The National Highway Traffic Safety Administration (NHTSA) reported in late April that Harley-Davidson is recalling 80,039 motorcycles in the U.S. A technical defect in the air filter box component poses a serious injury risk to riders. The root cause of the recall is a blocked vent behind the air filter box, stemming from excess manufacturing material.

This blockage prevents pressure from escaping, leading to extreme pressure buildup inside the crankcase. If the oil dipstick is removed for routine inspection without first relieving this pressure, hot oil can be forcefully expelled from the oil filler hole, risking burns or other injuries. The manufacturer has recorded at least one incident directly related to this defect.

The Road Glide model is included in the U.S. motorcycle manufacturer's recall. *Photo: Harley-Davidson*

The recall campaign affects several motorcycle models, including: Breakout (FXBR), Road Glide (FLTRX, FLTRXL, FLTRT), Street Glide (FLHX, FLHXL, FLHXU), Fat Boy (FLFB), and Heritage Classic (FLHLT). These motorcycles were produced from October 2023 to 11/2.

Although the estimated defect rate is only 0.4% of the total recalled volume, Harley-Davidson advises owners to pay special attention to unusual signs. These include: a loose vent hose, smoke from the exhaust, or abnormal oil consumption. The most noticeable indicator is a sensation of high pressure escaping when the oil dipstick is first opened.

The U.S. motorcycle manufacturer began issuing notifications in late April. Owners of affected vehicles will receive official notices from 11/5 to 20/5. Recalled bikes will undergo inspection of the air filter box vent at authorized dealerships. If a defect is found, technicians will perform the necessary repairs free of charge. Most cases will only require technical inspection and adjustment, rather than replacing new components.

Minh Vu (via Autoblog, NHTSA)