2003 Harley-Davidson FLHT problems

Filed Nov 23, 2009 · Electrical · 32,000 miles · GA

2003 harley-davidson flht electra glide standard. My motorcycle experienced a complete and total failure of all electrical systems to include an uncommanded engine failure at freeway speeds of approximately 65 MPH at the time of the event. H-d has a faulty design that does not permit the adequate cooling of a 50 amp self resetting circuit breaker located adjacent to the battery located slight aft and above the aft cylinder and cylinder exhaust exposed to extreme heating and inadequate cooling. Rider has no instrumentation to show impending electrical failure as the component lacks dangerous temperature warnings. This event occurred at night with the immediate and ultimate loss of all external lighting and engine power. This is clearly a design defect that needs dot investigation for a recall for mandatory installation of a cooling fan and temperature sensor. Rider is a lifelong rider, former military instructor pilot, current faa aviation safety inspector (operations) with extensive training and experience in aircraft and automotive accident investigation. Should this have been an aircraft investigation faa aai-100 would have been urged to mandate and emergency ad to correct the design fault.

Filed May 29, 2007 · Body, Transmission · 95,000 miles · SC

Part failure is eminent. The inner primary was poorly designed. The lack of a proper bushing has resulted in sever wear and a sloppy fit. The steel shifter shaft passes through the aluminum inner primary cover. The additional of a bushing in the design would prevent this failure.