Severity
Critical
CriticalActive
NHTSA recall · Reported November 23, 2004
HONDA 2003: ELECTRICAL SYSTEM:WIRING
ON CERTAIN MOTORCYCLES, THE ROUTING OF SOME WIRE HARNESSES MAY ALLOW A CONNECTOR TO CONTACT AND CHAFE AGAINST THE FUEL TANK.
Compiled from official public sources by the editorial team.
Verify with NHTSA →
Honda recalled ON CERTAIN MOTORCYCLES, THE ROUTING OF SOME WIRE HARNESSES MAY ALLOW A CONNECTOR TO CONTA… - a critical-severity action.
HONDA 2003: ELECTRICAL SYSTEM:WIRING was recalled by Honda in November 23, 2004. Reason: ON CERTAIN MOTORCYCLES, THE ROUTING OF SOME WIRE HARNESSES MAY ALLOW A CONNECTOR TO CONTACT AND CHAFE AGAINST…. Remedy: DEALERS WILL INSPECT THE WIRE HARNESS CONNECTOR POSITION AND CHECK FOR DAMAGE. IF ANY DAM…. Verify recall #04V549000 with the NHTSA before acting.
The recall
Honda issued this critical-severity NHTSA recall-ON CERTAIN MOTORCYCLES, THE ROUTING OF SOME WIRE HARNESSES MAY ALLOW A CONNECTOR TO CONTACT AND CHAFE AGAINST….
- Critical
- severity level
- November 23, 2004
- reported
Sourced from official NHTSA enforcement records. Verify recall #04V549000 with the agency before acting. Full product description, hazard, remedy, and related recalls are below.
Recall Insight
This NHTSA action (record #04V549000) was formally reported on November 23, 2004. It is classified under Critical severity, with a current status of Active. Honda is listed as the recalling firm. The number of affected units is not disclosed in the agency filing, which is common for drug and food recalls where lot-level tracking supersedes unit counts.
The documented reason for this recall is: ON CERTAIN MOTORCYCLES, THE ROUTING OF SOME WIRE HARNESSES MAY ALLOW A CONNECTOR TO CONTACT AND CHAFE AGAINST THE FUEL TANK. The specific hazard cited in the filing is: EVENTUALLY THE CHAFING MAY CAUSE A SHORT CIRCUIT AND BLOW AN IGNITION SYSTEM FUSE. THE ENGINE WILL THEN STALL WITHOUT WARNING, WHICH COULD CAUSE A CRASH.. Distribution data in the federal record shows the product reached: United States. Distribution scope directly affects the consumer exposure window and determines whether a recall remains regional or escalates into a nationwide advisory. The remedy documented by the agency is: DEALERS WILL INSPECT THE WIRE HARNESS CONNECTOR POSITION AND CHECK FOR DAMAGE. IF ANY DAMAGE IS FOUND, DEALERS WILL REPLACE THE NECESSARY PARTS. IF NO DAMAGE IS FOUND, DEALERS WILL REPOSITION THE CO… - consumers holding this product should act on that instruction rather than relying on general guidance.
Within the same product category the archive holds 6 closely related recalls - clustering in a narrow category often points to a systemic quality-control or supplier issue rather than a one-off defect. Always verify the recall number against the official agency record before acting.
Vehicles recalls over time
Where this recall sits in its category - 7,642 vehicles recalls on record
Of 101,704 recalls in the database, 24,878 are high severity, 72,426 moderate, and 4,400 low. This recall is classified high severity.
Counts reflect market size and reporting activity, not inherent danger, we do not rank products by risk from raw recall volume.
Affected scope
Unknown
Related Recalls
6
0 from same agency
Product description
ON CERTAIN MOTORCYCLES, THE ROUTING OF SOME WIRE HARNESSES MAY ALLOW A CONNECTOR TO CONTACT AND CHAFE AGAINST THE FUEL TANK.
Reason for recall
ON CERTAIN MOTORCYCLES, THE ROUTING OF SOME WIRE HARNESSES MAY ALLOW A CONNECTOR TO CONTACT AND CHAFE AGAINST THE FUEL TANK.
Hazard
EVENTUALLY THE CHAFING MAY CAUSE A SHORT CIRCUIT AND BLOW AN IGNITION SYSTEM FUSE. THE ENGINE WILL THEN STALL WITHOUT WARNING, WHICH COULD CAUSE A CRASH.
Remedy, what to do
DEALERS WILL INSPECT THE WIRE HARNESS CONNECTOR POSITION AND CHECK FOR DAMAGE. IF ANY DAMAGE IS FOUND, DEALERS WILL REPLACE THE NECESSARY PARTS. IF NO DAMAGE IS FOUND, DEALERS WILL REPOSITION THE CONNECTOR, AND MAKE SURE ADEQUATE CLEARANCE EXISTS. THE RECALL BEGAN ON DECEMBER 8, 2004. OWNERS SHOULD CONTACT HONDA AT 1-866-784-1870.
Recall Profile
| Attribute | Value |
|---|---|
| Agency | National Highway Traffic Safety Administration |
| Severity class | Critical |
| Status | Active |
| Recall number | 04V549000 |
| Date reported | November 23, 2004 |
| Date initiated | November 23, 2004 |
| Recalling firm | Honda |
| Affected scope | Not disclosed |
| Distribution | United States |
| Official source | NHTSA notice → |
Profile values are sourced directly from the official NHTSA enforcement record. Source: National Highway Traffic Safety Administration.
What to do with this recall
DEALERS WILL INSPECT THE WIRE HARNESS CONNECTOR POSITION AND CHECK FOR DAMAGE. IF ANY DAMAGE IS FOUND, DEALERS WILL REPLACE THE N…
- Check the recall number (04V549000) and product description against the item you own. Search the archive
- Confirm the current status and remedy on the official NHTSA notice before acting. NHTSA notice
- This is a Class I (high-risk) recall, stop using the product immediately and follow the disposal or return instructions. What to do next
This page summarizes the official NHTSA record for research and awareness; it is not legal, medical, or safety advice. Verify with the issuing agency before acting.
Frequently Asked Questions
What product was recalled? ▼
ON CERTAIN MOTORCYCLES, THE ROUTING OF SOME WIRE HARNESSES MAY ALLOW A CONNECTOR TO CONTACT AND CHAFE AGAINST THE FUEL TANK.. Recalled by Honda.
Why was this product recalled? ▼
ON CERTAIN MOTORCYCLES, THE ROUTING OF SOME WIRE HARNESSES MAY ALLOW A CONNECTOR TO CONTACT AND CHAFE AGAINST THE FUEL TANK.
What should consumers do? ▼
DEALERS WILL INSPECT THE WIRE HARNESS CONNECTOR POSITION AND CHECK FOR DAMAGE. IF ANY DAMAGE IS FOUND, DEALERS WILL REPLACE THE NECESSARY PARTS. IF NO DAMAGE IS FOUND, DEALERS WILL REPOSITION THE CONNECTOR, AND MAKE SURE ADEQUATE CLEARANCE EXISTS. THE RECALL BEGAN ON DECEMBER 8, 2004. OWNERS SHOULD CONTACT HONDA AT 1-866-784-1870.
Which agency issued this recall? ▼
This recall was issued by the NHTSA on November 23, 2004. Severity: Critical. Recall number: 04V549000.
Where was the recalled product distributed? ▼
Distribution: United States.
How do I check if my product is affected by a recall? ▼
Check the product description and recall number (04V549000) against your product. Visit the official NHTSA website for the most current information. You can also use our Recall Checker tool to search by product name or brand.
How do I report an injury from a recalled product? ▼
Report injuries to the issuing agency: CPSC at SaferProducts.gov, NHTSA at nhtsa.gov/report-a-safety-problem, or FDA via MedWatch. Document the product (photos, model/serial numbers, purchase receipts) and seek medical attention. Injury reports help agencies track hazard patterns and may strengthen enforcement actions.
Nearby Recalls in This Category
Other recalls in the same product category, useful for spotting patterns across the same defect class or manufacturer.
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Compare this recall with Yamazuki Recalls Youth All-Terrain Vehicles (ATVs) Due to R… →
Every figure on PlainRecalls is rendered directly from official FDA, CPSC and NHTSA recall records, no number is typed in by an editor. This recall: NHTSA, reported November 23, 2004. Severity classes follow each agency's own taxonomy (FDA Class I/II/III; CPSC and NHTSA by hazard type), and related-recall context is computed across the full archive. See our editorial standards & corrections policy, the methodology behind these numbers, or report a data error. Data current as of July 2026.