Top 10 Massive Harley-Davidson Recalls of Modern Times

With a legacy extending over a hundred years, Harley-Davidson is a familiar brand name. In motorcycle manufacturing, this U.S.-based company has produced some of the most reliable motorcycles Built in the U.S., even though its local impact seems to be waning, its international market share continues to expand.

Even so, despite that it has been made an abundance of highly successful bicycle models This company isn't infallible. Over the past few years, Harley-Davidson has faced several occasions where they were required to issue recalls for motorcycles or motorcycle components because of different types of flaws.

From brake and clutch issues to headlight failures, the company has faced significant recalls affecting up to hundreds of thousands of motorcycles. Based on reports from the National Highway Traffic Safety Administration (NHTSA) and Harley-Davidson records, we have gathered details on several major recall incidents. Below are 10 of the largest Harley-Davidson recalls in recent years.

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2015 Saddlebag Recall — 185,000

In 2015, Harley-Davidson initiated their largest recall due to problems with the saddlebags on specific bike models. These saddlebags, positioned beneath the motorcycle’s seat for rider convenience, can cause significant issues if they come loose unexpectedly while riding. Many Harley enthusiasts would likely agree that this is not an ideal scenario.

In January 2015, the firm looked into this matter following a rise in warranty claims regarding the flaw. They quickly found out that the saddlebag mounting receptacle had issues. Specifically, a spring inside the receptacle occasionally failed to supply adequate pressure, making it unable to keep the bag firmly attached and leading to situations where the bag would detach.

The recalled models included certain 2014 and 2015 touring motorcycles such as the Road King, Police Electra Glide, and Street Glide. These bikes were produced in the U.S. from May 3, 2013, through May 26, 2015. Meanwhile, in Brazil, the affected period was from July 2013 to June 2015. Altogether, over 185,000 units were part of this recall announced in July 2015.

2017 Oil Line Clamp Installation Mistake Recall — 46,000

Even some of the best Harley-Davidson motorcycles are known for their tendency to develop oil leaks, which confirmed their reputation. In May 2017, it was discovered that the clamps securing the oil cooler lines had been incorrectly fitted in several different motorcycle models. This led the company to announce a recall affecting approximately 46,000 motorcycles.

The consequence of the incorrect setup was that the oil line might come loose, causing engine oil to spill near the rear wheel. This situation could lead to loss of control over the motorcycle and subsequently cause an accident. According to the NHTSA report, they found evidence of just nine cases; out of these, two led to crashes with another incident resulting in minor injuries for the rider.

The sole proposed resolution was to inspect the problematic part. If deemed defective, customers received a complimentary fix. As per the NHTSA document, no compensation was provided. This initiative encompassed 10 distinct 2017 model lines, featuring the Road Glide, Street Glide, Road King, and Police Road King, amongst others.

Brake Malfunction Recalled in 2018 — 175,000

In January 2018, approximately 175,000 motorcycles were subject to a significant Harley-Davidson recall due to issues with the anti-lock brake (ABS) system. This component stops the wheels from locking during abrupt stops.

This issue has been identified across multiple VRSC, Touring, and CVO Touring Harley-Davidson motorcycles such as the Night Rod Special, Road King Police, and Electra Glide Classic, mainly from production years 2008 through 2011. Following an examination of approximately 43 reports which included a handful of accidents, the National Highway Traffic Safety Administration (NHTSA) concluded that initiating a national recall was essential.

In their notification, Harley-Davidson cited the problem as being due to The brake fluid used by bikers in their motorcycles. stating that users who did not perform the suggested biennial maintenance were prone to having deposits within their braking systems. These deposits resulted from DOT 4 brake fluid absorbing moisture, which made the brakes ineffective in certain model variants. Consequently, owners were advised to reach out to a company dealership for a complimentary brake fluid flush as a solution.

2018 Clutch System Recall — 238,300

A significant recall took place in October 2018, triggered by reports indicating that specific Harley-Davidson motorcycle clutches contained flaws which hindered their ability to disconnect properly. This affected the Touring, CVO Touring, and Trike models from 2017 and 2018, along with the 2017 Softail series.

The NHTSA report indicates that the secondary clutch actuator within the hydraulic clutch systems found in numerous motorcycles might experience leakage problems. This leakage can lead to significant fluid depletion over time, enabling air to infiltrate the system and consequently impairing the functioning of the clutch mechanism.

Individuals who might have been impacted were instructed to reach out to a dealership for verification. If their vehicle was included in the recall, they needed to get a new secondary actuator piston assembly fitted. Approximately 238,300 units worldwide faced this issue, with around 177,636 located within the U.S. This marked the firm’s fourth such recall related to clutches over half a decade. Notably, just two years earlier, another clutch defect prompted the return of 27,232 motorcycles.

2019 Brake Malfunction — 44,000

The Street 500 and Street 750 were once among the popular models. The top beginner motorcycle options from Harley-Davidson. Prior to being discontinued in 2021, these models stood out as ideal choices for newcomers and were the most affordable street motorcycles from the manufacturer. Nevertheless, in 2019, several variants faced scrutiny due to a braking problem that heightened the risk of crashes, leading the firm to initiate an extensive global recall.

The incident proved to be quite damaging for the U.S.-based company. Following a brake system recall due to failures back in January 2018, they faced yet another round of issues approximately one year later involving their bikes experiencing similar brake malfunctions. The problem stemmed from corrosion within the brake caliper piston bore, triggered primarily by exposure to harsh conditions such as road salt or humidity. Such corrosion led to brake dragging, heightening the danger of accidents. As per reports at the time of the recall, four collisions were officially recorded.

Harley-Davidson briefly stopped selling street motorcycles and proceeded with replacements for the impacted models. In the U.S., this involved approximately 12,800 units, with nearly 44,000 globally being affected.

2021 Headlight Malfunction Recall — 31,000

A malfunctioning headlight may not appear as a significant issue initially, yet once you hit the streets with your motorcycle, it transforms into a critical safety risk. Due to this concern, Harley-Davidson launched a recall in March 2021 affecting over 31,000 motorcycles.

The firm likely assumed that the shiny chrome plating in the headlamp assembly would serve mainly as an attractive feature rather than a source of trouble. Nonetheless, in certain model variants, this reflective surface emitted more heat than intended, leading to a breach at the end of the dual filament bulb. Consequently, this allowed the gas inside the bulb to leak out, ultimately resulting in total headlight malfunction.

A flaw affected certain 2019 through 2021 Sportster (XL) motorcycles. Additionally, the headlamps were available as replacements for earlier Sportster models from 2005 to 2017, along with Softail and Dyna models ranging from 2005 to 2011, and V-Rod models produced between 2005 and 2011, thus including those within the scope of the recall too. Motorcycle owners received notification about the recall, after which they had their bikes fitted with a new headlamp bulb shield featuring a matte interior coating designed to prevent future issues.

2022 Accidental Activation of Brake Lights — 200,000

In October 2022, Harley-Davidson faced yet another significant recall due to a software issue. It came to light that several Touring, CVO Touring, and CVO Trike models had brake lights that lit up regardless of whether the rider actually used the brakes. This necessitated a recall because it might cause confusion among other drivers or cyclists, potentially resulting in collisions from behind. Furthermore, this situation contravenes Federal Motor Vehicle Safety Standard No. 108: Lamps, Reflective Devices, and Associated Equipment.

The problem was first noticed by the company back in June 2021. Nonetheless, they concluded their investigation roughly four months afterward because of limited report occurrences. Yet as more grievances were filed, the probe got revived in 2022, leading to Harley-Davidson’s Executive Decision Authority (EDA) sanctioning an optional recall eventually.

The owners were advised to visit their dealerships for a software update to resolve this issue. The solution proved highly effective for Touring and CVO Touring models. However, for Trike and CVO Trike vehicles, dealers additionally needed to fit a new pressure switch during the service.

2023 Rear Shock Absorbers Fastening Components — 65,000

Shock absorbers rely heavily on their fasteners to remain securely attached. When Harley-Davidson found out that numerous motorcycles had components prone to breakage without warning, they initiated a recall. Specifically, the defective rear fastener might allow the shock absorber to touch the rear wheel, potentially causing gradual air leakage and making it challenging to control the bike effectively.

The recall took place in August 2023, though it encompassed models from as early as 2018. This action impacted several Softail motorcycle variants, specifically those equipped with a certain type of rear shock adjuster. The list of affected models includes the 2018-2019 FLDE, 2020-2023 FXLRS, 2018-2023 FLHCS, and 2022 FXRST. Despite representing just around 1% of all units manufactured, the overall quantity subject to recall reached 65,224 motorcycles. Additionally, some aftermarket rear suspension kits released during that timeframe shared the same problem; these were addressed through an independent recall affecting approximately 1,282 units.

2024 Concerns About Wire Safety — 47,000

In August 2024, Harley-Davidson faced significant criticism because of certain policies they implemented. The negative attention intensified further in September when the company had to announce their largest recall of the year, triggered by issues with defective electrical wires in several motorcycles.

As stated in the National Highway Traffic and Safety Administration report, the design flaw in the regulator output wire caused it to continuously grind against the front edge of the engine crankcase. This friction wore away the protective insulation on the wire. With this exposed wiring, there was an increased risk of a dangerous electrical short-circuiting incident occurring. Such an event had the potential not only to disable parts of the vehicle’s electric systems but also possibly result in a severe collision.

During their recall process, the company offered complimentary repairs for the regulator output wire harness on all impacted motorcycles from the 2024 model year, which included specific variants like the 2024 FLHX, FLHXSE, FLTRX, FLTRXSE, and FLTRXSTSE. They also installed an additional retaining strap to secure the wire properly. The total number of affected units was 46,923. Shipping of these recall kits started in October 2024.

2024 Brake Line Recall — 15,778

Once more, Harley-Davidson lifted the veil on yet another recall campaign just a short while after addressing issues related to their regulator wires. The recent issue turned out to be a flaw in the brake lines which impacted nearly 16,000 motorcycles. Among these recalled bikes, 739 were from the 2022 FXRST series, whereas the majority—comprising 15,039 units across model years 2022 through 2024—were part of the FXLRST lineup.

The cause of the problem was that the shielding layer on the brake lines deteriorated due to continuous rubbing against the fuel tank, which might lead to leakage of brake fluid. Upon examination, it became clear that this issue probably stemmed from the improper bending of the front-wheel brake lines during manufacturing.

Although this problem had the potential to impact the braking system and result in a collision, no crashes were documented when the recall was issued. Nonetheless, several field reports and durability tests were carried out as part of the inquiry that led to the recall.

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