The 2005 Harley-Davidson Sportster has 1 NHTSA recall campaign affecting an estimated 9,501 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 6 complaints with NHTSA, most often about the power train. Last updated July 5, 2026.
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.
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.
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.
Complaints by component
POWER TRAIN:MANUAL TRANSMISSION
2
ELECTRICAL SYSTEM:STARTER ASSEMBLY
1
FUEL SYSTEM, GASOLINE
1
FUEL SYSTEM, GASOLINE:CARBURETOR SYSTEM
1
SERVICE BRAKES, HYDRAULIC
1
Total complaints6
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“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…”
“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…”
“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…”
“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…”
“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…”
“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.…”
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2005 Harley-Davidson Sportster as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
contains ads and affiliate links. Full methodology.