The 2004 Buell Xb12s has 1 NHTSA recall campaign affecting an estimated 581 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 10 complaints with NHTSA, most often about the exterior lighting. Last updated July 5, 2026.
Recall campaigns
ELECTRICAL SYSTEM03V4940002003-12-02581 affected
Defect
ON CERTAIN MOTORCYCLES, THE WIRE THAT PROVIDES POWER TO THE HORN, DUE TO MISROUTING, CAN BECOME FRAYED FROM CONTACT WITH THE HORN BRACKET MOUNTING BOLT. AS A RESULT, THE HORN WIRE MAY BECOME EXPOSED, AND WHEN THE HORN BUTTON IS PUSHED, EITHER THE HORN CIRCUIT FUSE OR THE KEY SWITCH FUSE CAN BLOW.
Consequence
IF THE KEY SWITCH FUSE BLOWS, THE VEHICLE CAN STALL, WHICH COULD RESULT IN A CRASH. IF THE HORN FUSE BLOWS, THERE WILL BE A LOSS OF POWER TO THE HORN AND REAR BRAKE LIGHT.
Remedy
DEALERS WILL INSPECT AND CORRECT THE WIRE ROUTING, IF NECESSARY. OWNER NOTIFICATION BEGAN ON DECEMBER 23, 2003. OWNERS SHOULD CONTACT BUELL AT 1-414-342-4680.
Complaints by component
EXTERIOR LIGHTING:HEADLIGHTS
5
EXTERIOR LIGHTING:HEADLIGHTS:CONCEALMENT DEVICES
2
ELECTRICAL SYSTEM
1
ELECTRICAL SYSTEM:12V/24V/48V BATTERY:CABLES
1
ELECTRICAL SYSTEM:WIRING
1
Total complaints10
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“2004 buell xb12r. Poor lighting due to deterioration of inside reflector. *tr”
“Silver coating on headlights deteriorates rapidly causing poor illumination and unsafe night time driving and reducing the motorcycles visibility during the day. I am sure the light output is far below dot standards vehicle is an xb12r firebolt, not an xb12s. The xb12r was not listed as an option.…”
“Silver coating on headlights deteriorates rapidly causing poor illumination and unsafe night time driving and reducing the motorcycles visibility during the day. I am sure the light output is far below dot standards vehicle is an xb12r firebolt, not an xb12s. The xb12r was not listed as an option.…”
“Headlights become dimmer and dimmer, bulbs ok, chrome finish on inside of headlight housings comes off so bulbs do not reflect making night driving dangerous. Buell chat sites confirm others with xbr models having same failures. *jb”
“While riding my 2004 buell xb12s motorcycle though the asm america, inc. Parking lot (3440 east university drive phoenix az 85034) at approximately 11:00 am the on 07-19-06 the following occurred. The motorcycle lost all power and I coasted to a stop into a parking spot: 1.riding through the…”
“The coating on the inside of my headlight housing is falling off, drastically decreasing light output. I had them replaced under warranty once for this on 11/18/05, with 23870 miles on the bike. I am now hardly able to see at night again and I am sure that people can't see me as well either. *jb”
“Headlight on buell motorcycles "r" models (2004 to current year) degrades over time. The reflective coating material in the headlight housing degrades and turns to powder and causes the headlight to be un-useful. The degrade is cause by heat from the headlight. Failure isn't corrected as of today.…”
“Headlight on buell motorcycles "r" models (2004 to current year) degrades over time. The reflective coating material in the headlight housing degrades and turns to powder and causes the headlight to be un-useful. The degrade is cause by heat from the headlight. Failure isn't corrected as of today.…”
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2004 Buell Xb12s as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
contains ads and affiliate links. Full methodology.