RoadVitals

2003 Harley-Davidson Flstfi

Recalls, owner-reported complaints, investigations and safety data

Data refreshed

Owner complaintsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
1
Latest Sep 29, 2016
Safety recallsA safety recall is issued when a manufacturer or NHTSA determines that a vehicle has a safety-related defect or does not comply with a federal motor vehicle safety standard. Recall repairs are free. Whether a specific vehicle is covered depends on its VIN — a recall listed for a model year does not necessarily apply to every vehicle of that year.
1
Latest Apr 14, 2005
InvestigationsNHTSA opens an investigation to examine whether a safety defect may exist. An open investigation is not a determination that a defect exists, and many investigations close without a recall. Investigations can, however, lead to one.
0
Crash or fire reportedComplaints whose submitter recorded that a crash or a fire occurred. These are the reporter's own answers on the NHTSA form, not verified findings.
0

Overview

Our database contains 1 NHTSA owner-reported complaint for the 2003 Harley-Davidson Flstfi, most frequently naming the engine category. 1 safety recall has been issued covering this model year; and 6 manufacturer communications are on file.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

What owners report

Complaints grouped by the component NHTSA recorded

  • Engine1100.0%

Percentages are of component mentions. A single complaint can name more than one component, so these do not sum to the total complaint count.

Safety recalls

1 campaign cover this model year

Recalls apply to specific vehicles, not to every vehicle of a model year. Check your VIN with NHTSA or your manufacturer's dealer to confirm whether a recall affects your vehicle.

Check a VIN on NHTSA.gov
05V151000

EQUIPMENT:OTHER:LABELS

Apr 14, 2005
167,628 units potentially affected
The defect: CERTAIN SOFTAIL MOTORCYCLES FAIL TO COMPLY WITH THE REQUIREMENTS OF PART 567, 'CERTIFICATION.' THE VIN/CERTIFICATION LABEL CONTAINS INCORRECT TIRE SIZE AND INFLATION PRESSURES FOR THE FRONT WHEEL. THE LABEL STATES THE TIRE SIZE IS MT90B21 AND THE INFLATION PRESSURE AS 30 PSI, WHEREAS THE CORRECT TIRE SIZE IS MT90B16, AND THE CORRECT INFLATION PRESSURE IS 36 PSI.
The risk: THE CERTIFICATION LABEL IS INCORRECT GIVING IMPROPER INFORMATION.
The remedy: HARLEY- DAVIDSON WILL MAIL INSTRUCTIONS ALONG WITH CORRECTED FEDERAL CERTIFICATION LABEL. IF AN OWNER SO DESIRES, A DEALER CAN INSTALL THE LABEL FOR THEM. THE RECALL BEGAN ON JUNE 6, 2005. OWNERS MAY CONTACT HARLEY-DAVIDSON AT 1-414-343-4056.
HARLEY-DAVIDSON MOTOR COMPANYView on NHTSA.gov

Recent owner complaints

Reports submitted to NHTSA, shown in the owner's own words

Engine
Filed Sep 29, 2016

199-2005 TWIN CAM HARLEY DAVIDSON MOTORCYCLES HAVE A DEFECTIVE CAM CHAIN TENSIONER DESIGN. THESE PARTS CAN WEAR OUT IN SOME CASE IN LESS THAN 15,000 MILES AND REQUIRE AN EXPENSIVE REPLACEMENT COST RANGING FROM $800 TO OVER $8000. THE CAM CHAIN TENSIONER IS A SPRING DESIGN WITH A SMALL PLASTIC PAD. THERE ARE 2 CAM FOLLOWERS USED IN THE DESIGN. THE PADS WEAR AND THE PLASTIC IS DISTRIBUTED THROUGH THE OIL SYSTEM OF THE BIKE AND CAN CAUSE THE ENGINE TO FAIL. THIS IS THE FIRST TYPE OF FAILURE DUE TO THE CAM FOLLOWER. THE SECOND POSSIBLE FAILURE IS WHEN THE PAD WEARS OUT COMPLETELY AND THE SPRING GOES INTO THE CAM CHAIN WHICH CAN CAUSE THE ENGINE TO FAIL. IF THE ENGINE FAILS AND LOCKS UP DUE TO EITHER FAILURE THE REAR TIRE CAN LOCKUP AND SKID POSSIBLY CAUSING THE MOTORCYCLE TO CRASH BEFORE THE RIDER CAN DETERMINE WHAT IS HAPPENING AND REACT PROPERLY. HARLEY DAVIDSON RELEASED A SOMEWHAT BETTER DESIGN IN 2005 ON SELECT MODELS AND IN ALL MODELS IN 2006. THE NEW DESIGN IS SAID TO LAST FOR AT LEAST 50,000 MILE. THERE ARE OTHER 3RD PARTY DESIGNS ON THE MARKET THAT WILL LAST THE LIFE OF THE ENGINE. THERE IS NO MENTION OF THE NEED TO INSPECT/REPLACE THE CAM CHAIN TENSIONERS EVERY 15,000 MILES IN THE OWNERS MANUAL. I FOUND OUT FROM A FRIEND AND STARTED TO INVESTIGATE THE ISSUE. I SPOKE TO THE DEALER AND WAS TOLD THAT HARLEY DAVIDSON NOW CONSIDERS IT A WEAR PART. I AM SURE THAT IF IT WAS DISCLOSED WHEN THE MOTOR WAS FIRST RELEASED THAT SALES WOULD HAVE BEEN LESS THAN STELLAR. IF THIS WAS A CAR EXHIBITING A SORT OF PROBLEM THAT COULD CAUSE A FATAL CRASH AND EXPENSIVE REPAIR THAT THERE WOULD BE A RECALL TO FIX THE PROBLEM WITH NO COST TO THE OWNER. WITHOUT AN INSPECTION OF MOTOR COSTING AT LEAST $150 THERE IS NO RELIABLE WAY TO DETECT THE FACT THAT THE PARTS MAY SOON FAIL SO IT IS LIKE A TICKING TIME BOMB.

NHTSA ID
10910637
Incident
Sep 29, 2016
Mileage
16,000 mi

Manufacturer communications

A bulletin sent by a manufacturer to its dealers. Not a recall, and repairs are not necessarily free.

M1684

ELECTRICAL SYSTEM

SERVICE BULLETIN M1684: MARKET SPECIFIC BATTERY INTRODUCTION. PURPOSE: Initial Release. This bulletin informs dealers of the availability of new batteries for new Original Equipment (OE) vehicle production and in the Parts and Accessories (P&A) catalog. Availability of the new Absorbed Glass Mat (AGM) batteries will vary by market and will be transitioning over the next few months. NOTE: The ring terminal screws are not compatible between Leoch and East Penn batteries. The new batteries will include new ring terminal screws, which must be used. The ring terminal screws from the old battery need to be discarded.

M1555

ELECTRICAL SYSTEM

SERVICE BULLETIN M1555 (REV E): BATTERY WARRANTY GUIDELINES. PURPOSE: Revision E. Added: Added procedures for the DCA-8000 E Battery Tester.* Updated: All sections. This bulletin informs the dealership network that Harley-Davidson has provided guidelines for battery warranty.

M1490

ELECTRICAL SYSTEM

SERVICE BULLETIN M1490 (V 24.8.8): DIGITAL TECHNICIAN II - UPDATES AND RELEASE NOTES. PURPOSE: This bulletin informs dealers that Harley-Davidson has made a software update to Digital Technician II (DT II). DIGITAL TECHNICIAN II (PART NUMBER: HD-48650). Version 24.8.8. Release Date: Week of August 5, 2024. New Features for Harley-Davidson vehicles: Advanced Module Replace for 2021 and later Revolution Max; 2023 and later CVO Touring; and 2024 Street Glide (FLHX), Road Glide (FLTRX). New Features for LiveWire vehicles: Updated calibrations for 2024 S2DM EV1/ EV6; 2024 S2MH EV1; and 2024 S2DM, S2MH. Changes: Added Hand Control Module (HCM) (Part No. 71500522A and 71500536A) for reflash support.

PAB1158

ENGINE; POWER TRAIN

GENUINE MOTOR PARTS AND MOTOR ACCESSORIES BULLETIN PAB1158: OIL FILTER PACKAGING AND CASE QUANTITY UPDATE. PURPOSE: To inform dealerships that Harley-Davidson has made updates to oil filters including new part numbers, packaging design, and bulk case quantity changes.

M1490

ELECTRICAL SYSTEM

SERVICE BULLETIN M1490 (V 24.6.4): DIGITAL TECHNICIAN II - UPDATES AND RELEASE NOTES. PURPOSE: Revision. This bulletin informs dealers that Harley-Davidson has made a software update to Digital Technician II (DT II). DIGITAL TECHNICIAN II (PART NUMBER: HD-48650). Version 24.6.4. Release Date: Week of May 1, 2024. New Features for LiveWire S2DM and S2MH, 2024 Revolution® Max, and 2024 Touring.

PAB1146

EXTERIOR LIGHTING

GENUINE MOTOR PARTS AND MOTOR ACCESSORIES BULLETIN PAB1146: 68193-95 BULB WEDGE, FENDER TIP LAMP. Purpose: To inform dealers of an issue with the bulb wire terminals not being to specification. The light bulbs were used in numerous front and rear fender tip light assemblies for domestic and international applications.

Manufacturers file copies of the bulletins they send to dealers with NHTSA. These often describe diagnostic or repair procedures for a known condition. They are not recalls: repairs described in a bulletin are usually only free if the vehicle is still under warranty or the manufacturer has extended coverage.

Compare model years

Complaint and recall counts across every year of this model

Harley-Davidson Flstfi by model year
YearComplaintsRecallsInvestigationsIssue Index
2025000—
2006200—
2005010—
2004210—
2003Viewing110—
2002010—
2001100—

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers. Older model years have had longer for reports to accumulate.