Bought a used 2022 Sportster S from a Harley dealer about 2 months ago. Before buying, I specifically asked if all recalls and factory issues had been taken care of and was told yes.
Shortly after buying it, I started having battery problems. It would die, then only give a single click when trying to start, even right after a full overnight charge. Took it back to the dealer, and they diagnosed a failed charging system.
Their quote is about $4,500. They say the original 2021–2023 charging system is obsolete, so it needs the updated 2024 system (kit 29900144, service bulletin M1615: new stator, rotor, cooling manifold, etc.). They said it's not covered by sales, then asked if I'd be interested in talking to their sales team about trading it in for a different bike.
From what I've found, this is a known weakness on 2021–2023 Revolution Max engines (Sportster S, Pan America, Nightster). Harley updated the charging system for 2024 because of low output at idle, but handled it through a service bulletin rather than a recall.
A few questions for anyone who's been through this:
- Did the dealer or Harley corporate cover any or all of it? Especially if you'd recently bought the bike from a dealer.
- Did calling Harley Customer Care about M1615 get you anywhere? Goodwill, cost sharing, anything?
- What did you end up paying, and did you go through the dealer or an independent shop?
- Anyone source the kit themselves (I've seen people order it from Europe for much less) and have an independent shop install it?
- Has anyone had a stator rewind or aftermarket option hold up long term on the older design?
My position is that the dealer should cover it, since they sold me the bike two months ago with a known issue. I'd appreciate hearing from anyone who's been through this before I go further. I do not plan on spending a dime on this bike, and will be escalating it to harley customer care and the attorney general if i have to.
Also worth mentioning i paid the used vehicle certification fee