HD Clutch Recall 2018...Over 200,000 Affected!

[MDO]

I got my safety recall letter today. I was supposed to be there tomorrow at 10am, but we pushed it back to noon. We are forcast to get snow showers tonight. I had to break out my Tourmaster winter gauntlet gloves.

I have only used them once in 20 years, so there in great shape.

I don't normally ride when it's 22°, but I want to get this done. They are serving lunch to Veterans, so if there is no freezing issues, I'm gonna brave it & go.

 

[Ray55]

I got my recall notice yesterday, so today I went to the dealer and was talking to one of the service writers and he said that they sent out over 200 automated phone calls to owners about the recall and that they got 6 kits in the mail this past week. He said that they are expecting a lot more replacements next week.

 

[MDO]

19° this morning, but I braved it & went to my chosen dealer, Doc's HD & got the recall done. It took them about an hour. On the service order, they write it up for 1 recall kit, 1 bottle of DOT 4 brake fluid & 1.1 hours labor. I can't say that I noticed any difference in the clutch actuation/ engagement, but then again, I could not feel my fingers

Those Tourmaster winters gloves I thought were good, officially suck!

A couple good things, Doc's HD in St. Louis, served a BBQ lunch for Veterans today & also handed out a nice coffee mug. They are a very nice dealership. The owner, Beth, was there greeting & talking with everyone. A class organization.

 

[Free Bird]

A little detail on YouTube

 

[MDO]

On the order, they put the part price at $10.99 & the brake fluid at $7.99 + the labor.

 

[Free Bird]

On the order, they put the part price at $10.99 & the brake fluid at $7.99 + the labor.

That's odd... they said it was more like $150/bike but I won't have a receipt for the work for a while (after the paint)

 

[MDO]

That's odd... they said it was more like $150/bike but I won't have a receipt for the work for a while (after the paint)

That would be about right. $18.98 in parts + 1.1 hours labor.

220,000 vehicles × $150=$33 million.

 

[Free Bird]

That would be about right. $17.98 + 1.1 hours labor.

220,000 vehicles × $150=$33 million.

Oops... yes you said "plus labor":blush:

And yes BIG bucks. And I understand it was a design issue, not a defective part that they can push to a supplier. Wrong choice of materials for the application.

 

[MDO]

With the transmission fluid migrating to the primary on some engines, this could be an attempt to supplement the tranny fluid level with some fresh dot 4.

 

[Jack Klarich]

A little detail on YouTube

I see what looks like a gasket for the trap door in the bag

Any one confirm this?

 

[Free Bird]

I see what looks like a gasket for the trap door in the bag

Any one confirm this?

It is the seal on the back of the secondary clutch actuator (item 33 below). You can see the original installed and the replacement part from the kit in the video captures below

 

[Jack Klarich]

It is the seal on the back of the secondary clutch actuator (item 33 below). You can see the original installed and the replacement part from the kit in the video captures below

View attachment 63805

Look when he is holding the parts bag, I see what looks like a door cover gasket and the piston with the seal already installed

I dunno why the door would have to come off, the piston appears to deal the slave cylinder to the door. I am wondering if HD is wanting to check the inside of the trap door?

I do not trust this fix

 

[MDO]

I see the seal your talking about Jack. I'm just guessing, but they may change that seal if after the piston/seal change, it fails the leak down test.

I can imagine what the DOT 4 does to certain seals if it eats paint.

 

[Free Bird]

I see the seal your talking about Jack. I'm just guessing, but they may change that seal if after the piston/seal change, it fails the leak down test.

I can imagine what the DOT 4 does to certain seals if it eats paint.

Ah! I see what you're referring to Jack... Looks like the kit does come with a tranny side cover gasket. To MDO's point, likely backup in case the pressure test fails.... And I would agree that the fact they are sending 230k + cover gaskets out with the recall kits says there is likely a potential failure mode for the gasket or its intention that is not discussed in the recall letter.

 

[dannymax]

I had the recall work done yesterday, about an hour from arrival to departure (which included a complementary bike wash).

The service mgr showed me one of the kits, I don't recall seeing a gasket of the type shown above but honestly didn't check it out that closely. The service record showed 12 oz. of platinum hyd. fluid so a complete change was done....as you would expect. Once I de-trailer the bike today I will get a benchmark fluid level and monitor it over the 2019 riding season.

The extend-a-trailer tagged along like it wasn't even there and the bike rode comfortably with no complaints. A couple extra steps to load & unload but overall a nice low budget setup for the rare times I will be needing to trailer the bike.

 

[MDO]

John Maxwell does the clutch recall on a trike...Very good.

Here is a link to the clutch recall performed on a trike. Note to all- he has a different recall kit than the previous video??? It's a new derby cover O-ring.

 

[dannymax]

Here is a link to the clutch recall performed on a trike. Note to all- he has a different recall kit than the previous video??? It's a new derby cover O-ring.

The recall kit pictured in this video (with the derby cover o-ring) is the one used on my '17 FW.

 

[Jack Klarich]

AHHHAAAA, I thought I saw another gasket in the earlier post. I thought it was a tranny door gasket. Now it makes sense after checking the clutch plate lift to replace the derby cover o ring

Thanks Michael

 

[MDO]

AHHHAAAA, I thought I saw another gasket in the earlier post. I thought it was a tranny door gasket. Now it makes sense after checking the clutch plate lift to replace the derby cover o ring

Thanks Michael

I really like his videos. He has a way of cutting through the B.S.

I thought the same as you that it looked like a tranny door gasket. I am a bad boy in that I have had my derby cover off twice in a year & I re-used the original o-ring as it looked fine. It is not under that much pressure & I clean it & the mounting surface off with a lint free cloth. At my 10,000 mile service, I will be a good boy & replace it. :clapping:

Actually, QUAID HD replaced it at the 1,000 mile service, so it's not the original.

 

[Jack Klarich]

I thought the same as you that it looked like a tranny door gasket. I am a bad boy in that I have had my derby cover off twice in a year & I re-used the original o-ring as it looked fine. It is not under that much pressure & I clean it & the mounting surface off with a lint free cloth. At my 10,000 mile service, I will be a good boy & replace it. :clapping:

I like the rubber O ring type gasket better than the paper one.

I relube mine with some di-lectric grease and re use it, checking to make sure it is still pliable and has not shrunk

I have not changed one for many years now with NO leakage and a lot of miles and services

 

[Free Bird]

Mea Culpa Maxima..... I thought it was a tranny door seal too.

BUT.... Did you see the design of the seal to clutch pushrod contact surface!?!.... Rubber/teflon/polymer-of-some-sort surface on metal?????

I am glad Harley's don't fly.....

I REALLY miss cables...... Just sayin.....

 

[Jack Klarich]

Mea Culpa Maxima..... I thought it was a tranny door seal too.

BUT.... Did you see the design of the seal to clutch pushrod contact surface!?!.... Rubber/teflon/polymer-of-some-sort surface on metal?????

I am glad Harley's don't fly.....

I REALLY miss cables...... Just sayin.....

Yeah, I would think Brembo would have a better design

What I want to know is what change did they make this time? This is the 3rd running change I believe. The outer dust boot/ gasket looks pretty cheesie to me, tho the quad ring seal on the piston seals the brake fluid internally, Over all i see more problems with more miles Hope i am wrong To note mine has had no problems in over 18K miles. I have bled mine 2 times now and re lubed the perch @ 5K intervals

 

[Free Bird]

Yeah, I would think Brembo would have a better design

Didn't know if you had seen the working end of the AIM unit MDO found...but I agree with him... this is looking better and better

 

[Jack Klarich]

Didn't know if you had seen the working end of the AIM unit MDO found...but I agree with him... this is looking better and better

View attachment 63911

That is a good looking unit, I have read good reports on this one

 

[MDO]

Didn't know if you had seen the working end of the AIM unit MDO found...but I agree with him... this is looking better and better

View attachment 63911

It seems that the AIM piston has a bigger surface area. I wonder if that, in combination with a different spring, makes the 40% reduced clutch pull possible .

If I have any problems at all with the new OEM parts, I'm dropping the $280 for that unit. It's too important to be messing around.

 

[Jack Klarich]

Side by side, HD one on the right

The AIM looks way better to me

 

[MDO]

What do you think would cause their part to reduce clutch pull ?

I would like to see the back side of theirs like John Maxwell showed on the recall repair in the video.

 

[Jack Klarich]

What do you think would cause their part to reduce clutch pull ?

Depth or length of piston, if you look close you will see the difference in the pocket that the push rod sits in

I am wondering what the bore of the cylinder is? I know it has a steel piston ( The HD Brembo looks to be aluminum)

I n my experience with hydraulics , cylinders with aluminum pistons distort faster than steel, ( they will flex or side load easier) my guess is the heat factor Aluminum pistons most often are anodized surfaces to reduce rust, tho I have seen pretty severe scoring from this also. Mostly from abuse when it comes to fluid changes. Like you I cannot stress how important it is to stay up on the fluid

 

[MDO]

Watching the video, I'm assuming the fluid hydraulic pressure moves the rod to engage the clutch & the spring moves it back???

HD charges $60 for their actuator & AIM $280

I wish I was a machinest, I would R & D the AIM cylinder.

That's ripoff & duplicate.

 

[Jack Klarich]

Watching the video, I'm assuming the fluid hydraulic pressure moves the rod to engage the clutch & the spring moves it back???

HD charges $60 for their actuator & AIM $280

I wish I was a machinest, I would R & D the AIM cylinder.

That's ripoff & duplicate.

The hydraulic pressure moves the piston in and out, the square cut seal seals the piston to the cylinder ( the seal not only seals the cylinder , like brakes it also retracts the piston) Brembo uses the spring to keep constant tension on the piston to push rod IMO

This is a strange design WE have seen this on split wheel cylinders years ago