2019-2021 Harley-Davidson Sportster Motorcycles 0177 Headlights

March 31, 2021 NHTSA CAMPAIGN NUMBER: 21V225000

Headlights May Fail

A loss of both headlight beams can reduce visibility and increase the risk of a crash.

 

NHTSA Campaign Number: 21V225

Manufacturer Harley-Davidson Motor Company

Components EXTERIOR LIGHTING

Potential Number of Units Affected 31,346

 

Summary

Harley-Davidson Motor Company (Harley-Davidson) is recalling certain 2019-2021 Sportster (XL) motorcycles and 796 headlight assemblies that may have been sold as replacement parts for 2005-2019 Sportster, 2005-2017 Softail, 2005-2017 Dyna, and 2005-2011 V-Rod motorcycles. The glass bulb within the headlight assembly may fail, causing a loss of both high and low beams.

 

Remedy

Harley-Davidson will notify owners, and dealers will install a headlamp bulb shield, free of charge. The recall began April 15, 2021. Owners may contact Harley-Davidson customer service at 1-800-258-2464. Harley-Davidson’s number for this recall is 0177.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check for Harley-Davidson Recalls

 

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M1524

2021-04-08

 

M1524: RECALL 0177 – 2019 – 2021 SPORTSTER – HEADLAMP

 

Purpose for Service Bulletin

Harley-Davidson has learned the headlamp assembly (Part No. 68297-05A), used in 2019-2021 Sportsters® as seen in Table 1 may have a shorter life than expected. These configurations of vehicles built between February 1, 2019 and March 23, 2021 may develop a hole in the headlamp bulb tip due to thermal conditions caused by having a glossy, chrome finish on the interior of the bulb shield. This results in the sealed gas escaping and the powered filament failing prematurely. Switching to a different beam to restore lighting will then cause the second filament to fail.

A loss of both headlamp beams in succession may increase the risk of a crash.

 

NOTE

The new bulb shield has a matte interior finish.

 

Motorcycles Affected

Table 1.

Platform	Year	Model
Sportster	2019	XL883L, XL883N, XL1200C, XL1200CX, XL1200X, XL1200XS, XL1200NS
	2020	XL883N, XL1200CX, XL1200X, XL1200NS
	2021	XL883N, XL1200X, XL1200NS

 

Other vehicles not included in the recall population may have received a potentially affected headlamp assembly (68297-05A) as a replacement service part. 2005-2019 Sportsters, 2005-2017 Softails®, 2005-2017 Dynas® and 2005-2011 V-Rods® that had a replacement assembly installed between February 1, 2019 and April 6, 2021 are also covered for recall replacement as an SNV claim type.

 

Markets Affected

Domestic (DOM) and Canadian markets.

 

Part Numbers

Recall Bulb Shield Kit

Table 3. Kit Number

Part No.	Item Description
68297-05A	Headlamp Assembly

 

Recall Bulb Shield Kit

Table 3. Kit Number 

Kit No.	Item Description
91500107	Kit, Recall, Bulb, Headlamp

 

Kit Ordering Information

A single wave shipment containing 5 kits per dealer will start shipping the week of April 12, 2021.

After the five kits are depleted use the standard order system covered in M1483.

 

Required Dealer Action

1. Verify that vehicle is part of recall 0177.
2. H-Dnet.com > FAVORITES > MY TOOLBOX > Vehicle Information. Then enter the Vehicle

Identification Number (VIN) of the vehicle in question.

 

Remove

Visor Equipped Vehicles

1. See Figure 1. loosen bracket screws (2).
2. See Figure 2. Remove bracket to visor screws (2) and washers (3).
3. Remove visor (1).

 

All Vehicles

1. Remove bulb. See the service manual.

 

Bulb Shield

1. See Figure 3. Remove screw (3).
2. Remove bulb shield (2).

 

Install

New Bulb Shield

NOTE

Do not touch or get oils on the bulb or new bulb shield (2). Clean gloves are recommended.

 

1. See Figure 3. Position bulb shield (2).
2. Apply threadlocker to threads of screw (3).

Consumable: LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (BLUE) (99642-97)

 

NOTE

Due to the reuse of the self-tapping screw, do not exceed recommended torque.

3. Install screw (3). Tighten.

Torque: 5.8–6 in-lbs (0.66–0.68 N·m)

 

All Vehicles

1. Install bulb. See the service manual.

 

Visor Equipped Vehicles

1. See Figure 2. Position visor (1).
2. Install bracket to visor washers (3) and screws (2). Tighten. Torque: 35–44 in-lbs (4–5 N·m)
3. See Figure 1. Hand tighten visor bracket screws (2).
4. Align visor to the rim of the headlamp assembly.
5. Tighten visor bracket screws. Torque: 10–16 ft-lbs (13.5–21.6 N·m)

 

Supplemental Procedure Video

Always review the appropriate service procedure prior to performing it. This video is intended to supplement, not replace, documented service procedures. Attempting service procedures without the proper training, tools, equipment, and manuals could result in death or injury to you or others. This could also damage the motorcycle or cause the motorcycle to operate improperly. (10406a)

This video is a supplement of the procedure covered in the document. This video can only be viewed through Service Information Portal (SIP).

 

Dealer Inventory Instructions

Make the repairs as stated in the Required Dealer Action : Bulb Shield.

File a warranty claim per Table 5 or Table 7.

 

Credit Procedure

NOTE

Enter bulletin and recall number into comment section of claim.

 

U.S. Market

On Vehicle Bulb Shield Repair – US Market

Submit a warranty claim per Table 4 for all on vehicle bulb shield repair.

 

Table 4. On Vehicle Bulb Shield Repair – US Market 

ITEM	DATA
Claim Type	SRC
Problem Part Number	68297-05A
Quantity	Leave Blank
Primary Labor Code	2824
Time	0.2 h
Customer Concern Code	0177
Condition Code	9981
Replacement Part No.	91500107
Quantity	1

 

Upon submission of the properly completed claim, dealers are credited 0.2 h of labor time for performing the procedure. Submit campaign events on their own warranty claim. Do not mix claims with other warranty events.

 

Inventory Bulb Shield Repair – US Market

Submit a warranty claim per Table 5 for all in-stock inventory bulb shield repair.

 

Table 5. Inventory Bulb Shield Repair – US Market 

ITEM	DATA
Claim Type	SNV
Problem Part Number	68297-05A
Quantity	Leave Blank
Primary Labor Code	Leave Blank
Event Detail Labor Code	8888
Time	0.1 h
Customer Concern Code	0177
Condition Code	9982
Replacement Part No.	91500107
Quantity	1

 

Upon submission of the properly completed claim, dealers are credited 0.1 h of labor time for performing the procedure. Submit campaign events on their own warranty claim. Do not mix claims with other warranty events.

 

Canadian Market

On Vehicle Bulb Shield Repair – Canadian Market

Submit a warranty claim per Table 6 for all on vehicle bulb shield repair.

 

Table 6. On Vehicle Bulb Shield Repair – Canadian Market 

ITEM	DATA
Claim Type	SRC
Problem Part Number	68297-05A
Quantity	Leave Blank
Primary Labor Code	2828
Time	0.2 h
Customer Concern Code	0177
Condition Code	9983

 

Upon submission of the properly completed claim, dealers are credited 0.2 h of labor time for performing the procedure, plus appropriate administrative time. Submit campaign events on their own warranty claim. Do not mix claims with other warranty events.

 

Inventory Bulb Shield Repair – Canadian Market

Submit a warranty claim per Table 7 for all in-stock inventory bulb shield repair.

 

Table 7. Inventory Bulb Shield Repair – Canadian Market 

ITEM	DATA
Claim Type	SNV
Problem Part Number	68297-05A
Quantity	Leave Blank
Primary Labor Code	Leave Blank
Event Detail Labor Code	8888
Time	0.1 h
Customer Concern Code	0177
Condition Code	9984

 

Upon submission of the properly completed claim, dealers are credited 0.1 h of labor time for performing the procedure, plus appropriate administrative time. Submit campaign events on their own warranty claim. Do not mix claims with other warranty events.

 

Return Parts

Dealer may be requested to ship the part back to Harley-Davidson, if the part is not requested follow the direction below.

Hold all claimed parts for 60 d from date of credit issued for possible field inspection and/or request to return to factory. After 60 d, destroy and discard the parts.

 

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IMPORTANT SAFETY RECALL

Owner Notification

This notice applies to your vehicle, VIN #

April 15, 2021

Harley-Davidson Recall No. 0177

NHTSA Recall No. 21V225

 

Dear Harley-Davidson® Motorcycle Owner:

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.

Harley-Davidson Motor Company, Inc. has decided that a defect which relates to motor vehicle safety exists on certain model year 2019 – 2021 Sportster (XL) models (see model list below). We are notifying you because our records indicate that you may own one of these motorcycles.

 

What is the Issue?

High-heat conditions caused by having a glossy, chrome finish on the interior of the bulb shield in the headlamp assembly may cause a hole to develop in the tip of the dual-filament bulb. This hole may allow the sealed gas to escape from the bulb, which can cause the powered filament to fail prematurely.  Investigation of this issue indicates that switching to a different beam (high to low or low to high) to restore lighting causes the second filament to fail.  A loss of both high and low headlamp beams in succession may reduce visibility and increase the risk of a crash.

 

What Should You Do?

Recall kits that include a new headlamp bulb shield will be available beginning the week of April 12. To schedule an appointment to have your motorcycle repaired, contact your Harley-Davidson dealer. The repair will be performed at no cost to you and should take less than one hour. However, due to scheduling, the dealer may require your motorcycle for a longer period. Once the service has been completed, your dealer will ask you to sign a recall claim.

 

IMPORTANT: If you choose to ride your motorcycle before this safety recall service has been completed, to reduce the risk associated with this condition, we recommend that you check for proper headlamp function before every ride. Note: If the Security Lamp in the speedometer remains continuously lit, this could be an indication that one or both headlamp filaments has failed. If you experience a filament failure (high or low) during a ride, you may switch to the other filament, but be advised that if the recall condition exists on your motorcycle, the second filament will fail within 10 minutes or less.

If you have sold your motorcycle and have an address for the current owner, it is important that you forward this notice to the new owner. Alternatively, you may contact us at the Harley- Davidson phone numbers listed below and provide us with the new contact information so that we may notify the new owner of this recall. Also, federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten (10) days.

 

What If You Have Additional Questions or Concerns?

If you previously paid to remedy the specific condition that is the subject of this recall, you may be eligible for reimbursement. For more information regarding eligibility, or if you take your motorcycle to your dealer on a mutually agreed upon date and they are unable to perform the required service to your satisfaction, please contact Harley-Davidson Motor Company, Inc. for immediate assistance at 1-800-258-2464 in the U.S. or 1-414-343-4056 world-wide.

If you are still having difficulty getting your vehicle serviced in a reasonable time, you may write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington, DC 20590; or call the toll-free Auto Safety Hotline at 1-888-327-4236  (TTY:1-800-424-9153); or go to https://www.safercar.gov.

We regret any inconvenience this may cause you, but we are initiating this action in the interest of your personal safety and satisfaction with our products. Thank you for your cooperation.

 

Sincerely,

 

Harley-Davidson Motor Company, Inc. Recall 0177

 

Model Year List (production date range: 02/01/19 to 03/23/21)

Year	Models
2019	XL883L, XL883N, XL1200C, XL1200CX, XL1200X, XL1200XS, XL1200NS
2020	XL883N, XL1200CX, XL1200X, XL1200NS
2021	XL883N, XL1200X, XL1200NS

 

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IMPORTANT SAFETY RECALL INFORMATION

 

Safety Recall Campaign 0177 – XL Headlamp Bulb Shield

 

SUMMARY

• Harley-Davidson Motor Company, Inc. has decided that a defect which relates to motor vehicle safety exists on certain model year 2019 – 2021 Sportster (XL) models built between 02/01/2019 and 03/23/2021 in the DOM, CAL, and CAN configurations.
• A hole may develop in the tip of the dual-filament bulb in the headlamp assembly, part number 68297-05A. This hole may allow the sealed gas to escape from the bulb, thereby causing the powered filament to fail prematurely.  Switching to a different beam (high to low or low to high) to restore lighting causes the second filament to fail.  A loss of both high and low headlamp beams in succession during nighttime riding may increase the risk of a crash.

 

KEY DATES

• On or about 4/08/2021: Service Bulletin posts
• On or about 4/12/2021: Recall kits begin shipping
• On or about 4/15/2021: Owner notification letters begin mailing

 

CONTACT 

• U.S. dealers: Call 800-664-7762 and select the appropriate prompts
• International dealers: Contact their regional office

 

April 6, 2021

 

Dear Dealer:

Harley-Davidson has learned that thermal conditions caused by having a glossy, chrome finish on the interior of the bulb shield in the XL Headlamp Assembly, part number 68297-05A, used on certain model year 2019 – 2021 XL models (see model list below) for the DOM, CAL, and CAN configurations built between 02/01/19 and 3/23/21, may cause a hole to develop in the tip of the dual-filament bulb. This hole may allow the sealed gas to escape from the bulb, which can cause the powered filament to fail prematurely.  Investigation of this issue indicates that switching to a different beam (high to low or low to high) to restore lighting causes the second filament to fail.  A loss of both high and low headlamp beams in succession during nighttime driving may increase the risk of a crash.

 

We have voluntarily declared that this condition constitutes a safety defect to allow us to formally recall (Campaign 0177) all affected motorcycles. The remedy is to first confirm that the motorcycles are covered by this recall. If covered, perform the recommended recall update per Service Bulletin M1524 to replace the bulb shield in the headlamp.  As part of Campaign 0177, any affected headlamp assemblies (part number 68297-05A) in your service parts inventory must also be updated with the recall remedy.  Service Bulletin M1524 outlines the repair and credit procedures for the recall update. Please reference the bulletin for additional information.

 

In the interest of our customers’ safety, and as required by federal law, you may sell but not deliver any affected motorcycles until the remedy is complete. Please refer to H-Dnet / My Toolbox / Warranty Campaign Center. Select “Safety Campaign Open VIN list,” then select “0177” Campaign to view the VIN list.

 

In accordance with federal regulations administered by the National Highway Traffic Safety

Administration (NHTSA) and other appropriate market- specific government agencies, HarleyDavidson Motor Company, Inc. or authorized Harley-Davidson dealers will provide notice to all owners of record of affected products with direction to arrange for the recall service.

 

We take pride in the quality standards and controls we employ in our drive to lead the industry and deliver the world’s most desirable motorcycles. Thank you for your cooperation.

 

Sincerely,

 

Harley-Davidson Motor Company, Inc.

Recall 0177

 

For: Dealer Operator, General Manager, All P&A Roles, All Service Roles, Vehicle Sales Manager

Sent to: All U.S, Canada, Guam and Puerto Rico Dealers

 

Model Year List (production date range: 02/01/19 to 03/23/21)

Year	Models
2019	XL883L, XL883N, XL1200C, XL1200CX, XL1200X, XL1200XS, XL1200NS
2020	XL883N, XL1200CX, XL1200X, XL1200NS
2021	XL883N, XL1200X, XL1200NS

 

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14 Affected Products

Vehicles

MAKE	MODEL	YEAR
HARLEY-DAVIDSON	XL1200C	2019
HARLEY-DAVIDSON	XL1200CX	2019-2020
HARLEY-DAVIDSON	XL1200NS	2019-2021
HARLEY-DAVIDSON	XL1200X	2019-2021
HARLEY-DAVIDSON	XL1200XS	2019
HARLEY-DAVIDSON	XL883L	2019
HARLEY-DAVIDSON	XL883N	2019-2021

 

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8 Associated Documents

Remedy Instructions and TSB

RCRIT-21V225-7394.pdf 271.493KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-21V225-6848.pdf 156.395KB

 

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Recall 573 Report – Amendment 1

RCLRPT-21V225-9417.PDF 216.983KB

 

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Recall Acknowledgement

RCAK-21V225-5516.pdf 696.858KB

 

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Defect Notice 573 Report

RCLRPT-21V225-9033.PDF 216.413KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V225-2292.pdf 183.88KB

 

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Recall Quarterly Report #3, 2021-4

RCLQRT-21V225-8692.PDF 211.323KB

 

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Recall Quarterly Report #1, 2021-2

RCLQRT-21V225-9461.PDF 211.136KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V225&docType=RCL

 

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