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Harley-Davidson XL Recalls & Complaints by Model Year

NHTSA lists 4 safety recalls and 7 owner complaints across 8 model years of the Harley-Davidson XL (1989–2005). The most-complained-about year is 2005.

4
safety recalls, all years
7
owner complaints, all years
1990
year with most recalls
2005
year with most complaints

Pick your Harley-Davidson XL model year

Model yearRecallsComplaints
2005 Harley-Davidson XL13
1999 Harley-Davidson XL02
1998 Harley-Davidson XL02
1997 Harley-Davidson XL10
1996 Harley-Davidson XL10
1995 Harley-Davidson XL10
1990 Harley-Davidson XL20
1989 Harley-Davidson XL10

What Harley-Davidson XL owners complain about

Across all model years, owners have filed 7 complaints with NHTSA. The 2005 model year has the most, with 3.

All Harley-Davidson XL recalls (4)

Every NHTSA safety campaign that lists a Harley-Davidson XL, most recent first, with the model years each one covers.

  1. Tank assembly (fuel system)

    NHTSA 04V465000 Reported 2,828 vehicles potentially affected HARLEY-DAVIDSON MOTOR COMPANY

    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…

    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.

    Model years: 2005

  2. Fuel injection system (fuel system)

    NHTSA 96V204000 Reported 176,515 vehicles potentially affected HARLEY-DAVIDSON MOTOR CO.

    The effects of reformulated gasoline along with certain usage of the fuel supply valve affects the supply of gasoline to the carburetor. This condition requires two factors: (1) the use of reformulated fuels containing mbte and (2) starting the motorcycle with the fuel valve handle in the off position.

    Remedy: Dealers the replace the diaphragm in the fuel valve.

    Model years: 1995, 1996, 1997

  3. Cables (electrical system)

    NHTSA 90V002000 Reported 1,914 vehicles potentially affected HARLEY-DAVIDSON MOTOR CO.

    A short circuit could develop due to possible chafing where the battery cable is close to the evaporative emissions control system.

    Remedy: Replace battery cable and other appropriate parts.

    Model years: 1989, 1990

  4. Cables (electrical system)

    NHTSA 90V102000 Reported 3,268 vehicles potentially affected HARLEY-DAVIDSON MOTOR CO.

    Wireform that secures rubber grommets, which serve as a routing guide for the positive battery cable, may not meet specifications.

    Remedy: Replace positive battery cable wireform with wireform that that meets specifications.

    Model years: 1990

Other Harley-Davidson models

Source: NHTSA recall and complaint databases and EPA fuel economy data, October 2026. Complaint counts are owner reports to NHTSA, not verified defects. Recall counts are safety campaigns that list this model year; whether a particular car was already repaired depends on its VIN. How this data is compiled.