NHTSA vehicle safety data

2005 Harley-Davidson Sportster Recalls & Complaints

The 2005 Harley-Davidson Sportster has 2 NHTSA recall campaigns and 4 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Harley-Davidson dealer.

NHTSA recall and complaint data for the 2005 Harley-Davidson Sportster. Recall data is refreshed daily from NHTSA.

2005 Harley-Davidson Sportster owner complaints

Owners have filed 4 complaints with NHTSA about the 2005 Harley-Davidson Sportster, describing incidents dated May 23, 2005 to August 18, 2009.

Most-cited components

Fuel/Propulsion System 2 complaints
Power Train 2 complaints
Electrical System 1 complaint
Service Brakes 1 complaint

Newest complaints

ODI #10317090 · Filed March 5, 2010
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…
ODI #10152592 · Filed March 13, 2006
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…
ODI #10135543 · Filed September 7, 2005
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…

Read all 4 complaints

HARLEY-DAVIDSON/FUEL VALVE

NHTSA #04V607000 · Fuel System, Gasoline — Carburetor System · NHTSA notice

Reported December 23, 2004 · HARLEY-DAVIDSON MOTOR COMPANY

Potentially affected: 9,501 vehicles

Harley-Davidson campaign 0118 · Owners notified February 7, 2005

Defect description

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.

Safety 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.

Manufacturer 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.

HARLEY-DAVIDSON/REPLACEMENT FUEL VALVES

NHTSA #04E094000 · Fuel System, Gasoline — Carburetor System · NHTSA notice

Reported December 21, 2004 · HARLEY-DAVIDSON MOTOR COMPANY

Potentially affected: 364 vehicles

Owners notified January 27, 2005

Defect description

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.

Safety consequence

Manufacturer 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.

try.vin has no NCAP crash-test rating on file for the 2005 Harley-Davidson Sportster. NHTSA rates some vehicles by body style — pickups by cab, vans by roof height — so check nhtsa.gov/ratings.

4 owner complaints have been filed with NHTSA for the 2005 Harley-Davidson Sportster.

Power Train; Electrical System

ODI #10317090

Incident: August 18, 2009 · Filed: March 5, 2010

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 BIKE. IN THE PROCESS OF REPAIRING THE DAMAGE, THE CREATED A PROBLEM IN THE TRANSMISSION. IT LOCKED UP IN 3RD GEAR WHEN DOWN SHIFTING, THE CONSUMER COMPLAINED BUT WAS TOLD THAT WAS THE WAY IT SHIFTED. ALSO, THE STARTER HESITATED WHEN STARTING THE BIKE. UPDATED 07/01/10.*JB

Fuel System, Gasoline

ODI #10152592

Incident: March 7, 2006 · Filed: March 13, 2006

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.

Service Brakes, Hydraulic; Fuel System, Gasoline

ODI #10135543

Incident: August 10, 2005 · Filed: September 7, 2005

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 RIDING IT BACK TO THE DEALER BECAUSE OF THE IMPORTANCE OF USING THE FRONT BRAKE WHILE MOTORCYCLE RIDING. *NM

Power Train

ODI #10126717

Incident: May 23, 2005 · Filed: June 27, 2005

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

Other Harley-Davidson Sportster model years

Check your 2005 Harley-Davidson Sportster VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Harley-Davidson Sportster at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

Check a Harley-Davidson VIN