| Issue ID | 1174092 |
| Internal NHTSA # | 10704750 |
| Manufacurer | Harley-Davidson Motor Company |
| Brand | HARLEY-DAVIDSON |
| Model | XL883 |
| Model Year | 2004 |
| File date | 31/08/12 |
| Component | SERVICE BRAKES |
| Product type code | VEHICLE |
| Description of the problem | My wife was riding her motorcycle to work and had just left our residence. She was approaching a curve in the road and went to apply her brakes to slow down before entering it. The rear brake pedal failed with absolutely no pressure. She was able to downshift, slow down, and safely return to our residence. Upon inspecting the rear brake system, we could find no obvious defects (no leaks, fluid full and proper type, pads good, and caliper functioning). Initially we thought the rear brake pads may be too worn (although there was approximately 0. 25" of material left on both pads) and replaced the pads. After this was done, we could see the caliper move, the pads contact the rotor, but there was insignificant pressure to stop the rear wheel. We began researching online and discovered numerous people have reported rear master cylinder failure after having the rear tire or brake calipers removed for service (we had replaced tires on the motorcycle approximately a year before). All signs pointed to the secondary seal inside the master cylinder rupturing and failing. We contacted our local harley davidson dealer to inquire about a possible recall and was told there wasn't any reported issue. We purchased a rear master cylinder rebuild kit and repaired the cylinder. Our finding was exactly as described and expected: the secondary internal seal was ruptured. We believe this is a serious issue that h-d is aware of and should be made to rectify. If my wife had to make a sudden or emergent stop, the failure could have caused her serious injury and/or death. Please investigate this matter before someone does suffer a preventable accident or death. |
| Vehicle Mileage at Failure | 20000 |
| Number of Occurences | 1 |
| Source of the issue | NHTSA WEB SITE |
| City and State | CONROE, TX |
| VIN pattern | XXXXXX |
| Was vehicle invloved in a crash? | N |
| Was vehicle involved in a fire? | N |
| Was incedent reported to police? | N |
| Was medical attention required? | N |
| Was part original equipment? | |
| No. of injured persons | 0 |
| No. of fatalities | 0 |
| Date of purchase | 07/08/26 |
| Was original owner? | N |
| Anti-lock brakes | N |
| Cruise control | N |
| Number of cylinders | |
| Drive train type | |
| Transmission type | |
| Vehicle speed | 30 |
| DoT tire identifier | |
| Tire size | |
| Location of tire code | |
| Type of tire failure code | |
| Was defective tire repaired? | |
| Date of manufacture | |
| Type of child seat code | |
| Type of restraint | |
| Dealer's name | |
| Dealer's telephone number | |
| Dealer's city | |
| Dealer's state code | |
| Dealer's ZIP code |