2021-2026 Harley-Davidson Sportster S Recalled
Technically, this is a recall of a recall
Another day, another recall, and in a troubling trend, yet another recall to correct a problem that was supposed to be fixed in a previous recall. We’ve seen this happen recently with the Kawasaki Ninja ZX-6R, and again for the Ducati Panigale V4 and Streetfighter V4, with both manufacturers issuing second recalls for the same problem. The latest example is from Harley-Davidson for the 2021-2026 Sportster S to prevent a problem with upper triple clamps cracking.
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While the Kawasaki and Ducati examples were because the original fixes proved insufficient, Harley-Davidson’s recall may potentially be more embarrassing, as the first recall’s repair kit may have been shipped with the original faulty upper triple clamp. Even worse, even kits with the “corrected” clamps may also have casting anomalies in the ribs added to prevent the clamps from cracking. So, in a way, this is a recall of a previous recall.
These issues turn the focus to the component supplier, Wanfeng Magnesium Technology, from Weihai, China, which is responsible for casting and shipping the upper triple clamps. So, yes, you have the added aspect of quality control issues from a Chinese parts supplier for Harley-Davidson. Wanfeng also partners with major automotive manufacturers like Audi, BMW, and American brands like Ford and Stellantis, but that’s unlikely to stop this development from triggering large swaths of the Harley faithful. And in this case, the outrage would be justified, considering the circumstances.
The problem was first identified in September of 2024, after a customer noticed a crack in the upper triple clamp while washing a Sportster S. Harley-Davidson opened an investigation, including engineering and materials analysis, with lab testing under different load conditions. Harley-Davidson then initiated the first recall on September 3, 2025, covering 8,424 Sporter S motorcycles. As of that point, it received six warranty claims, and one reported crash resulting in minor injuries that may be related to the problem.
The first recall replaced the component parts numbered 45900245 and 45900365 with a revised clamp numbered 45900365A, which was also included in the production of 2026 Sportster S models.
Fast forward to December 19, 2025, when a Harley-Davidson dealer identified a recall kit that included the outdated 45900365 upper triple clamp. Harley-Davidson then put a hold on recall kit shipments and began inspecting its inventory. That’s how Harley-Davidson discovered some recall kits contained the wrong part, while others included the “corrected” pieces with casting anomalies. No additional field reports or crashes have been made so far.
Harley-Davidson initiated the second recall procedures on February 2, 2026, affecting 8,498 motorcycles (presumably the original recall population plus another 74 new 2026 models) plus 1,002 recall kits currently in dealer inventory.
Dealerships will inspect their inventory and all recalled Sportster S models for the outdated upper triple clamp or signs of casting anomalies, and replace them with corrected parts.
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Dennis has been a part of the Motorcycle.com team since 2008, and through his tenure, has developed a firm grasp of industry trends, and a solid sense of what's to come. A bloodhound when it comes to tracking information on new motorcycles, if there's a new model on the horizon, you'll probably hear about it from him first.
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I have had HDs for 30+ years - all bought from new. My current Road King (2014 model) has 170,000km on it and has had NO ISSUES riding through snow (yes, it does snow in Australia), desert and mountain, freeways and dirt roads in the outback. Regular maintenance, replacing worn parts and riding them sensibly means they will last forever. OK it has Italian brakes and German electrics but aren't they just the best quality available? Over priced? Not when you consider the excellent resale value - total cost is related to depreciation. And did I mention ease of maintenance? No chain adjustment, lubrication or replacement. No valve clearance adjustment. Easy access to all the common maintenance areas like battery, clutch, brakes, oils and filters. These things are all simple to do at home - even for the ham-fisted DIYers saving $1,000s. I even had a sidecar attached to the Sportster for 5 years and the extra load on the frame, wheels and engine did no harm. The only bad thing about HD ownership is listening to all the ignorant haters.
I always thought when they went to China. Having stuff made, they made a bad choice. That should have went to Taiwan, and there is a difference between the republic of China or Taiwanese. Then, the year stuff being made in China? I've sold their scooters from both places. For years and there's definitely a difference in the quality and quality control.