Vehicle recall 78V159000 · July 19, 1978
Harley-Davidson FLH1200, FLH80 and 5 more models
The involved motorcycles were manufactured with front brake master cylinders in which the plunger piston bore diameter was honed .015 inches over maximum specifications.
Source: NHTSA data as of September 22, 2026. Last refreshed Sep 23, 2026, 2:43 AM UTC.
- Summary
- The involved motorcycles were manufactured with front brake master cylinders in which the plunger piston bore diameter was honed .015 inches over maximum specifications. This oversized bore results in a poor fit between the elastomeric piston cup and the cylinder bore, which allows fluid leakage from the hydraulic system.
- Remedy
- Dealer will inspect and, if necessary, replace the front brake master cylinder assembly at no cost to owner.
- Notes
- Vehicle description: motorcycles.system: service brakes; hydraulic system.consequences of defect: fluid depletion could result in loss of brakingeffectiveness, loss of vehicle control, and an accident.note: insufficient brake fluid in the system may be indicated by fluid leakagearound the master cylinder and increased free play in the hand lever.
Recall details
- NHTSA campaign
- 78V159000
- Reported to NHTSA
- July 19, 1978
- Filed by
- HARLEY-DAVIDSON MOTOR CO.
- Owner notification
- August 11, 1978
- Vehicles potentially affected
- 342
- Initiated by
- the manufacturer
- Components
- Service brakes, hydraulic › Foundation components › Master cylinder
Vehicles covered
As listed by NHTSA. A recall usually covers only some vehicles of each model and year, often a production date range.
- Harley-Davidson FLH1200 (1978): 1978
- Harley-Davidson FLH80 (1978): 1978
- Harley-Davidson FX1200 (1978): 1978
- Harley-Davidson FXE1200 (1978): 1978
- Harley-Davidson FXS1200 (1978): 1978
- Harley-Davidson XLCH1000 (1979): 1979
- Harley-Davidson XLH1000 (1979): 1979
Has your Harley-Davidson been repaired?
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