2004 Harley-Davidson Sportster 1200r recalls & complaints
Source: NHTSA, updated daily. Last checked 2026-10-19. Recalls apply to specific VINs — run your VIN to confirm.
1 safety recall, most serious first
1. Brakes
What's wrong, in plain English: Anything that slows the car down. Treat brake recalls as urgent. 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.
What could happen: THE PISTON MAY NOT RETURN COMPLETELY. IF THIS HAPPENS, THE REAR BRAKE LIGHT COULD REMAIN ILLUMINATED WHICH COULD CAUSE A CRASH OR INJURIES.
The fix: DEALERS WILL REBUILD THE MASTER CYLINDER. THE RECALL BEGAN ON JULY 10, 2006. OWNERS MAY CONTACT HARLEY DAVIDSON AT 1-414-343-4056.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 2004 SPORTSTER 1200R.
- Book a repair at any authorized Harley-Davidson dealer. Quote NHTSA campaign 06V201000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Manufacturer hotline: 1-414-343-4056.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER
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: THE PISTON MAY NOT RETURN COMPLETELY. IF THIS HAPPENS, THE REAR BRAKE LIGHT COULD REMAIN ILLUMINATED WHICH COULD CAUSE A CRASH OR INJURIES.
Remedy: DEALERS WILL REBUILD THE MASTER CYLINDER. THE RECALL BEGAN ON JULY 10, 2006. OWNERS MAY CONTACT HARLEY DAVIDSON AT 1-414-343-4056.
Notes: HARLEY-DAVIDSON RECALL NO. 0125. CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.
Useful for owners
- OBD2 code reader — see what the car's computer is reporting
- 2004 Harley-Davidson Sportster 1200r owner's manual
Owner complaints filed with NHTSA
Most complained-about parts: Brakes (4), Hydraulic (4).
Complaints are unverified reports from owners. A pattern (many complaints about the same part) matters more than any single one.
Read recent complaints (4)
05/28/2008 · Brakes · crash
TL*THE CONTACT OWNED A 2004 HARLEY DAVIDSON SPORTSTER. WHILE DRIVING APPROXIMATELY 65 MPH, THE CONTACT APPLIED THE BRAKE TO SLOW DOWN, BUT THE BRAKES LOCKED AND NEVER UNLOCKED. THE VEHICLE SLID TO A STOP ON ITS SIDE AND THE CONTACT SUSTAINED INJURIES. THE MOTORCYCLE WAS SEVERELY DAMAGED. THERE WAS NO POLICE REPORT. THE CURRENT AND FAILURE MILEAGES WER…
08/25/2006 · Brakes
DT*: THE CONTACT STATED THE VEHICLE'S BRAKES WERE INOPERABLE. THERE WAS A NHTSA RECALL, #06V201000, REGARDING THE MASTER CYLINDER. THE PARTS NEEDED TO REPAIR THE VEHICLE WERE NOT AVAILABLE AT THE LOCAL DEALERSHIP. THE MANUFACTURER CONFIRMED THE PARTS WERE NOT AVAILABLE.
08/04/2006 · Brakes
DT*: THE CONTACT STATED NHTSA RECALL LETTER, #06V201000 WAS RECEIVED REGARDING THE MASTER CYLINDER. THE PARTS NEEDED TO REPAIR THE VEHICLE WERE NOT AVAILABLE AT THE LOCAL DEALERSHIP. THE MANUFACTURER CONFIRMED THE PARTS ARE NOT AVAILABLE. THE VEHICLE HAS NOT EXHIBITED PROBLEMS RELATING TO THE RECALL DEFECT.
08/03/2006 · Brakes
DT*: THE CONTACT STATED THAT A RECALL LETTER WAS RECEIVED PERTAINING TO THE FRONT MASTER BRAKE CYLINDER ASSEMBLY. WHILE DRIVING AT NIGHT, THE BACK BRAKE LIGHTS MALFUNCTIONED AND WOULD NOT WARN VEHICLES TRAVELING FROM BEHIND THE MOTORCYCLE THAT IT WAS ABOUT TO STOP. THE MOTORCYCLE WAS TAKEN INTO THE DEALERS FOR REPAIRS AND THE PART WAS UNAVAILABLE. THE MA…