Motorcycle, gasoline, built in United States. Owner complaints on file from Oct 30, 2024 to Sep 23, 2026.
Owner complaints about this model year, by the year they were filed with NHTSA.
Owner complaints by component. Hover or focus a bar for the crash, fire, injury or death count.
Check a specific vehicle by VIN on NHTSA's site: a campaign may cover only part of a model year's production.
| Campaign | Filed | Subject | Component | Vehicles | Remedy |
|---|---|---|---|---|---|
| 22V-030 | Jan 25, 2022 | Instrument cluster module may not display the speedometer and neutral indicator at start-up when the module is below freezing temperatures | Electrical system | 3,917 | Software update |
The full text of every complaint filed with NHTSA about this model year, newest first. Complaints are filed by owners and are not verified by NHTSA; NHTSA removes personal details before publishing.
13 complaints on file, page 1 of 1.
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 complaint 11766287My 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 complaint 11766286The 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 complaint 11764364The 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 complaint 11746095The 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 complaint 117460922021 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 complaint 11744734The 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 complaint 11737691While 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 complaint 11737606The Harley pan America has 2 electrical issues causing safety concerns. The right hand control module fails randomly causing the bike to continue running when turning off. The charging system randomly drops voltage causing the motorcycle to go into a limp mode while driving limiting speed to 55 and reduced throttle input which causes safety concerns while driving down the road. Harley Davidson is aware of the issues but will not repair the issues. This is a common problem with most Harley pan americas. Harley has updated the charging system on newer models along with the right hand control module but will not issue a recall to fix the previous model bikes affected by these problems
NHTSA complaint 11735318The charging system is not working at low rpm causing bike to die at stop signs. Not safe in heavy traffic. The dealer has checked the system and will require an upgrade kit because the parts in the bike now are note available. The kit $2600 plus labor. The extend warranty will not cover this because it’s an upgrade kit. This is a known issue with these bike and refuse to take care of this!
NHTSA complaint 11734699The fuel pump for the engine is known for failing due to ethanol in the fuel reacting with the bare aluminum. Harley Davidson has recognized this issue with the newer model but has not recalled any of its previous models. This could cause a serious safety risk for the rider or other pedestrians on the roadway as this could cause the bike to suddenly lose all power causing an accident. Many people have mentioned this known issue but Harley Davidson still refuses to seal the aluminum tanks or replace the tank with the later model ones that are already sealed. Harley Davidson’s solution for this problem has been to continue replacing the fuel pump with a new one identical to the one that failed at the customers expense. No warning lamps or messages appear when the pump is failing or completely failed occasionally riders have stated they begin hearing a growling or screeching sound from the tank soon before failure. Others have stated that the fuel pump has left them stranded or in a dangerous situation due to the pump failing while on the roadway with no warning. A recall to reseal or replace the tanks on older model years needs to be done to ensure the safety of the rider and others on the roadway.
NHTSA complaint 11713121OEM Stator and Rotor failure around 10,000 miles. Failure of adhesive laminate for magnets causing magnets to separate from assembly causing engine to knocking sound, electrical power voltage drop, engine may shut down while in operation / at idle causing safety issue in traffic. In 2024, manufacturer revised design for engine case, increased size of stator and rotor parts, and changed other related electronic parts. Manufacturer then discontinued original part and created an "upgrade kit" for previous 2021-2023 models. Manufacturer has discontinued the sale and replacement of problematic part in model years 2021-2023. Owners of vehicles with model years 2021-2023 that experience failure of OEM stator and rotor now discontinued part are required to purchase "upgrade kit" with additional motor parts to accommodate the increased size of replacement part and required pay additional hours in labor rates for installation. Contacting manufacturer customer care, representative explained there will be no assistance from manufacturer to cover increased expenses for repair of discontinued part at fault.
NHTSA complaint 11689629The stator/ rotor on the 2021 Pan America will fail resulting in engine failure, leaving the rider exposed in traffic or stranded. In my case the amp gauge went below 12 and the battery light came on while riding in traffic. Even while running the engine at high RPM's the amp's won't reach 12 (positive charging). My motorcycle died while idling at two traffic lights. I was able to get it restarted and make it home before the battery completely drained. I talked to the local Harley Dealer, and have read forum reports. The 2021 stator/ rotor is not available but has been replaced by a 2024 upgrade kit. The cost for the kit is $3,500 (some report $6,000) including labor. Harley Davidson is aware that the rotor will separate from the stator and not generate power resulting in engine failure. This is evidenced by the fact that the original part has been replaced. They know that part is defective. I called Harley Customer Service this morning and was told there is nothing they will do. I will be taking the bike in for repairs next week.
NHTSA complaint 11622753Technical service bulletins and other notices the manufacturer sent to dealers. A bulletin is not a recall; the 60 most recent are listed.