMVSS 1 : 108 – Lamps, reflective devices, and assoc. Equipment FMVSS 2 : NR Description of the Safety Risk : If the brake lamp(s) remain on, this may increase the risk of a rear end collision by a following vehicle. Description of the Cause : Certain motorcycles in the identified population motorcycles may exhibit a condition that may result in the brake lamp(s) remaining illuminated. Identification of Any Warning that can Occur : A rider may detect that the brake lamp(s) is illuminated during the pre-ride inspection. Involved Components : Component Name 1 : NR Component Description : NR Component Part Number : NR Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : 6/10/2021 – 10/28/2021 – Harley-Davidson’s Technical Subcommittee (TSC) investigated reports of brake lamps remaining illuminated on some MY20 Touring motorcycles. The TSC requested parts back from the field, engaged the suppliers and requested support in the investigation, and enlisted the support of H-D Engineering. Warranty and Customer Contact records were reviewed and analyzed. Based upon the information and data available (including the low frequency of known incidents and the fact that this condition can correct itself based on riding patterns/behavior), the TSC decided to close its investigation. Part 573 Safety Recall Report 22V-781 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 5/12/2022 – The TSC reopened its investigation after receiving reports that indicated a higher occurrence rate of this potential issue. 5/13/2022 – 8/24/2022 – The TSC reviewed updated Warranty and Customer Contact records. A software change was implemented at H-D assembly plants that eliminated this potential issue on future production. The TSC elected to monitor this issue monthly. 9/2/2022 – 9/13/2022 – After reviewing field data while in monitor status, the TSC moved this issue back to Active status. An updated search and analysis of warranty and customer contacts data was performed. The TSC escalated this issue to H-D’s Field Action Committee (FAC). 9/20/2022 – The FAC reviewed the TSC’s findings and analysis and escalated the matter to H-D’s Executive Decision Authority (EDA). 9/21/2022 – 10/10/2022 – The EDA met two times to discuss and review the information available. In addition, H-D reached out to NHTSA’s Office of Defect Investigation to discuss the circumstances associated with this issue. 10/11/2022 – Based upon the information developed during the investigation, the EDA authorized a voluntary recall to address this condition. Description of Remedy : Description of Remedy Program : Owners of affected motorcycles will be advised to arrange service with an authorized Harley-Davidson dealer, who will perform the remedy at no charge to the customer. Dealers will apply a software update to affected Touring and CVO Touring vehicles. Dealers will apply a software update and install a new pressure switch on affected Trike and CVO Trike vehicles. How Remedy Component Differs from Recalled Component : Updated software will address this condition on Touring and CVO Touring models. Updated software and a new pressure switch will address this condition on Trike and CVO Trike models. Identify How/When Recall Condition was Corrected in Production : Production motorcycles beginning on 06/24/2022 have been updated and are not subject to the recall condition. Recall Schedule : Description of Recall Schedule : Harley-Davidson will notify the dealer network between 10/21/2022 and 10/28/2022. Owner notification letters will be sent between 10/26/2022 and 11/02/2022. Planned Dealer Notification Date : OCT 21, 2022 – OCT 28, 2022 Planned Owner Notification Date : OCT 26, 2022 – NOV 02, 2022 Part 573 Safety Recall Report 22V-781 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-781 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Harley-Davidson Motor Company Submission Date : OCT 18, 2022 NHTSA Recall No. : 22V-781 Manufacturer Recall No. : 0635 Manufacturer Information : Manufacturer Name : Harley-Davidson Motor Company Address : 3700 W. Juneau Avenue Milwaukee WI 53201-0653 Company phone : (414) 343-4056 Population : Number of potentially involved : 199,349 Estimated percentage with defect : NR Vehicle Information : Vehicle 1 : 2019-2022 Harley-Davidson Trike and CVO Trike (all models) Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : This recall includes a total of 31,554 MY 2019 – 2022 Trike and CVO Trike motorcycles that were manufactured with software that determines if/when the brake lamp(s) should be illuminated. Motorcycles produced after 06/24/2022 are equipped with a new pressure switch and a software calibration update that addresses the potential concern. Production Dates : JUL 06, 2018 – JUN 23, 2022 VIN Range 1 : Begin : 1HD1MAF14KB850024 End : 1HD1MCP19NB854018 ✔ Not sequential Vehicle 2 : 2020-2022 Harley-Davidson Touring and CVO Touring (all models) Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : This recall includes a total of 167,795 MY 2020 – 2022 Touring and CVO Touring motorcycles that were manufactured with software that determines if/when the brake lamp(s) should be illuminated. Motorcycles produced after 06/24/2022 are equipped with a software calibration update that addresses the potential concern. Production Dates : JUL 02, 2019 – JUN 23, 2022 VIN Range 1 : Begin : 1HD1KRP18LB600080 End : 1HD1FMP11NB645226 ✔ Not sequential Part 573 Safety Recall Report 22V-781 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Noncompliance : Description of the Noncompliance : Certain Touring, CVO Touring, Trike and CVO Trike motorcycles may exhibit a condition that can result in the brake lamp(s) remaining illuminated regardless of whether the service brakes are applied. This condition may constitute a noncompliance with FMVSS 108, S7.3.5 and Table 1-c. FMVSS 1 : 108 – Lamps, reflective devices, and assoc. Equipment FMVSS 2 : NR Description of the Safety Risk : If the brake lamp(s) remain on, this may increase the risk of a rear end collision by a following vehicle. Description of the Cause : Certain motorcycles in the identified population motorcycles may exhibit a condition that may result in the brake lamp(s) remaining illuminated. Identification of Any Warning that can Occur : A rider may detect that the brake lamp(s) is illuminated during the pre-ride inspection. Involved Components : Component Name 1 : NR Component Description : NR Component Part Number : NR Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : 6/10/2021 – 10/28/2021 – Harley-Davidson’s Technical Subcommittee (TSC) investigated reports of brake lamps remaining illuminated on some MY20 Touring motorcycles. The TSC requested parts back from the field, engaged the suppliers and requested support in the investigation, and enlisted the support of H-D Engineering. Warranty and Customer Contact records were reviewed and analyzed. Based upon the information and data available (including the low frequency of known incidents and the fact that this condition can correct itself based on riding patterns/behavior), the TSC decided to close its investigation. Part 573 Safety Recall Report 22V-781 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 5/12/2022 – The TSC reopened its investigation after receiving reports that indicated a higher occurrence rate of this potential issue. 5/13/2022 – 8/24/2022 – The TSC reviewed updated Warranty and Customer Contact records. A software change was implemented at H-D assembly plants that eliminated this potential issue on future production. The TSC elected to monitor this issue monthly. 9/2/2022 – 9/13/2022 – After reviewing field data while in monitor status, the TSC moved this issue back to Active status. An updated search and analysis of warranty and customer contacts data was performed. The TSC escalated this issue to H-D’s Field Action Committee (FAC). 9/20/2022 – The FAC reviewed the TSC’s findings and analysis and escalated the matter to H-D’s Executive Decision Authority (EDA). 9/21/2022 – 10/10/2022 – The EDA met two times to discuss and review the information available. In addition, H-D reached out to NHTSA’s Office of Defect Investigation to discuss the circumstances associated with this issue. 10/11/2022 – Based upon the information developed during the investigation, the EDA authorized a voluntary recall to address this condition. Description of Remedy : Description of Remedy Program : Owners of affected motorcycles will be advised to arrange service with an authorized Harley-Davidson dealer, who will perform the remedy at no charge to the customer. Dealers will apply a software update to affected Touring and CVO Touring vehicles. Dealers will apply a software update and install a new pressure switch on affected Trike and CVO Trike vehicles. How Remedy Component Differs from Recalled Component : Updated software will address this condition on Touring and CVO Touring models. Updated software and a new pressure switch will address this condition on Trike and CVO Trike models. Identify How/When Recall Condition was Corrected in Production : Production motorcycles beginning on 06/24/2022 have been updated and are not subject to the recall condition. Recall Schedule : Description of Recall Schedule : Harley-Davidson will notify the dealer network between 10/21/2022 and 10/28/2022. Owner notification letters will be sent between 10/26/2022 and 11/02/2022. Planned Dealer Notification Date : OCT 21, 2022 – OCT 28, 2022 Planned Owner Notification Date : OCT 26, 2022 – NOV 02, 2022 Part 573 Safety Recall Report 22V-781 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-781 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Harley-Davidson Motor Company Submission Date : OCT 29, 2022 NHTSA Recall No. : 22V-781 Manufacturer Recall No. : 0635 Manufacturer Information : Manufacturer Name : Harley-Davidson Motor Company Address : 3700 W. Juneau Avenue Milwaukee WI 53201-0653 Company phone : (414) 343-4056 Population : Number of potentially involved : 199,419 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2020-2022 Harley-Davidson Touring and CVO Touring (See Addendum A) Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : This recall includes a total of 167,847 MY 2020 – 2022 Touring and CVO Touring motorcycles that were manufactured with software that determines if/when the brake lamp(s) should be illuminated. Motorcycles produced after 06/24/2022 are equipped with a software calibration update that addresses the potential concern. Production Dates : JUL 02, 2019 – JUN 23, 2022 VIN Range 1 : Begin : 1HD1KRP18LB600080 End : 1HD1FMP11NB645226 ✔ Not sequential Vehicle 2 : 2019-2022 Harley-Davidson Trike and CVO Trike (See Addendum A) Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : This recall includes a total of 31,572 MY 2019 – 2022 Trike and CVO Trike motorcycles that were manufactured with software that determines if/when the brake lamp(s) should be illuminated. Motorcycles produced after 06/24/2022 are equipped with a new pressure switch and a software calibration update that addresses the potential concern. Production Dates : JUL 06, 2018 – JUN 23, 2022 VIN Range 1 : Begin : 1HD1MAF14KB850024 End : 1HD1MCP19NB854018 ✔ Not sequential Part 573 Safety Recall Report 22V-781 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Noncompliance : Description of the Noncompliance : Certain Touring, CVO Touring, Trike and CVO Trike motorcycles may exhibit a condition due to software that determines when/if the brake lamp should be illuminated that can result in the brake lamp(s) remaining illuminated regardless of whether the service brakes are applied. This condition may constitute a non-compliance with FMVSS 108, S7.3.5 and Table 1-c. FMVSS 1 : 108 – Lamps, reflective devices, and assoc. Equipment FMVSS 2 : NR Description of the Safety Risk : If the brake lamp(s) remain on, this may increase the risk of a rear end collision by a following vehicle. Description of the Cause : Certain motorcycles in the identified population motorcycles may exhibit a condition that may result in the brake lamp(s) remaining illuminated. Identification of Any Warning that can Occur : A rider may detect that the brake lamp(s) is illuminated during the pre-ride inspection. Involved Components : Component Name 1 : NR Component Description : NR Component Part Number : NR Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : 6/10/2021 – 10/28/2021 – Harley-Davidson’s Technical Subcommittee (TSC) investigated reports of brake lamps remaining illuminated on some MY20 Touring motorcycles. The TSC requested parts back from the field, engaged the suppliers and requested support in the investigation, and enlisted the support of H-D Engineering. Warranty and Customer Contact records were reviewed and analyzed. Based upon the information and data available (including the low frequency of known incidents and the fact that this condition can correct itself based on riding patterns/behavior), the TSC decided to close its investigation. Part 573 Safety Recall Report 22V-781 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 5/12/2022 – The TSC reopened its investigation after receiving reports that indicated a higher occurrence rate of this potential issue. 5/13/2022 – 8/24/2022 – The TSC reviewed updated Warranty and Customer Contact records. A software change was implemented at H-D assembly plants that eliminated this potential issue on future production. The TSC elected to monitor this issue monthly. 9/2/2022 – 9/13/2022 – After reviewing field data while in monitor status, the TSC moved this issue back to Active status. An updated search and analysis of warranty and customer contacts data was performed. The TSC escalated this issue to H-D’s Field Action Committee (FAC). 9/20/2022 – The FAC reviewed the TSC’s findings and analysis and escalated the matter to H-D’s Executive Decision Authority (EDA). 9/21/2022 – 10/10/2022 – The EDA met two times to discuss and review the information available. In addition, H-D reached out to NHTSA’s Office of Defect Investigation to discuss the circumstances associated with this issue. 10/11/2022 – Based upon the information developed during the investigation, the EDA authorized a voluntary recall to address this condition. Description of Remedy : Description of Remedy Program : Owners of affected motorcycles will be advised to arrange service with an authorized Harley-Davidson dealer, who will perform the remedy at no charge to the customer. Dealers will apply a software update to affected Touring and CVO Touring vehicles. Dealers will apply a software update and install a new pressure switch on affected Trike and CVO Trike vehicles. How Remedy Component Differs from Recalled Component : Updated software will address this condition on Touring and CVO Touring models. Updated software and a new pressure switch will address this condition on Trike and CVO Trike models. Identify How/When Recall Condition was Corrected in Production : Production motorcycles beginning on 06/24/2022 have been updated and are not subject to the recall condition. Recall Schedule : Description of Recall Schedule : Harley-Davidson will notify the dealer network between 10/21/2022 and 10/28/2022. Owner notification letters will be sent between 10/26/2022 and 11/02/2022. Planned Dealer Notification Date : OCT 21, 2022 – OCT 28, 2022 Planned Owner Notification Date : OCT 26, 2022 – NOV 02, 2022 Part 573 Safety Recall Report 22V-781 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 * NR – Not Reported
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