The 2004 Harley-Davidson Sportster 1200r has 1 NHTSA recall campaign affecting an estimated 9,506 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 4 complaints with NHTSA, most often about the service brakes, hydraulic. Last updated July 5, 2026.
Recall campaigns
SERVICE BRAKES, HYDRAULIC06V2010002006-06-089,506 affected
Defect
ON CERTAIN MOTORCYCLES, THE FRONT MASTER BRAKE CYLINDER ASSEMBLY HAD BEEN BUILT WITH INADEQUATE LUBRICATION ON THE SECONDARY CUP. THIS COULD CAUSE THE SLIDING RESISTANCE OF THE PISTON TO BE EXCESSIVE, WHICH IN TURN COULD CAUSE THE RETURN OF THE PISTON TO BE SLOW UPON RELEASE OF THE BRAKE.
Consequence
THE PISTON MAY NOT RETURN COMPLETELY. IF THIS HAPPENS, THE REAR BRAKE LIGHT COULD REMAIN ILLUMINATED WHICH COULD CAUSE A CRASH OR INJURIES.
Remedy
DEALERS WILL REBUILD THE MASTER CYLINDER. THE RECALL BEGAN ON JULY 10, 2006. OWNERS MAY CONTACT HARLEY DAVIDSON AT 1-414-343-4056.
Complaints by component
SERVICE BRAKES, HYDRAULIC
2
1crashes1injuries
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER
2
Total complaints4
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“Tl*the contact owned a 2004 harley davidson sportster. While driving approximately 65 mph, the contact applied the brake to slow down, but the brakes locked and never unlocked. The vehicle slid to a stop on its side and the contact sustained injuries. The motorcycle was severely damaged. There was…”
“Dt*: the contact stated the vehicle's brakes were inoperable. There was a nhtsa recall, #06v201000, regarding the master cylinder. The parts needed to repair the vehicle were not available at the local dealership. The manufacturer confirmed the parts were not available.”
“Dt*: the contact stated nhtsa recall letter, #06v201000 was received regarding the master cylinder. The parts needed to repair the vehicle were not available at the local dealership. The manufacturer confirmed the parts are not available. The vehicle has not exhibited problems relating to the…”
“Dt*: the contact stated that a recall letter was received pertaining to the front master brake cylinder assembly. While driving at night, the back brake lights malfunctioned and would not warn vehicles traveling from behind the motorcycle that it was about to stop. The motorcycle was taken into…”
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2004 Harley-Davidson Sportster 1200r as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
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