2021 Harley-Davidson RA1250S

My motorcycle suffered a serious engine failure at approximately 12,500 km (7,800 miles) while I was riding. Before the failure, I noticed an unusual ticking/rattling noise coming from the engine, especially when the engine was under load or when the throttle was closed. The failure occurred while riding and caused a sudden loss of engine performance. This happened while I was in traffic and I was extremely close to having an accident because the motorcycle did not respond as expected when I needed power. After the motorcycle was inspected, the failure was found to be related to the camshaft/cam chain tensioning system. The cam chain tensioner had become loose and the resulting failure caused internal engine damage, including damage to components in the valve train. The motorcycle had been properly maintained and serviced, and there was no missed scheduled maintenance that could explain the failure. The mileage was also relatively low for such a serious internal engine failure. What concerns me is that I am now finding other reports describing similar failures on Revolution Max engines, particularly involving the cam chain tensioner and its retaining bolt. If a tensioner can lose its position during normal operation and cause the cam timing to fail, the consequences can be extremely serious. In my case, this was not simply a mechanical failure that left me stranded. It created an actual safety risk while riding and nearly caused an accident. I am sharing this as a separate report because I believe these incidents should be documented individually. If other Pan America owners have experienced similar cam chain tensioner, cam chain, camshaft or valve train failures, especially on 2021–2022 models, please share your mileage, symptoms and the exact components that failed. I hope Harley-Davidson and the relevant authorities will look at these reports collectively rather than treating each failure as an isolated incident.

NHTSA ID

11766287

Incident

Jul 8, 2026

My motorcycle suffered a serious engine failure at approximately 12,500 km (7,800 miles) while I was riding. Before the failure, I noticed an unusual ticking/rattling noise coming from the engine, especially when the engine was under load or when the throttle was closed. The failure occurred while riding and caused a sudden loss of engine performance. This happened while I was in traffic and I was extremely close to having an accident because the motorcycle did not respond as expected when I needed power. After the motorcycle was inspected, the failure was found to be related to the camshaft/cam chain tensioning system. The cam chain tensioner had become loose and the resulting failure caused internal engine damage, including damage to components in the valve train. The motorcycle had been properly maintained and serviced, and there was no missed scheduled maintenance that could explain the failure. The mileage was also relatively low for such a serious internal engine failure. What concerns me is that I am now finding other reports describing similar failures on Revolution Max engines, particularly involving the cam chain tensioner and its retaining bolt. If a tensioner can lose its position during normal operation and cause the cam timing to fail, the consequences can be extremely serious. In my case, this was not simply a mechanical failure that left me stranded. It created an actual safety risk while riding and nearly caused an accident. I am sharing this as a separate report because I believe these incidents should be documented individually. If other Pan America owners have experienced similar cam chain tensioner, cam chain, camshaft or valve train failures, especially on 2021–2022 models, please share your mileage, symptoms and the exact components that failed. I hope Harley-Davidson and the relevant authorities will look at these reports collectively rather than treating each failure as an isolated incident.

NHTSA ID

11766286

Incident

Jul 8, 2026

The cam chain tensioner failed while driving down the road, resulting in reduced power during a pass that almost resulted in an accident. There are no maintenance requirements for this component and there are numerous reports of this failing in motorcycles equipped with the Revolution Max engine. On this engine, the cam chain tensioner is held in place with a bolt that is apparently a torque to spec item with no locking mechanism. During the course of normal operation, the bolt backs out and can have varying degrees of damage. In this case, the forward cylinder cam chain became dislodged from the cams, resulting in a dead cylinder and eventually destroying the intake cam. A cursory check was done approximately 4 weeks prior to the incident, and no excess play was noted at that time. Note that there is no spec that I am aware of for excess play or interval to check it. This is a large enough issue that there are aftermarket companies that sell kits that contain Lock Tite on bolts to remedy this.

NHTSA ID

11764364

Incident

Sep 2, 2026

The engine stalled when I was exiting the freeway due to the charging system failure. This is the second time the charging system failed. The first failure has been documented on NHTSA complaint number 11746092. I paid the Harley Davidson SLC dealership in April 2024 to have the charging system repaired and replaced. Harley Davidson had released a service bulletin acknowledging charging system deficiencies on 2021-2023 Pan America models and subsequently redesigned the entire charging system for the2024 model year. This is a documented pattern and not just an isolated failure. Regarding the repair in April 2024, the dealership replaced the failed stator with the same poorly designed part number instead of upgrading to the redesigned charging system. Now only two years and 9,000 miles later I'm experiencing the same problems as before.

NHTSA ID

11746095

Incident

Jun 10, 2026

The charging system for the battery failed when I was on an out of state road trip. The voltage of the bike would drop between 11 and 12 volts when slowing down. I slowed down to make a tight turn on a canyon highway when the bike lost power and stalled. The motorcycle continued to stall several more times while in motion on the highway and I had a difficult time restarting the motorcycle on the side of the highway each time. I ended up purchasing a new battery thinking it would solve the problem. It worked for another few hundred miles until the new battery was also depleted and I had the same issue on the side of the highway outside Sedona. I had to rent a Uhaul for $551 to be able to return home safely. I took the motorcycle to the Harley Davidson dealership in Salt Lake City and paid approx. $1,248 to have the Stator and charging system replaced. Harley Davidson had released a service bulletin acknowledging charging system deficiencies on 2021-2023 Pan America models and subsequently redesigned the entire charging system for the 2024 model year. This is a documented pattern and not just an isolated failure. Regarding the repair in April 2024, the dealership replaced the failed stator with the same poorly designed part number instead of upgrading to the redesigned charging system.

NHTSA ID

11746092

Incident

Apr 20, 2024

2021 H-D Pan America charging system (stator and/or rotor) failing per dealer testing. Not covered by warranty or extended warranty. Motorcycle is currently at the dealer awaiting parts. Was advised not to ride it because it could run erratic, shut off unexpectedly (very dangerous), fail to start, etc. Possible the magnets can separate from the electrical rotor and cause catastrophic damage requiring engine replacement.

NHTSA ID

11744734

Incident

Jun 6, 2026

The ignition kill switch is a known problem all over the internet. When the kill switch is switched the bike continues to run. The more the switch has worn, the longer the delay. I'm afraid at some point it's just not going to kill the engine at all which is a major safety hazard.

NHTSA ID

11737691

Incident

Sep 4, 2025

While going through an intersection at 50 mph the dashboard goes black and resets just like you switched the motor cycle off. This has happened to me three times in last 6 months. Dealer says it’s a bad switch and has since been redesigned and he will sell me one for $406.00, for an extra $100.00 they will install it for me. Plus towing to get my job working motorcycle to the dealer.

NHTSA ID

11737606

Incident

May 13, 2026

SERVICE BULLETIN M1490 (V 26.8.3): 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 Version 26.8.3, Release Date: Week of July 24, 2026. NOTE: Software version (26.4.3) will need to be manually installed only if current software version of DT II is (26.0.2). After (26.4.3) is manually installed, automatic updates will bring DT II to the latest software version. Refer to bulletin M1713 for instructions. New Features - Harley-Davidson: 2023-2024 Touring: Updated Electronic Control Module (ECM) calibration offerings. LiveWire: S2DM/MH/AP: Calibration bundle 10.2.28: Telematic Control Unit (TCU) reflash updates. Change: Vehicle Setup: Body Control Module (BCM) – Tire Pressure Monitoring System (TPMS) Replacement: Correct issue where tire size selections were not available. System Info – Auxiliary Load Controller (ALC): Added Bike configuration field. Data Items – Trike ECM: Improved display of Gear Position when in reverse. Amp – Added support for (Part No. 76001619).

SERVICE BULLETIN M1490 (V 26.7.3): 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 26.7.3. Release Date:• Week of June 11, 2026. NOTE Software version (26.4.3) will need to be manually installed only if current software version of DT II is (26.0.2). After (26.4.3) is manually installed, automatic updates will bring DT II to the latest software version. Refer to bulletin M1713 for instructions.

SERVICE BULLETIN M1490 (V 26.6.2): 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 26.6.2. Release Date: Week of April 22, 2026. NOTE: Software version (26.4.3) will need to be manually installed only if current software version of DT II is (26.0.2). After (26.4.3) is manually installed, automatic updates will bring DT II to the latest software version. Refer to bulletin M1713 for instructions. New Features: 2026 Police • Vehicle Setup: Civilianize; LiveWire • S2: Del Mar (S2DM), Mulholland (S2MH), Alpinista (S2AP) - Calibration bundle 10.2.20: Vehicle Supervisory Controller (VSC) and Onboard Charger (OBC) reflash updates. Changes: 2026 Trike • Update “Reverse Lockout Reason” resize column.

SERVICE BULLETIN M1490 (V 26.5.2): 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 26.5.2 Release Date: Week of March 30, 2026. NOTE Software version (26.4.3) will need to be manually installed only if current software version of DT II is (26.0.2). After (26.4.3) is manually installed, automatic updates will bring DT II to the latest software version. Refer to bulletin M1713 for instructions. New Features. 2024: Pan America (RA1250), Pan America Special (RA1250S), CVO Pan America (RA1250SE) • Updated Body Control Module (BCM) reflash calibration. 2024-2026: CVO Road Glide ST (FLTRXSTSE) • Updated Electronic Control Module (ECM) reflash calibration. 2026: CVO Street Glide ST (FLHXSTSE) • Updated ECM reflash calibration. Changes. 2026 Trike • Update “Reverse Lockout Reason” to support new values, • “Vehicle setup: Gear Indicator Calibration” – improve operation. 2025-2026 Softail • Update reflash for Softail Speedometer (SPDO) – enable operation of auxiliary lamp telltale. LiveWire S2 • Provide reflash support for Vehicle Supervisory Controller (VSC) hardware (Part No. 41001756RE).

SERVICE BULLETIN M1720 (REV A): PAN AMERICA ELECTRONIC CONTROL MODULE (ECM) UPDATE. PURPOSE: Initial release 3/3/2026. Revision A. 3/30/2026. Updated: Purpose for Service Bulletin and Required Dealer Action. Adjust information for 2024 models. Purpose for Service Bulletin. This bulletin informs dealers that there is an Electronic Control Module (ECM) update available for 2021-2025 RA1250, RA1250S, RA1250ST and RA1250SE on Digital Technician II (DT II). The update improves engine function by addressing engine operation after a cold start by improving idle stability and improved Quickshifter function. For 2021-2024 models the Body Control Module (BCM) and ECM update must both be completed. If only the ECM is updated, a nuisance Diagnostic Trouble Code (DTC) U040000 will populate and not be able to be cleared. Because of this, the BCM update should be done first and then the ECM.

SERVICE BULLETIN M1679: AFTERMARKET EXHAUST HEADER DEBRIS. PURPOSE: Initial release. This bulletin informs dealers that Harley-Davidson has identified instances of premature engine failure due to abrasive particle wear, specifically from debris inside new aftermarket exhaust headers. Recent evaluations have identified that certain newly manufactured exhaust headers may contain residual hard particles that, if not removed prior to installation, can migrate through the engine system and cause accelerated component wear or severe mechanical damage.