2005 Harley-Davidson Touring recalls & complaints
Source: NHTSA, updated daily. Last checked 2026-10-19. Recalls apply to specific VINs — run your VIN to confirm.
3 safety recalls, most serious first
1. Fuel system
What's wrong, in plain English: Fuel lines, tank or pump. Fuel problems usually mean a leak, and leaks mean fire risk. 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.
What could happen: 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.
The fix: 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…
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 2005 TOURING.
- Book a repair at any authorized Harley-Davidson dealer. Quote NHTSA campaign 04E094000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Manufacturer hotline: 1-414-342-4080.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: FUEL SYSTEM, GASOLINE:CARBURETOR SYSTEM
Summary: 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.
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 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.
2. Fuel system
What's wrong, in plain English: Fuel lines, tank or pump. Fuel problems usually mean a leak, and leaks mean fire risk. 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.
What could happen: 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.
The fix: 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.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 2005 TOURING.
- Book a repair at any authorized Harley-Davidson dealer. Quote NHTSA campaign 04V607000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Manufacturer hotline: 1-414-342-4080.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: FUEL SYSTEM, GASOLINE:CARBURETOR SYSTEM
Summary: 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.
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.
3. Fuel system
What's wrong, in plain English: Fuel lines, tank or pump. Fuel problems usually mean a leak, and leaks mean fire risk. 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.
What could happen: THESE SITUATIONS COULD CAUSE SERIOUS PERSONAL INJURY OR CREATE A FIRE HAZARD FOR PERSONS OR PROPERTY ON OR NEAR THE MOTORCYCLE.
The fix: 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.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 2005 TOURING.
- Book a repair at any authorized Harley-Davidson dealer. Quote NHTSA campaign 04V465000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Manufacturer hotline: 1-414-343-4056.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY
Summary: 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.
Consequence: THESE SITUATIONS COULD CAUSE SERIOUS PERSONAL INJURY OR CREATE A FIRE HAZARD FOR PERSONS OR PROPERTY ON OR NEAR THE MOTORCYCLE.
Remedy: 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.
Notes: CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).
Useful for owners
- OBD2 code reader — see what the car's computer is reporting
- Compact car fire extinguisher
- 2005 Harley-Davidson Touring owner's manual
Owner complaints filed with NHTSA
Most complained-about parts: Electrical system (6), Suspension (2), Vehicle Speed Control (2), Engine (2), Body / structure (1).
Complaints are unverified reports from owners. A pattern (many complaints about the same part) matters more than any single one.
Read recent complaints (8)
09/26/2005 · Electrical system
THE HORN ON MY 2005 HARLEY DAVIDSON FLHTCUI DOES NOT WORK PROPERLY. THE HORN IS VERY MUFFLED AND IS ONLY AUDIBLE FOR APPROX 50 FEET. *8NM
09/23/2005 · Electrical system
FAULTY HORN ON HARLEY DAVIDSON MOTORCYCLES(FLHT),SAFETY HAZARD,WORKS INTERMITTENTLY. *JB
09/23/2005 · Electrical system
HORN CONTINUALLY FAILS TO OPERATE. HAVE TAKEN IT TO THE DEALER MULTIPLE TIMES ONLY TO BE TOLD THAT IT IS A CHRONIC PROBLEM WITH 2005 HARLEY DAVIDSON MOTORCYCLES AND THERE IS NO FIX.*JB
09/22/2005 · Electrical system
THE HORN ON MY BRAND NEW 2005 HARLEY-DAVIDSON ULTRA CLASSIC HAS NOT WORKED PROPERLY SINCE I HAVE HAD THE BIKE AND THE DEALERSHIP WHERE I PURCHASED THE BIKE TOLD ME THAT THEY CANNOT REPAIR THE HORN. *NM
09/22/2005 · Electrical system
THE HORN ON MY 05 HARLEY DAVIDSON MOTORCYLE DOES NOT WORK. THE DEALERSHIP AND ALL THE OTHER DEALERSHIPS THAT SERVICE HARLEY DAVIDSON'S IN THE AREA KNOW OF NO FIX FOR THE PROBLEM. THEY SAY ALL THE NEW BIKES HAVE DISFUNCTIONAL HORNS AND THE REPLACEMENT PARTS ARE JUST AS BAD. IT IS VERY IMPORTANT TO HAVE A FUNCTIONAL HORN ON A MOTORCYCLE BECAUSE PEOPLE SIMPL…
09/02/2005 · Body / structure
DT: THE CONSUMER STATED WHILE RIDING HIS BIKE, THE CONNECTION PIN CAME OUT OF THE MOUNTING BRACKET AND THE SADDLE BAG DRAGGED ON THE GROUND. HE WAS TRAVELING AT 60 MPH. HE SAYS THERE WAS NO WARNING. THE DEALERS FIRST RESPONSE WAS THIS COULD NOT HAPPEN. THE DEALER WAS ABLE TO DUPLICATE THE PROBLEM. DEALER AND MANUFACTURER WERE CALLED AND HE IS WAITING FO…
08/03/2005 · Suspension · crash
MOTORCYCLE DEVELOPED A HIGH SPEED WOBBLE,WAS TRAVELING IN NEVADA IR15 AT APPROXIMATELY 90 MPH,HANDLEBARS WENT VIOLENTLY RIGHT AND LEFT. COULD NOT STOP THEM FROM MOVING BACK AND FORTH. MOTORCYCLE FORCED ME TO THE ROAD,FIRST IMPACT WAS THE RIGHT SIDE OF MOTORCYCLE. THE MOTORCYCLE FORCED ME TO THE GROUND. *NM
07/29/2005 · Vehicle Speed Control
WHILE DRIVING ON THE INTERSTATE AT APPROXIMATELY 60 MPH THE CRUISE CONTROL STARTED TO ACCELERATE T ON ITS OWN. I COULD NOT GET IT TO TURN OFF UNTIL IT HIT 85 MPH. AFTER THAT THE CRUISE CONTROL WAS INOPERABLE UNTIL THE POWER WAS TURNED OFF. *NM