Harley-Davidson Motor Company: Safety Recalls in 2004

Updated on March 19, 2026.

There were 8 safety recalls made by Harley-Davidson Motor Company in 2004. See the details of the recalls below.

You can also see similar information for other manufacturers.

Data Source: NHTSA.

See this for other years:

December 23, 2004

(Campaign #: 0118)

HARLEY-DAVIDSON/FUEL VALVE

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.

NHTSA ID: 04V607000

Component: FUEL SYSTEM, GASOLINE

# of Units Affected: 9,501

Consequence Summary:

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.

Corrective Action:

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.

Park Outside Advisory: No

Do not Drive Advisory: No

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December 21, 2004

(Campaign #: NR (Not Reported))

HARLEY-DAVIDSON/REPLACEMENT FUEL VALVES

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.

NHTSA ID: 04E094000

Component: FUEL SYSTEM, GASOLINE

# of Units Affected: 364

Consequence Summary:

Corrective Action:

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.

Park Outside Advisory: No

Do not Drive Advisory: No

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December 6, 2004

(Campaign #: 0117)

HARLEY-DAVIDSON/ABS BRAKES WIRING HARNESS

CERTAIN POLICE MOTORCYCLES WERE BUILT WITH A DEFECTIVE WIRING HARNESS. THE ANTILOCK BRAKE SYSTEM (ABS ) IS WIRED THROUGH THE SAME FUSE CIRCUIT AS THE ABS MALFUNCTION WARNING LIGHT.

NHTSA ID: 04V573000

Component: SERVICE BRAKES, HYDRAULIC

# of Units Affected: 72

Consequence Summary:

THE OPERATOR OF THE MOTORCYCLE WOULD LOSE POWER TO THE ABS WARNING LIGHT AT THE SAME TIME HE LOSES POWER TO THE ABS BRAKE SYSTEM IF THIS PARTICULAR FUSE WOULD BLOW. THE WARNING LIGHT WOULD NOT ILLUMINATE DUE TO THE LOSS OF ELECTRICAL POWER TO THE MOTORCYCLE AND THE OPERATOR MIGHT NOT BE AWARE THAT THE ABS BRAKES WERE NOT FUNCTIONAL. THE GAUGES ARE ALSO WIRED THROUGH THIS FUSE CIRCUIT AND, SHOULD THIS FUSE FLOW, WOULD ALSO CEASE TO FUNCTION.

Corrective Action:

DEALERS WILL REPLACE THE WIRING HARNESS. THE RECALL BEGAN DECEMBER 27, 2004. OWNERS SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-343-4056.

Park Outside Advisory: No

Do not Drive Advisory: No

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November 26, 2004

(Campaign #: 0116)

HARLEY-DAVIDSON/ACCESSORY VOLTAGE REGULATOR

CERTAIN HARLEY-DAVIDSON AFTERMARKET VOLTAGE REGULATOR COVERS, P/N 74593-04 THAT CAN BE INSTALLED ON 2004 AND 2005 FXD, FXDX, FXDI, FXDXI DYNA GLIDE MOTORCYCLES, OR 2005 FXDC AND FXDCI DYNA GLIDE MODEL MOTORCYCLES. THE COVER MAY CONTACT THE FRONT FENDER UNDER CERTAIN CIRCUMSTANCES.

NHTSA ID: 04E086000

Component:

# of Units Affected: 464

Consequence Summary:

CONTACT MAY ALLOW THE COVER AND THE FENDER TO LOCK TOGETHER, THEREBY LIMITING SUSPENSION TRAVEL AND STEERING, POSSIBLY RESULTING IN A VEHICLE CRASH.

Corrective Action:

HARLEY-DAVIDSON WILL NOTIFY ITS CUSTOMERS AND REPAIR THE MOTORCYCLES BY REMOVING THE ACCESSORY COVER FREE OF CHARGE. THE RECALL BEGAN DECEMBER 22, 2004. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT HARLEY DAVIDSON AT 1-414-343-4056.

Park Outside Advisory: No

Do not Drive Advisory: No

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September 30, 2004

(Campaign #: NR (Not Reported))

HARLEY-DAVIDSON/FUEL CANISTERS

ON CERTAIN MOTORCYCLES, A CONDITION OCCURS THAT COULD ALLOW PRESSURE TO BUILD UP IN THE FUEL TANK. ON FUEL INJECTED VEHICLES, THIS CONDITION COULD CAUSE FUEL TO SPRAY OUT UNEXPECTEDLY WHEN THE FUEL CAP IS REMOVED. ON CARBURETED VEHICLES, EXCESSIVE FUEL COULD BE TRANSFERRED TO THE CARBURETOR, WHICH WOULD EVENTUALLY ALLOW FUEL TO DRIP FROM THE AIR CLEANER.

NHTSA ID: 04V465000

Component: FUEL SYSTEM, GASOLINE

# of Units Affected: 2,828

Consequence Summary:

THESE SITUATIONS COULD CAUSE SERIOUS PERSONAL INJURY OR CREATE A FIRE HAZARD FOR PERSONS OR PROPERTY ON OR NEAR THE MOTORCYCLE.

Corrective Action:

DEALERS WILL TEST EACH CANISTER FOR BLOCKAGE, THEN REPLACE AS NECESSARY. THE RECALL BEGAN NOVEMBER 4, 2004. OWNERS SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-343-4056.

Park Outside Advisory: No

Do not Drive Advisory: No

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May 7, 2004

(Campaign #: 0114)

HARLEY-DAVIDSON/TAIL LIGHT BULB

ON CERTAIN DYNA, XL, AND TOURING MOTORCYCLES, THE TAIL LIGHT BULB CAN FALL OUT OF THE SOCKET.

NHTSA ID: 04V218000

Component: EXTERIOR LIGHTING

# of Units Affected: 31,070

Consequence Summary:

THE TAIL LIGHT AND THE BRAKE LIGHT BECOME INOPERATIVE, WHICH COULD LEAD TO A CRASH.

Corrective Action:

DEALERS WILL REPLACE THE BULBS. OWNER NOTIFICATION BEGAN ON JUNE 3, 2004. OWNERS SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-342-4680.

Park Outside Advisory: No

Do not Drive Advisory: No

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March 18, 2004

(Campaign #: 0113)

HARLEY-DAVIDSON/CIRCUIT BREAKER

ON CERTAIN TOURING AND POLICE MODEL MOTORCYCLES, THE 40 AMP MAIN CIRCUIT BREAKER CAN "OPEN" FOR REASONS OTHER THAN WHICH IT WAS DESIGNED, CAUSING AN UNEXPECTED INTERRUPTION OF ALL ELECTRICAL POWER TO THE MOTORCYCLE.

NHTSA ID: 04V134000

Component: ELECTRICAL SYSTEM

# of Units Affected: 81,496

Consequence Summary:

THIS CONDITION COULD CAUSE THE MOTORCYCLE TO STALL, WHICH COULD RESULT IN A CRASH.

Corrective Action:

DEALERS WILL REPLACE THE CIRCUIT BREAKER. OWNER NOTIFICATION BEGAN APRIL 23, 2004. OWNERS SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-343-4056.

Park Outside Advisory: No

Do not Drive Advisory: No

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February 2, 2004

(Campaign #: 0112)

HARLEY-DAVIDSON/FUEL HOSE

ON CERTAIN FUEL INJECTED MOTORCYCLES, THE RUBBER FUEL HOSE HAS THE POTENTIAL TO SEPARATE FROM THE INNER LINER CAUSING A FUEL LEAK.

NHTSA ID: 04V052000

Component: FUEL SYSTEM, GASOLINE

# of Units Affected: 4,593

Consequence Summary:

THIS COULD RESULT IN A FIRE.

Corrective Action:

DEALERS WILL REPLACE THE FUEL LINE ASSEMBLY. OWNER NOTIFICATION BEGAN ON FEBRUARY 12, 2004. OWNERS SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-342-4680.

Park Outside Advisory: No

Do not Drive Advisory: No

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