Buell 1125R stalling problems

Filed May 2, 2013 · Engine · 1,400 miles · MO

Tl* the contact owns a 2009 buell 1125r. The contact stated that when the vehicle became hot and the engine fan would engage, the vehicle overheated and stalled. The vehicle was taken to the dealer where it was determined that the stator and the clutch had failed. The dealer replaced the original clutch and changed the wiring harness from a 4-charge to a 3-charge stator and clutch. The wiring harness failure also drained the battery prematurely. The contact changed the battery three times before discovering the failure. The dealer stated that the manufacturer was aware of the problem and had three different companies producing the wiring harness and stator for the clutch, but the failure had not been corrected. The failure mileage was 1,400 and the current mileage was 3,509.

Filed Oct 9, 2012 · Electrical · 10,000 miles · FL · fire

Tl* the contact owns a 2009 buell 1125r motorcycle. The contact stated that while driving 30 MPH, the vehicle stalled with the illumination of the low battery warning light. The vehicle was towed to the dealer for inspection where they stated that the stator needed to be replaced because it had overheated and burned out. The vehicle was repaired but the failure recurred. The manufacturer was notified and stated that the vehicle was no longer under warranty. The failure mileage was 10,000. The VIN was unavailable.

Filed Jun 23, 2012 · Electrical · 13,572 miles · SD

The charging system stator failed and stopped charging the motorcycle, which could lead to a possible stall in traffic.

Filed May 8, 2012 · Electrical · 4,051 miles · CA

Tl* the contact owns a 2009 buell 1125r. The contact stated that while driving approximately 30 MPH, the battery light illuminated on the instrument panel and the vehicle suddenly stalled. The vehicle was towed to the dealer for a diagnostic test. The technician stated that the stator and regulator would have to be replaced. The vehicle was not repaired. The approximate failure mileage was 4,051.

Filed Mar 21, 2012 · Engine · 1,400 miles · FL

Tl* the contact owns a 2009 harley davidson buell 1125r motorcycle. The contact stated that the vehicle would stall frequently and without warning. In addition, the turn signals and gauges would become inoperative. The vehicle was taken to the dealer who replaced parts that were unknown to the contact. The repair did not correct the failure. The manufacturer was notified who offered no assistance. The failure mileage was 1,400 and the current mileage was 8,242.

Filed Oct 12, 2011 · Electrical · 9,500 miles · OH

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.

Filed Oct 11, 2011 · Electrical · 15,000 miles · SC

While driving down road at about 30-35mph, low voltage light came on. Had harley davidson diag and repair burnt stator. Was returned vehicle and charging system worked. Had charging system overlay harness installed by harley davidson. Since then, have had 2 failed voltage regulators, 1 failed battery and have been left stranded numerous times due to discharged battery. Vehicle has stalled at very low speeds(1-5 MPH) while in stop and go traffic on I-26 in the middle lane. Batt was so discharged with no current problems(other than 1 leg of charging being disabled due to harness overlay). Had to push bike by hand across several lanes of traffic during rush hour to get to safety. Vehicle now has 20,000 miles and will have second new regulator installed on 10-14-11.

Filed Jul 5, 2011 · Electrical · 11,000 miles · OH

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.

Filed Jun 21, 2011 · Electrical · 3,706 miles · OH

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.

Filed Jun 20, 2011 · Electrical · 00

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.