Recall 21V623 affects 4 2017-2018 Starcraft Bus Allstar Xl buses for a fuel-heater fire risk. Free repair at any franchised Starcraft Bus dealer once available.
Starcraft Bus is recalling 4 2017-2018 Allstar Xl transit buses with Cummins B6.7 diesel engines because the electric fuel heater can overheat, melt nearby plastic, catch fire, or stall the engine. A fire increases injury risk and a stall raises crash risk; the Starcraft Bus dealer repair will be free once available.
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What's wrong?
The diesel fuel heater in the 2017-2018 Starcraft Bus Allstar Xl is an electric pre-heater inside the fuel module. Its job is to warm diesel fuel so it flows properly through the fuel system before the engine uses it. The heater depends on controlled electrical heat and intact plastic around the module to keep fuel contained and moving.
On affected buses, excessive electrical heating inside the fuel heater can overheat the element. That heat can melt nearby plastic in the fuel module. Melted plastic and fuel seepage around that area create a fire risk, and damage at the module can also interrupt fuel delivery enough for the engine to stall.
Visible warning signs include melted material around the fuel heater or fuel seepage seen during service. Smoke can come before or with a fire. The engine can also become harder to start as the fuel heater problem gets worse.
Who's affected?
Spans the 2017 and 2018 Allstar Xl, with both model years tied to the same fuel heater component.
| 2018 Starcraft Bus Allstar Xl | fuel system |
|---|---|
| 2017 Starcraft Bus Allstar Xl | fuel system |
| Units affected | 4 |
| Field incidents | NHTSA has logged no field incidents to date. |
A matching year and model does not guarantee inclusion. Check your VIN to confirm whether this recall applies to your specific bus.
What's the safety risk?
A fire increases the risk of injury, and an engine stall increases the risk of a crash. Treat fuel seepage, melting around the fuel heater, smoke, or harder starting as a reason to stop using the bus and call the dealer. Repair will be free at any franchised Starcraft Bus dealer once available.
What should I do?
- Check your VIN to confirm your 2017-2018 Starcraft Bus Allstar Xl is included in this recall.
- Contact Forest River customer service to ask whether the free Cummins fuel-heater replacement is open for your VIN.
- Ask a franchised Starcraft Bus dealer about the Cummins fuel-heater replacement that fixes the heater that can overheat, melt plastic, catch fire, or stall the engine.
- Reference recall number 21V623 and Forest River recall 05-1401 when you call.
- Drive with caution until the repair is complete. Pull over safely and shut the bus off if the engine stalls or you smell smoke or burning plastic.
What happens at the repair
Once the repair opens, a Starcraft Bus technician will replace the electric fuel heater in the fuel module with a newly designed fuel heater. The final dealer repair will be free once available. Reimbursement is expected through a recall-specific plan for units not covered by the manufacturer's limited warranty. Keep prior repair invoices and contact Forest River customer service about the claim process if you already paid for a related fuel heater repair.
| Reimbursement | Reimbursement available |
|---|
Timeline
| August 10, 2021 | NHTSA published the recall |
|---|---|
| August 18, 2021 | Owner notification mailed |
| September 19, 2021 | Dealer notification began |
| September 19, 2021 | Dealer notification ended |
| September 19, 2021 | Interim owner notification (was planned for this date) |
Frequently asked questions
What is recall 21V623?
Recall 21V623 covers 4 2017-2018 Starcraft Bus Allstar Xl transit buses with Cummins B6.7 diesel engines. The electric fuel heater in the fuel module can overheat, melt nearby plastic, start a fire, or lead to engine stalling. Cummins will replace the fuel heater for free.
What should I do if my 2017-2018 Starcraft Bus Allstar Xl is on this recall?
Check your VIN to confirm your specific bus is included in recall 21V623. If it is, contact a franchised Starcraft Bus service location or Forest River customer service at 1-800-348-7440 and ask where to complete the Cummins fuel-heater replacement. Reference Forest River recall 05-1401 when you call.
Is the recall repair free?
Yes. Federal recall law requires the safety recall repair to be performed at no cost. For recall 21V623, Cummins will replace the fuel heater with a newly designed fuel heater free of charge.
What is the safety risk?
The safety risk is fire or engine stalling. NHTSA campaign 21V623 says a fire increases the risk of injury, and an engine stall increases the risk of a crash. Confirm the VIN before returning the bus to regular service.
When were owners notified about recall 21V623?
Owner notification letters were mailed August 18, 2021. If you bought the bus used or never received a notice, check your VIN and reference recall 21V623, or Forest River recall 05-1401, when you contact service.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/21V623000 |
|---|---|
| Starcraft Bus customer service | 1-800-348-7440 |
| NHTSA recall # | 21V623 |
| NHTSA recall # (full) | 21V623000 |
Source documents
-
Download Quarterly Report (PDF) - Download Recall Investigation Document (PDF) (PDF)
- Download Owner Notification Letter (PDF)
- Download Owner Notice (PDF)
- Download Recall Report (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 20, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →