2005 Harley-Davidson Sportster recalls & complaints
Source: NHTSA, updated daily. Last checked 2026-10-20. Recalls apply to specific VINs — run your VIN to confirm.
2 safety recalls, most serious first
1. Fuel system
What's wrong, in plain English: Fuel lines, tank or pump. Fuel problems usually mean a leak, and leaks mean fire risk. 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.
What could happen: 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.
The fix: DEALERS WILL INSPECT THE FUEL VALVE AND REPLACE IT, IF NECESSARY. THE RECALL BEGAN JANUARY 27, 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…
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 2005 SPORTSTER.
- Book a repair at any authorized Harley-Davidson dealer. Quote NHTSA campaign 04E094000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Manufacturer hotline: 1-414-342-4080.
- 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: FUEL SYSTEM, GASOLINE:CARBURETOR SYSTEM
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: 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.
Remedy: DEALERS WILL INSPECT THE FUEL VALVE AND REPLACE IT, IF NECESSARY. THE RECALL BEGAN JANUARY 27, 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.
Notes: CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-327-4236.
2. Fuel system
What's wrong, in plain English: Fuel lines, tank or pump. Fuel problems usually mean a leak, and leaks mean fire risk. CERTAIN MOTORCYCLES MAY HAVE BEEN PRODUCED WITH DEFECTIVE FUEL SHUT-OFF VALVES. THE FUNCTIONALITY OF THE 'ON' POSITION AND THE 'RESERVE' POSITION OF THE VALVE MAY HAVE BEEN REVERSED.
What could happen: 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.
The fix: DEALERS WILL INSPECT THE FUEL VALVE AND REPLACE IT, IF NECESSARY. THE RECALL BEGAN FEBRUARY 7, 2005. OWNERS SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-342-4080.
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 2005 SPORTSTER.
- Book a repair at any authorized Harley-Davidson dealer. Quote NHTSA campaign 04V607000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Manufacturer hotline: 1-414-342-4080.
- 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: FUEL SYSTEM, GASOLINE:CARBURETOR SYSTEM
Summary: CERTAIN MOTORCYCLES MAY HAVE BEEN PRODUCED WITH DEFECTIVE FUEL SHUT-OFF VALVES. THE FUNCTIONALITY OF THE 'ON' POSITION AND THE 'RESERVE' POSITION OF THE VALVE MAY HAVE BEEN REVERSED.
Consequence: 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.
Remedy: DEALERS WILL INSPECT THE FUEL VALVE AND REPLACE IT, IF NECESSARY. THE RECALL BEGAN FEBRUARY 7, 2005. OWNERS SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-342-4080.
Notes: HARLEY-DAVIDSON RECALL NO. 0118. CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-327-4236.
Useful for owners
- OBD2 code reader — see what the car's computer is reporting
- 2005 Harley-Davidson Sportster owner's manual
Owner complaints filed with NHTSA
Most complained-about parts: Equipment (3), Transmission / drivetrain (2), Fuel system (2), Gasoline (2), Wheels / tires (1).
Complaints are unverified reports from owners. A pattern (many complaints about the same part) matters more than any single one.
Read recent complaints (7)
03/22/2011 · Equipment
I AM A 55 YEAR OLD U.S. TAXPAYING REGISTERED VOTER WHO HAS BEEN RIDING MOTORCYCLES FOR OVER 42 YEARS. I HAVE ADEQUATE HEALTH INSURANCE,OWN MY HOME,FAMILY MAN AND HAVE BEEN AT THE SAME JOB FOR 28 YEARS.I HATE WEARING MOTORCYCLE HELMETS AND HATE EVEN MORE,THE GOVERNMENT TELLING ME THAT I HAVE TO WEAR ONE WHEN I RIDE MY BIKE.I STRONGLY BELIEVE IN FREEDOM OF CH…
03/16/2011 · Equipment
I WANT TO COMPLAIN ABOUT MANDATORY USE OF MOTORCYCLE HELMETS. I BELIEVE ANY PERSON WHO IS LEGALLY OPERATING A PROPERLY REGISTERED, LICENSED AND INSURED MOTORCYCLE SHOULD HAVE THE RIGHT TO DECIDE FOR HIM OR HERSELF IF HE/SHE WANTS TO WEAR A HELMET OR NOT. FORCING ALL MOTORCYCLE RIDERS TO WEAR A HELMET IS DISCRIMINATION AND SHOULD NOT BE ENFORCED. *TR
03/12/2010 · Wheels / tires
THERE IS A COMPANY - DNA SPECIALTY INC. 1415 W. 178TH ST. GARDENA CA, 90248 TEL: (310) 767 - 4070 FAX: (310) 767 - 4091 WORLD WIDE TOLL: (800) 608 - 4446 MAKING "SEALED SPOKE WHEELS" FOR MOTORCYCLES SO THEY RUN WITHOUT TUBES. THE PROBLEM IS, THEY ARE NOT BEING SEALED CORRECTLY AND LEAKING AIR!! NOT A HUGE DEAL FOR ME... I JUST GET…
03/05/2010 · Transmission / drivetrain
TL* THE CONTACT OWNS A 2005 HARLEY DAVIDSON SPORTSTER 1200 CUSTOM MOTORCYCLE. THE TRANSMISSION WOULD NOT DOWN SHIFT TO 3RD GEAR BECAUSE IT WOULD LOCK. THE CONTACT WOULD HAVE TO UP SHIFT TO FOURTH AND FIFTH GEAR BEFORE DOWN SHIFTING TO FIRST GEAR. THIS WENT ON FOR A MONTH. THE DEALER KEPT REPAIRING THE FAILURE, AT LEAST FOUR TIMES UNTIL THE WARRANTY HAS RAN…
03/13/2006 · Fuel system
DT*: THE CONTACT STATED THERE IS A PROBLEM WITH THE FUEL SYSTEM DELIVERY CONCERNING THE CARBURETOR. THE VEHICLE INTERMITTENTLY FAILED TO TURN OFF OR START AND LOST POWER WHILE DRIVING AT VARIOUS SPEEDS. AFTER INSPECTING THE VEHICLE THE DEALERSHIP REPLACED THE FUEL VALVE, THE DRIVE BELT AND ADJUSTED THE TIMING. THE PROBLEMS STILL EXISTS AND THE VEHICLE H…
09/07/2005 · Brakes
NOT LONG AFTER MY 1000 MILE NEW VEHICLE CHECKUP, MY 2005 XL883R SPORTSTER'S FRONT BRAKE LEVER WOULD COLLAPSE TO THE HANDLE BAR. THE FRONT BRAKE WOULD OPERATE, BUT THE LEVER WOULD NOT RETURN TO THE REGULAR POSITION. ALSO THE BRAKE LIGHT WOULD STAY ON. AFTER RIDING A FEW HUNDRED YARDS, AND REPEATEDLY SQUEEZING THE BRAKE LEVER, THE LEVER WOULD FINALLY…
06/27/2005 · Transmission / drivetrain
DT: 2005 HARLEY DAVIDSON WITH 37 MILES ON IT. AFTER THE OWNER LEFT WITH THE MOTORCYCLE SHE NOTICED THAT IT WAS CHOKING AND MAKING TERRIBLE NOISES WHEN THE TRANSMISSION WAS ENGAGED. THE NOISE BEING A SEVERE CLICKING IN 4TH AND 5TH GEARS. IT WA S A TERRIBLE RATTLE AND RINGING IN THE TRANSMISSION. MOTORCYCLE WAS STALLING IN THE MIDDLE OF THE ROAD. IT WOUL…