Recall 0632 – Brake Fluid Warning Decals – 2021-2022 Harley-Davidson XL1200X, XL883N, & 2021 XL1200NS XL Sportster Motorcycles

“This site contains affiliate links for which OEMDTC may be compensated”

March 16, 2022 NHTSA CAMPAIGN NUMBER: 22V160000

Brake Fluid Warning Labels May Detach/FMVSS 122

Missing brake fluid warning labels may lead to improper brake system maintenance, affecting brake performance and increasing the risk of a crash.

 

NHTSA Campaign Number: 22V160

Manufacturer Harley-Davidson Motor Company

Components SERVICE BRAKES, HYDRAULIC, EQUIPMENT

Potential Number of Units Affected 4,177

 

Summary

Harley-Davidson Motor Company (Harley-Davidson) is recalling certain 2021-2022 XL1200X, XL883N, and 2021 XL1200NS XL Sportster motorcycles. The brake fluid warning labels may detach from the brake fluid reservoir caps. As such, these motorcycles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 122, “Motorcycle Brake Systems.”

 

Remedy

Harley-Davidson will mail replacement labels to owners, free of charge. Owners may also take their motorcycles to a dealer for label inspection and replacement, free of charge. Owner notification letters were mailed April 4, 2022. Harley’s number for this recall is 0632.

 

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

 


Supplemental Procedure Video

WARNING

Always review the appropriate service procedure prior to performing it. This video is intended to supplement, not replace, documented service procedures. Attempting service procedures without the proper training, tools, equipment, and manuals could result in death or injury to you or others. This could also damage the motorcycle or cause the motorcycle to operate improperly. (10406a)

 

This video is a supplement of the procedure covered in the document. This video can only be viewed through Service Information Portal (SIP).

https://serviceinfo.harley-davidson.com/sip/content/document/ view?id=1615454891662166318

 

Purpose for Service Bulletin

This bulletin informs dealers that Harley-Davidson has learned that certain 2021 and 2022 XL Sportster motorcycles may not be compliant with Federal Motor Vehicle Safety Standard (FMVSS) No. 122, Motorcycle Brake Systems. Due to a non-uniform edge, the brake fluid warning decal(s) may not be adequately affixed to the front and rear brake master cylinder cover.

 

Motorcycles Affected

2021 and 2022 Sportster XL models.

 

Inspect

1. Try to remove the decal from front and rear brake master cylinder fluid cover with a finger nail.

2. If the decal cannot be removed with a finger nail, no further action is required.

 

Failure

1. If the decal begins to lift from the front or rear master cylinder cover, completely remove the decal.

 

NOTE

  • Do not clean with denatured alcohol, mineral spirits or other solvents. Damage to components may occur.
  • For maximum bond, surface must be clean and dry.

2. Ensure that surface is clean and dry.

 

Install Decal

NOTE

  • Apply in ambient temperatures between 21–38 °C (70–100 °F).
  • Parts cannot be repositioned after initial installation. Do not remove protective film from adhesive until ready to apply.
  • Do not bend emblem to fit contour of mounting surface.
  • Allow at least 24 hours after application before exposing the area to vigorous washing, strong water spray or extreme weather.
  • The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature.

 

1. Remove protective film from back of decal.

NOTE

  • Protect adhesive from grease, oil, dust, dirt and fingerprints.
  • Once applied, do not shift decal.

2. Position decal in center of master cylinder fluid cover relief.

3. Apply even pressure across entire surface. Hold in place for 15 seconds.

4. Wait 20 minutes before touching decal.

5. If needed, repeat steps 1-4 for other master cylinder fluid cover relief.

 


Chronology :

02/03/2022 – Harley-Davidson’s Technical Subcommittee (TSC) was made aware of a potential issue with MY22 XL (all models) built at York Vehicle Operations. An audit performed on 01/28/2022 revealed that the brake fluid warning decal, part number 44791-07 (DECAL, FRT MSTR CYL/DOT 4), was missing from the front brake master cylinder cap on one of the vehicles inspected during the audit.

02/03/2022 – 02/28/2022 – The TSC conducted a root cause and scope analysis. This included an audit of vehicles as well as discussions with the supplier. The TSC’s investigation indicated that due to a non-uniform edge on the decal, the brake fluid warning statement on some of these vehicles may not be permanently affixed.

03/03/2022 – The Field Action Committee (FAC) reviewed the TSC’s findings and analysis and escalated the matter to H-D’s Executive Decision Authority (EDA).

03/08/2022 – Based upon the information developed during the investigation, the EDA determined that this condition may constitute a noncompliance with FMVSS 122, S5.1.9, and authorized a recall to address this condition. There have been no reports of any accidents or injuries related to this issue.

 


5 Affected Products

Vehicles

MAKE MODEL YEAR
HARLEY-DAVIDSON XL1200NS 2021
HARLEY-DAVIDSON XL1200X 2021-2022
HARLEY-DAVIDSON XL883N 2021-2022

 


8 Associated Documents

Noncompliance Notice 573 Report

RCLRPT-22V160-3532.PDF 217.992KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [212.88 KB]

 


Recall Acknowledgement

RCAK-22V160-1787.pdf 645.505KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [630.38 KB]

 


Recall 573 Report – March 24, 2022

RCLRPT-22V160-8153.PDF 218.05KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [212.94 KB]

 


Remedy Instructions and TSB

RCRIT-22V160-7447.pdf 125.805KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [122.86 KB]

 


Manufacturer Notices(to Dealers,etc)

RCMN-22V160-3359.pdf 118.411KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [115.64 KB]

 


ISSUED Owner Notification Letter(Part 577)

RCONL-22V160-3233.pdf 301.768KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [294.70 KB]

 


Recall Quarterly Report #1, 2022-2

RCLQRT-22V160-4901.PDF 211.152KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [206.20 KB]

 


Recall Quarterly Report #3, 2022-4

RCLQRT-22V160-2148.PDF 211.333KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [206.38 KB]

 


Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V160&docType=RCL

 


 

Bestseller No. 1
Prestone AS401 DOT 3 Synthetic Brake Fluid - 32 oz.
  • Provides an extra margin of safety in extreme braking conditions
  • Mix of polyglycol ethers ensures hot brake-system operation will not create dangerous vapor
  • Excellent for ABS, disc and drum brake systems
  • Delivers braking power when needed by avoiding a spongy pedal
  • Both wet and dry boiling points exceed the minimum government standards
Bestseller No. 2
LUCAS OIL 10826 Brake Fluid - 1 Quart
  • High quality blend of polyethylene glycol ethers and additives
  • Compatible with all brake system rubber components and other brake fluids
  • Prevents seal hardening or softening
  • Protects against rust and corrosion
  • Provides excellent lubricity
Bestseller No. 3
BOSCH ESI6-32N Brake Fluid (Direct Replacement for DOT 3, DOT 4, and DOT 5.1) - 1 Quart
  • High compatibility. Use with or direct replacement for DOT 3, DOT 4, and DOT 5. 1
  • Extended Service Interval (ESI): Lasts 100% longer than DOT 3, 50% longer than DOT 4, and 10% longer than DOT 5. 1
  • Exceeds all DOT 3, DOT 4, and DOT 5. 1 standards
  • Wet boiling point ~ 365 DegreeF/Viscosity at -40 DegreeC ~ 685mm2/s
  • Standard brake fluid has a recommended change interval of 2 years. The recommended change interval for Bosch ESI6 is 3 years.
Bestseller No. 4
Johnsen's 2234 Premium DOT-3 Brake Fluid - 1 Gallon
  • Premium DOT 3 Brake Fluid has a minimum boiling point of 450°F
  • Meets and exceeds DOT 3 and all other Federal and SAE specifications and standards for motor vehicle brake fluids
  • Mixes with all DOT 3 approved brake fluids
  • Designed for use in disc, drum and ABS brake systems
SaleBestseller No. 5
Johnsen's 5034 Premium Synthetic DOT-4 Brake Fluid - 1 Gallon
  • Synthetic quality brake fluid
  • Contains special ingredients to guard against vapor lock and moisture absorption
  • Exceeds requirements for both DOT 3 and DOT 4 brake fluids
  • Specially formulated for DOT 4 brake fluid applications
  • Designed for use in disc, drum and ABS brake systems
Bestseller No. 6
ACDelco GM Original Equipment 10-4110 DOT 3 Hydraulic Brake Fluid - 16 oz
  • Premium brake and hydraulic clutch fluid that protects internal components from corrosion under normal use
  • High boiling point to minimize brake fluid boiling and vapor lock
  • Excellent low temperature capability and stability when used where lower cold viscosities are required
  • Excellent low temperature capability and stability when used where lower cold viscosities are required
SaleBestseller No. 7
Liqui Moly BRAKE FLUID DOT 4 1LTR
  • Premium oil imported from Germany
Bestseller No. 8
Quicksilver 8M0128415 DOT 4 Brake Fluid – 12 Ounce
  • The 336⁰F wet boil point and 521⁰F dry boil point exceeds common characteristics for DOT 4 brake fluids
  • Provides corrosion protection in brake components
  • Matches needs of all DOT 4 manufacturer recommendations
  • Compatible with all DOT 3 and DOT 4 applications
Bestseller No. 9
ATE Original TYP 200 Racing Quality DOT 4 Brake Fluid, 1 Liter Can
  • Minimal decrease of boiling point due to excellent water locking properties
  • Non-foaming when filling and bleeding the brake system
  • Excellent corrosion protection due to selected additives
  • High safety tolerance against steam bubbles
  • Makes brake fluid changing intervals of up to 3 years possible
SaleBestseller No. 10
Motul MTL100949 8068HL RBF 600 Factory Line Dot-4 100 Percent Synthetic Racing Brake Fluid-500, 300. ml, 2 Pack
  • 2 Pack
  • Dry boiling point 594 degrees F
  • Motul 600 brake fluid is 100 percent synthetic and has an extremely high boiling poin
  • Helping to prevent vapor lock and brake fade during hard use
  • This brake fluid exceeds both DOT 3 and DOT 4 specifications

Last update on 2024-04-12 / Affiliate links / Images from Amazon Product Advertising API

This product presentation was made with AAWP plugin.

 


Leave a Comment

Share to...