Model year record

2005 Harley-Davidson Sportster recalls & problems

The 2005 Harley-Davidson Sportster has 2 safety recalls and 4 owner complaints on file with NHTSA. The most-reported problem area is power train (2 complaints).

Recalls2safety recalls

Complaints4filed by owners

Crashes · fires0 · 0reported in complaints

Injuries · deaths0 · 0reported in complaints

Safety recalls

Fuel system, gasolineDec 23, 2004

Carburetor system

Recall 04V6070009,501 vehicles

Problem: 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.
Risk: 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.
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.

Fuel system, gasolineDec 21, 2004

Carburetor system

Recall 04E094000364 vehicles

Problem: 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.
Risk: 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.
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 PROPER OPERATION AS SOON AS POSSIBLE.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

What owners report

Problem area	Complaints	Typical mileage*
Power trainManual transmission	2	—
Fuel system, gasolineCarburetor system	2	—
Service brakes, hydraulic	1	—
Electrical systemStarter assembly	1	—

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Power train › Manual transmission
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 OUT. THERE IS STILL A FAILURE WITH THE MOTOR CYCLE. THE MANUFACTURER WAS CALLED AND THEY STATED THERE SHOULD BE NO FAILURE BECAUSE THEY HAVE REPAIRED THE PROBLEMS. THE FAILURE MILEAGE WAS 8,500 THE CURRENT MILEAGE IS 9,000. UPDATED 5/10/10 *CN THE CONSUMER STATED THE ESTABLISHMENT WHERE HE PURCHASED THE BIKE FROM HAD AN ACCIDENT WITH THE…
Aug 18, 2009 · 8,500 miles
Fuel system, gasoline › Carburetor 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 HAS NOT BEEN RETURNED TO THE DEALER.
Mar 7, 2006 · 9,200 miles
Fuel system, gasoline
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 STAY FULLY AWAY FROM THE HANDLEBAR. THE ABOVE PROBLEM HAPPENS EVERYTIME I RIDE THE SPORTSTER, AND NOW THE LEVER COLLAPSES AGAINST THE HANDLEBAR, AND THE FRONT BRAKE DOES NOT WORK. THE BIKE IS UNDER WARRANTY, HOWEVER I WANTED TO REPORT THE PROBLEM BECAUSE I CAN'T BELIEVE MY BIKE IS THE ONLY BIKE IN THE US TO HAVE THIS PROBLEM. I'M WORRIED ABOUT…
Aug 10, 2005
Power train › Manual transmission
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 WOULD MAKE A NOISE AND DIE IN THE MIDDLE OF THE ROAD. THE DEALERSHIP TOOK CARE OF THE STALLING, AND IT WAS NOW NOT AS BAD, BUT IS STILL STALLING/ CRACKING/RATTLING, AND RINGING WORSE. MOTORCYCLE IS IN THE SHOP FOR A SECOND TIME, AND THE DEALER HAS NOT EVEN LOOKED AT IT AS OF YET. *AK
May 23, 2005 · 37 miles

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.