Harley-Davidson® 2005 Factory Recalls
Here are the recalls for 2005 Harley-Davidson's that I know about. For 2005 there were approximately 145,000 bikes recalled for one reason or another. Chances are you '05 is on the list with these numbers. If all of these had been taken back to the dealer and fixed it seems like it would have broken the MoCo. I wonder how many of these bikes are wandering around out there without having gone back for their required fixes? If you know of any recalls that I have missed then please let me know. If I have missed anything you know about then email me at biners@crowderinc.com.
Dyna, Softail, Sportster, Touring
NHTSA Campaign ID: 04E094000 & 04V607000
Component: Fuel System, Gasoline: Carburetor SystemPotential Number of Units Affected: 20,094
Defect Summary: Certain fuel shut-off valves used as replacement equipment, P/NOs 61338-02, 62169-02a, 61338-94d, and 62169-95c for use on certain 2005 carbureted Sportsters, Dyna, Softail, and Touring model motorcycles. These valves may have been produced with the functionality of the 'ON' position and the 'RESERVE' position of the valve may have been reversed.
Consequence Summary: If the bike were operating with the valve in the 'ON' position, the bike could run out of fuel, the expected fuel reserve will not be available. This could lead to the driver running out of gas without warning, increasing the risk of a crash.
Corrective Summary: Dealers will inspect the fuel valve and replace it, if necessary. The recall is expected to begin during January 2005. Owners should contact Harley-Davidson at 1-414-342-4080. If you have had or installed a replacement fuel shut-off valve in your motorcycle, please take your vehicle to your dealer to have the valve inspected for proper operation as soon as possible.
Dyna, Touring, V-Rod, XL
NHTSA Campaign ID: 04V465000
Component: Fuel System, Gasoline: Storage: Tank AssemblyPotential Number of Units Affected: 2828
Defect Summary: On certain motorcycles, a condition occurs that could allow pressure to build up in the fuel tank. On fuel injected vehicles, this condition could cause fuel to spray out unexpectedly when the fuel cap is removed. On carbureted vehicles, excessive fuel could be transferred to the carburetor, which would eventually allow fuel to drip from the air cleaner.
Consequence Summary: These situations could cause serious personal injury or create a fire hazard for persons or property on or near the motorcycle.
Corrective Summary: Dealers will test each canister for blockage, then replace as necessary. The recall is expected to begin on October 11, 2004. Owners should contact Harley-Davidson at 1-414-343-4056.
FLHPEI, FLHPI, FLHTPI
NHTSA Campaign ID: 05V293000
Component: Service Brakes, Hydraulic: AntilockPotential Number of Units Affected: 1552
Defect Summary: On certain police and escort motorcycles, the anti-lock brake system (ABS) lines may have been reversed during installation procedures.
Consequence Summary: This could cause the front brake to lock up if an ABS event is triggered, which could result in a crash.
Corrective Summary: Dealers will inspect and re-route the ABS brake lines. The manufacturer has not yet provided an owner notification schedule. Owners should contact Harley Davidson at 1-414-343-4056.
FLHTCSE2
NHTSA Campaign ID: 05V428000
Component: Service Brakes, Hydraulic: Foundation Components: Hoses, Lines/Piping, and FittingsPotential Number of Units Affected: 462
Defect Summary: Certain motorcycles may have front brake lines which could lead due to a manufacturing defect
Consequence Summary: Should this component fail when in use on the motorcycle, all functionality of the front brake system would be lost without warning, increasing the risk of a crash.
Corrective Summary: Dealers will inspect the front brake line and replace if the braze is not visible. The recall is expected to begin during October 2005. Owners should contact Harley-Davidson at 1-414-343-4056.
FLSTC, FLSTCI, FLSTF, FLSTFI, FLSTN, FLSTNI
NHTSA Campaign ID: 05V151000
Component: Equipment: Other: LabelsPotential Number of Units Affected: 110,000
Defect Summary: Certain motorcycles fail to comply with the requirements of Part 567, 'Certification.' The VIN/Certification label contains incorrect tire size and inflation pressures for the front wheel. The label states the tire size is MT90B21 and the inflation pressure as 30 PSI, whereas the correct tire size is MT90B16, and the correct inflation pressure is 36 PSI.
Consequence Summary: The Certification label is incorrect giving improper information.
Corrective Summary: Harley-Davidson will mail instructions along with corrected federal Certification label. If an owner so desires, a dealer can install the label for them. The recall is expected to begin on April 28, 2005. Owners should contact Harley-Davidson at 1-414-343-4056.
FXD, FXDC, FXDCI, FXDI, FXDX, FXDXI
NHTSA Campaign ID: 04E086000
Component: SteeringPotential Number of Units Affected: 464
Defect Summary: Certain Harley-Davidson aftermarket voltage regulator covers, P/N 74593-04 that can be installed on 2004 and 2005 FXD, FXDX, FXDI, FXDXI Dyna Glide motorcycles, or 2005 FXDC and FXDCI Dyna Glide model motorcycles. The cover may contact the front fender under certain circumstances.
Consequence Summary: Contact may allow the cover and the fender to lock together, thereby limiting suspension travel and steering, possibly resulting in a vehicle crash.
Corrective Summary: Harley-Davidson will notify its customers and repair the motorcycles by removing the accessory cover free of charge. The recall is expected to begin during December 2004. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Harley Davidson at 1-414-343-4056.
Sportster 883R, Sportster 1200R,
NHTSA Campaign ID: 06V201000
Component: Service Brakes, Hydraulic: Foundation Components: Master CylinderPotential Number of Units Affected: 9506
Defect Summary: On certain motorcycles, the front master brake cylinder assembly had been built with inadequate lubrication on the secondary cup. This could cause the sliding resistance of the piston to be excessive, which in turn could cause the return of the piston to be slow upon release of the brake.
Consequence Summary: The piston may not return completely. If this happens, the rear brake light could remain illuminated which could cause a crash or injuries.
Corrective Summary: Dealers will rebuild the master cylinder. The recall is expected to begin on July 10, 2006. Owners may contact Harley-Davidson at 1-414-343-4056.
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