I was at my local dealer today looking for some parts and noticed there is a recall for 2006 & 2007 XL1200L and XL1200N motorcycles built between 10/31/05 and 5/16/07. The bulletin is number M-1208 dated 7/5/07 and the recall is number 0131. If you are the registered owner with H-D you will receive a letter in the mail about the recall.

It involves adding a heat shield to the inside of the rear exhaust pipe so you can't burn your leg on the bare exhaust pipe. I could not get a copy of it since they were busy today and they had just printed it out. Maybe one of the dealership guys can post the actual bulletin in the bulletin section (http://www.xlforum.net/vbportal/forums/forumdisplay.php?f=222).

Nothing today on any fuel pump or rear master cylinder issues that I saw.

--Chris

ooooooooooooooooo, what are the rear master cylinder issues????

Our's feels kinda wonky.

As for the heat shield, that sounds stupid.

K

On the heat shield, the issue is people are burning their pants or legs on the rear pipe. I've never heard about it here on the XLF, but I guess H-D has. Not good.

On the rear master cylinder issue, people have been having some problems on the rubbermounts:
http://xlforum.net/vbportal/forums/showthread.php?t=65452
http://www.xlforum.net/vbportal/forums/showthread.php?p=799458

There are others if you search too. I just remembered now though that there was a requirement in the manuals at one point to rebuild the master cylinder at 2 years or after a certain number of miles, but I have to find out what year that was exactly. Also related, any bike with DOT4 should have the fluid flushed every two years regardless of mileage.

--Chris

Sorry, the brake thing I remember was this. In the 2005 manual at least, it calls for you to replace the following components every four years:


Front brake lever pin
Brake caliper pins
Brake caliper boots and bushings
Rear master cylinder outer boot
Brake rubber components in master cylinders and calipers


In addition, they want the following replaced at 25,000 miles, regardless of the time passed I guess (25,000 miles or four years, whichever comes first):


Brake caliper boots and bushings


That's right: for 2005, they want all those things replaced every four years. Since we're not at four years yet, I doubt not doing these things is causing any of the rear master cylinder troubles. But they sure upped the maintenance requirements for the brakes on 2005.

I didn't check the 2004 or any of the later manuals so I don't know if the requirements are the same or not. This is just an example.

--Chris

Interesting.

I can't put my finger on it, but when she test rode the 1200L she said it felt
"squishy" so I figured it just needed to be bled.

They dealer said they "fixed it" but we never asked how (maybe I should now).

And I've ridden it since, and it just doesn't feel as strong as the rear lever on our 05.

It moves more and doesn't give as firm feeback or I think, as good braking???

Kev

On the heat shield, the issue is people are burning their pants or legs on the rear pipe. I've never heard about it here on the XLF, but I guess H-D has. Not good.

I am surprised they are recalling this. There are other problems that are mentioned more frequently. I only saw it posted once on a forum (not XLF) where someone's pant leg actually set on fire. My only other experience of it was on a 04 Roadster (strangely not included in the recall). My friend has actually lost several pairs of pants riding that bike as he seems to burn a hole in his pant leg every other ride. :doh

I can't put my finger on it, but when she test rode the 1200L she said it felt
"squishy" so I figured it just needed to be bled.

They dealer said they "fixed it" but we never asked how (maybe I should now)

The brake pedal will feel as if there is air in the line. It can actually get bad enough that the brake pedal won't work. However, when you go to try to bleed the brakes they won't bleed. Mine also had orange globs in the brake fluid.

That's right: for 2005, they want all those things replaced every four years. Since we're not at four years yet, I doubt not doing these things is causing any of the rear master cylinder troubles. But they sure upped the maintenance requirements for the brakes on 2005.

Isn't japanese stuff (like the brakes) suppose to be more reliable and less maintenance intense? :laugh

H-D recently expanded this recall. It will now apply to these additional models:

2007
883
883L
883R
1200R
XL50

2006
XL1200R

There was a letter sent to the dealers on December 21, 2007 and they are updating the bulletin which is now M-1208B. If your bike is affected and you are the owner of record with Harley-Davidson, you will receive a recall notice in the mail.

--Chris

Don't know where this heat shield goes, but I put a perforated shield on my rear head pipe (over the factory heat shield) at 100miles after I burned my leg twice.
You can see the shield in the thumbnails on my post:
http://xlforum.net/vbportal/forums/showthread.php?t=52052&page=2