*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.
Engine
My motorcycle suffered a serious engine failure at approximately 12,500 km (7,800 miles) while I was riding. Before the failure, I noticed an unusual ticking/rattling noise coming from the engine, especially when the engine was under load or when the throttle was closed. The failure occurred while riding and caused a sudden loss of engine performance. This happened while I was in traffic and I was extremely close to having an accident because the motorcycle did not respond as expected when I needed power. After the motorcycle was inspected, the failure was found to be related to the camshaft/cam chain tensioning system. The cam chain tensioner had become loose and the resulting failure…
Jul 8, 2026Wheels
My motorcycle suffered a serious engine failure at approximately 12,500 km (7,800 miles) while I was riding. Before the failure, I noticed an unusual ticking/rattling noise coming from the engine, especially when the engine was under load or when the throttle was closed. The failure occurred while riding and caused a sudden loss of engine performance. This happened while I was in traffic and I was extremely close to having an accident because the motorcycle did not respond as expected when I needed power. After the motorcycle was inspected, the failure was found to be related to the camshaft/cam chain tensioning system. The cam chain tensioner had become loose and the resulting failure…
Jul 8, 2026Power train
The cam chain tensioner failed while driving down the road, resulting in reduced power during a pass that almost resulted in an accident. There are no maintenance requirements for this component and there are numerous reports of this failing in motorcycles equipped with the Revolution Max engine. On this engine, the cam chain tensioner is held in place with a bolt that is apparently a torque to spec item with no locking mechanism. During the course of normal operation, the bolt backs out and can have varying degrees of damage. In this case, the forward cylinder cam chain became dislodged from the cams, resulting in a dead cylinder and eventually destroying the intake cam. A cursory check…
Sep 2, 2026Electrical system
The engine stalled when I was exiting the freeway due to the charging system failure. This is the second time the charging system failed. The first failure has been documented on NHTSA complaint number 11746092. I paid the Harley Davidson SLC dealership in April 2024 to have the charging system repaired and replaced. Harley Davidson had released a service bulletin acknowledging charging system deficiencies on 2021-2023 Pan America models and subsequently redesigned the entire charging system for the2024 model year. This is a documented pattern and not just an isolated failure. Regarding the repair in April 2024, the dealership replaced the failed stator with the same poorly designed part…
Jun 10, 2026Electrical system
The charging system for the battery failed when I was on an out of state road trip. The voltage of the bike would drop between 11 and 12 volts when slowing down. I slowed down to make a tight turn on a canyon highway when the bike lost power and stalled. The motorcycle continued to stall several more times while in motion on the highway and I had a difficult time restarting the motorcycle on the side of the highway each time. I ended up purchasing a new battery thinking it would solve the problem. It worked for another few hundred miles until the new battery was also depleted and I had the same issue on the side of the highway outside Sedona. I had to rent a Uhaul for $551 to be able to…
Apr 20, 2024Electrical system
2021 H-D Pan America charging system (stator and/or rotor) failing per dealer testing. Not covered by warranty or extended warranty. Motorcycle is currently at the dealer awaiting parts. Was advised not to ride it because it could run erratic, shut off unexpectedly (very dangerous), fail to start, etc. Possible the magnets can separate from the electrical rotor and cause catastrophic damage requiring engine replacement.
Jun 6, 2026Electrical system
The ignition kill switch is a known problem all over the internet. When the kill switch is switched the bike continues to run. The more the switch has worn, the longer the delay. I'm afraid at some point it's just not going to kill the engine at all which is a major safety hazard.
Sep 4, 2025Electrical system
While going through an intersection at 50 mph the dashboard goes black and resets just like you switched the motor cycle off. This has happened to me three times in last 6 months. Dealer says itâs a bad switch and has since been redesigned and he will sell me one for $406.00, for an extra $100.00 they will install it for me. Plus towing to get my job working motorcycle to the dealer.
May 13, 2026
Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.