Harley Davidson Electra Glide Standard (EFI) 2005 Owner's manual

2005 Electra Glide Standard (EFI) ­ Owner's Manual

Safety First

Safe Operating Rules: Touring Models

Before operating your new motorcycle it is your responsibility to read and follow the operating and maintenance instructions in this manual, and follow these basic rules for your personal safety.

Know and respect the rules of the road (see RULES OF THE ROAD section). Carefully read and observe the rules contained in the RIDING TIPS booklet accompanying this Owner's Manual. Read and familiarize yourself with the contents of the MOTORCYCLE HANDBOOK for your state.

Before starting engine, check for proper operation of brake, clutch, shifter, throttle controls, correct fuel and oil supply.

Do not use aftermarket parts and custom made front forks which can adversely affect performance and handling. Removing or altering factory installed parts can adversely affect performance and could result in death or serious injury. (00001a)

Use only Harley­Davidson approved parts and accessories. Use of certain other manufacturer's performance parts will void your new motorcycle warranty. See your Harley­ Davidson dealer for details.

Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a)

When refueling your motorcycle, the following rules should be observed.

Refuel in a well ventilated area with the engine turned off. Remove fuel filler cap slowly.

Do not smoke or allow open flames or sparks when refueling or servicing the fuel system. Always close the fuel supply valve when the engine is not running. This prevents flooding of the carburetor and the surrounding area with gasoline.

Do not fill fuel tank above the bottom of the filler neck insert. Leave air space to allow for fuel expansion.

Do not store motorcycle with gasoline in tank within the home or garage where open flames, pilot lights, sparks or

electric motors are present. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00003a)

Engine exhaust from this product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. (00004e)

Wheel weights on wheels without spokes contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. (00356b)

Do not run motorcycle in a closed garage or confined area. Inhaling motorcycle exhaust, which contains poisonous carbon monoxide gas, could result in death or serious injury. (00005a)

The jiffy stand locks when placed in the full forward (down) position with vehicle weight on it. If the jiffy stand is not in the full forward (down) position with vehicle weight on it, the vehicle can fall over which could result in death or serious injury. (00006a)

Be sure jiffy stand is fully retracted before riding. If jiffy stand is not fully retracted, it can contact the road surface causing a loss of vehicle control, which could result in death or serious injury. (00007a)

A new motorcycle must be operated according to the special break­in procedure. See

Break­in Riding Rules.

Operate motorcycle only at moderate speed and out of traffic until you have become thoroughly familiar with its operation and handling characteristics under all conditions.

NOTE:

We recommend that you obtain information and formal training in the correct motorcycle riding

technique. The Motorcycle Safety Foundation® offers beginning and advanced rider safety courses. Call (949)727­3227 for information.

Travel at speeds appropriate for road and conditions and never travel faster than posted speed limit. Excessive speed can cause loss of vehicle control, which could result in death or serious injury. (00008a)

Do not exceed the legal speed limit or drive too fast for existing conditions. Always reduce speed when poor driving conditions exist. High speed increases the influence of any other condition affecting stability and increases the possibility of loss of control.

Pay strict attention to road surfaces and wind conditions. Any two wheeled vehicle may be subject to upsetting forces such as wind blasts from passing trucks, holes in the pavement, rough road surfaces, rider control error, etc. These forces may influence the handling characteristics of your motorcycle. If this happens, reduce speed and guide the motorcycle with a relaxed grip to a controlled condition. Do not brake abruptly or force the handlebar. This may aggravate an unstable condition.

Keep cargo weight concentrated close to the motorcycle and as low as possible to minimize the change in the motorcycle's center of gravity. Distribute weight evenly on both sides of the vehicle and do not load bulky items too far behind the rider or add weight to the handlebars or front forks. Do not exceed maximum specified load in each saddlebag.

NOTE:

New riders should gain experience under various conditions while driving at moderate speeds.

Operate your motorcycle defensively. Remember, a motorcycle does not afford the same protection as an automobile in an accident. One of the most common accident situations occurs when the driver of the other vehicle fails to see or recognize a motorcycle and turns left into the on­coming motorcyclist. Operate only with headlamp on.

Wear an approved helmet, clothing, and foot gear suited for motorcycle riding. Bright or light colors are best for greater visibility in traffic, especially at night. Avoid loose, flowing garments and scarves.

Avoid contact with exhaust system and wear protective clothing that completely covers legs while riding. Exhaust pipes and mufflers get very hot when engine is running and remain too hot to touch, even after engine is turned off. Failure to wear protective clothing could result in burns or other serious injury. (00009a)

When carrying passengers, it is your responsibility to instruct them on proper riding procedures. (See Riding Tips for Motorcyclist included in your Harley­Davidson Owner's Kit.)

Do not allow other individuals, under any circumstances, to operate your motorcycle unless you know they are experienced, licensed riders and are thoroughly familiar with the operation of your particular motorcycle.

Protect your motorcycle against theft. After parking your motorcycle, lock the steering head and remove ignition key from switch. Set security alarm if present.

Safe motorcycle operation requires alert mental judgment combined with a defensive driving attitude. Do not allow fatigue, alcohol or drugs to endanger your safety or that of others. Vehicles equipped with a sound system should have the volume adjusted to a nondistracting

level before operating vehicle.

Maintain your motorcycle in proper operating condition in accordance with Regular Service Intervals: 2005 Touring Models. Particularly important to motorcycle stability is proper tire inflation pressure, tread condition, and proper adjustment of wheel bearings and steering head bearings.

Do not operate vehicle with forks locked. Locking the forks restricts the vehicle's turning ability, which could result in death or serious injury. (00035a)

Perform the service and maintenance operations as indicated in the regular service interval table. Lack of regular maintenance at the recommended intervals can affect the safe operation of your motorcycle, which could result in death or serious injury. (00010a)

Do not operate motorcycle with loose, worn or damaged steering or suspension systems. Contact a Harley­ Davidson dealer for repairs. Loose, worn or damaged steering or suspension components can adversely affect stability and handling, which could result in death or serious injury. (00011a)

Regularly inspect shock absorbers and front forks. Replace leaking, damaged or worn parts that can adversely affect stability and handling, which could result in death or serious injury. (00012a)

Use Harley­Davidson replacement fasteners. Aftermarket fasteners can adversely affect performance, which could result in death or serious injury. (00013a)

See Harley­Davidson service manual for proper torque values.

Aftermarket fasteners may not have the specific property requirements to perform properly.

Be sure tires are properly inflated, balanced and have adequate tread. Inspect your tires regularly and see a Harley­Davidson dealer for replacements. Riding with

excessively worn, unbalanced or under­inflated tires can adversely affect stability and handling, which could result in death or serious injury. (00014a)

Replace punctured or damaged tires. In some cases, small punctures in the tread area may be repaired from within the demounted tire by a Harley­Davidson dealer. Speed should NOT exceed 50 mph (80 km/h) for the first 24 hours after repair, and the repaired tire should NEVER be used over 80 mph (130 km/h). Failure to follow this warning could result in death or serious injury. (00015a)

Do not exceed the motorcycle Gross Vehicle Weight Rating (GVWR). Exceeding the GVWR can affect stability and handling, which could result in death or serious injury. (00016a)

GVWR is the sum of the weight of the motorcycle, accessories, and the maximum weight of the rider, passenger and cargo that can be safely carried.

The GVWR is shown on the information plate located on the frame steering head.

Do not tow a disabled motorcycle. Towing can adversely affect stability and handling, which could result in death or serious injury. (00017a)

Do not pull a trailer with a motorcycle. Pulling a trailer can cause tire overload, reduced braking efficiency and adversely affect stability and handling, which could result in death or serious injury. (00018b)

Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention.

Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a)

Batteries, battery posts, terminals and related accessories

contain lead and lead compounds, and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. (00019d)

Consult a Harley­Davidson dealer regarding any questions or problems that occur in the operation of your motorcycle. Failure to do so can aggravate an initial problem, cause costly repairs, cause an accident and could result in death or serious injury. (00020a)

Be sure all equipment required by federal, state and local law is installed and in good operating condition.

Do not open storage compartments while riding. Distractions while riding can lead to loss of control, which could result in death or serious injury. (00082a)

Rules of the Road

Keep to the right side of the road centerline when meeting other vehicles coming in the opposite direction. Ride to left of center of your lane to avoid oily pavement ahead.

Always sound your horn, actuate your turn signals, and exercise caution when passing other vehicles going in the same direction. Never try to pass another vehicle going in the same direction at street intersections, on curves, or when going up or down a hill.

At street intersections give the right­of­way to the vehicle on your right. Do not presume you have the right­of­way, as the other driver may not know it is your turn.

Always signal when preparing to stop, turn or pass.

All traffic signs, including those used for the control of traffic at intersections, should be obeyed promptly. SLOW DOWN signs near schools and CAUTION signs at railroad crossings should always be observed and your actions governed accordingly.

When intending to turn to the left, signal at least 100 feet (30.5 meters) before reaching the turning point. Move over to the centerline of the street (unless local rules require otherwise), slow down, enter the intersection of the street and then turn carefully to the left.

Never anticipate a traffic light. When a change is indicated from GO to STOP (or vice versa) in the traffic control systems at intersections, slow down and wait for the light to change. Never run through a yellow or red traffic light.

While turning either right or left, watch for pedestrians, animals, as well as vehicles.

Do not leave the curb or parking area without signaling. Be sure your way is clear to enter moving traffic. A moving line of traffic always has the right­of­way.

Be sure your license plate is installed in the position specified by law and is clearly visible at all times. Keep the plate clean.

Ride at a safe speed that is consistent with the type of highway you are on. Pay strict attention to whether the road is dry, oily, icy or wet.

Watch for debris such as leaves or loose gravel.

Weather and traffic conditions on the highway dictate adjusting your speed and driving habits accordingly.

Accessories and Cargo

Harley­Davidson Motor Company cannot test and make specific recommendations concerning every accessory or combination of accessories sold. Therefore, the rider must be responsible for safe operation of the motorcycle when installing accessories or carrying additional weight.

See the Accessory and Cargo section in your Owner's Manual. Improper loading of cargo or installation of accessories can affect motorcycle stability and handling, which could result in death or serious injury. (00021a)

Do not exceed the motorcycle Gross Vehicle Weight Rating (GVWR). Exceeding the GVWR can affect stability and handling, which could result in death or serious injury. (00016a)

GVWR is the sum of the weight of the motorcycle, accessories, and the maximum weight of the rider, passenger and cargo that can be safely carried.

The GVWR is shown on the information plate which is located on the frame down tube.

Do not pull a trailer with a motorcycle. Pulling a trailer can cause tire overload, reduced braking efficiency and adversely affect stability and handling, which could result in death or serious injury. (00018b)

Accessory and Cargo Guidelines

The following guidelines should be used when equipping a motorcycle, carrying passengers and/or cargo.

Travel at speeds appropriate for road and conditions and never travel faster than posted speed limit. Excessive speed can cause loss of vehicle control, which could result in death or serious injury. (00008a)

Do not exceed the legal speed limit or drive too fast for existing conditions. Always reduce speed when poor driving conditions exist. High speed increases the influence of any other condition affecting stability and increases the possibility of loss of control.

Pay strict attention to road surfaces and wind conditions. Any two wheeled vehicle may be subject to upsetting forces such as wind blasts from passing trucks, holes in the pavement, rough road surfaces, rider control error, etc. These forces may influence the handling

characteristics of your motorcycle. If this happens, reduce speed and guide the motorcycle with a relaxed grip to a controlled condition. Do not brake abruptly or force the handlebar. This may aggravate an unstable condition.

Keep cargo weight concentrated close to the motorcycle and as low as possible. This minimizes the change in the motorcycle's center of gravity.

Distribute weight evenly on both sides of the vehicle.

Do not load bulky items too far behind the rider or add weight to the handlebars or front forks.

Do not exceed maximum specified load in each saddlebag.

Luggage racks are designed for lightweight items. Do not overload racks.

Be sure cargo is secure and will not shift while riding and recheck the cargo periodically. Accessories that change the operator's riding position may increase reaction time and affect handling of the motorcycle.

Additional electrical equipment may overload the motorcycle's electrical system possibly resulting in electrical system and/or component failure.

The front and/or rear guard(s) can provide limited leg and cosmetic vehicle protection under unique circumstances. (Fall over while stopped, very slow speed slide.) It is not made or intended to provide protection from bodily injury in a collision with another vehicle or any other object.

(00022a)

Large surfaces such as fairings, windshields, back rests, and luggage racks can adversely affect handling. Only genuine Harley­Davidson items designed specifically for the motorcycle model should be used with proper installation.

Do not use aftermarket parts and custom made front forks which can adversely affect performance and handling. Removing or altering factory installed parts can adversely affect performance and could result in death or serious injury. (00001a)

Only Touring Harley­Davidson Motorcycles are suitable for sidecar use. Consult a Harley­Davidson dealer. Use of motorcycles other than Touring models with sidecars could result in death or serious injury. (00040a)

Identification

2005 Touring Models

This section provides left and right side views of your 2005 Touring motorcycle. Please refer to the CONTROLS AND INDICATORS and OPERATION sections for specific details about each

component.

NOTE:

Specifications in this publication may not match those of official certification in some markets due to timing of publication printing, variance in testing methods, and/or vehicle differences. Customers seeking officially recognized regulatory specifications for their vehicle should refer to certification documents and/or contact their respective dealer or distributor.

1.Ignition/headlamp key switch/fork lock

2.Fuses

3.Rear suspension air valve

4.Rear sprocket and drive

5.Clutch inspection cover

6.Primary chain inspection cover

7.Engine oil filter

2005 Ultra Classic Electra Glide (FLHTCU) ­ Left Side View

1.Ignition module/ECM

2.Battery

3.ACC connector (under seat)

4.Air cleaner

5.Front brake master cylinder and reservoir

6.Speedometer and tachometer

7.Rear brake master cylinder

8.Transmission fill plug

9.Engine oil fill plug and dipstick

10.Turn signal/security module (under seat)

2005 Ultra Classic Electra Glide (FLHTCU) ­ Right Side View

1.Ignition/headlamp key switch/fork lock

2.Fuses

3.Rear suspension air valve

4.Rear sprocket and drive

5.Clutch inspection cover

6.Primary chain inspection cover

7.Engine oil filter

2005 Electra Glide Classic (FLHTC) ­ Left Side View

1.Ignition module/ECM

2.Battery

3.ACC connector (under seat)

4.Air cleaner

5.Front brake master cylinder and reservoir

6.Speedometer and tachometer

7.Rear brake master cylinder

8.Transmission fill plug

9.Engine oil fill plug and dipstick

10.Turn signal/security module (under seat)

2005 Electra Glide Classic (FLHTC) ­ Right Side View

1.Ignition/headlamp key switch/fork lock

2.Fuses

3.Rear suspension air valve

4.Rear sprocket and drive

5.Clutch inspection cover

6.Primary chain inspection cover

7.Engine oil filter

2005 Electra Glide Standard (FLHT) ­ Left Side View

1.Ignition module/ECM

2.Battery

3.ACC connector (under seat)

4.Air cleaner

5.Front brake master cylinder and reservoir

6.Speedometer and tachometer

7.Rear brake master cylinder

8.Transmission fill plug

9.Engine oil fill plug and dipstick

10.Turn signal/security module (under seat)

2005 Electra Glide Standard (FLHT) ­ Right Side View

1.Fork lock

2.Ignition/headlamp key switch

3.Fuses

4.Rear suspension air valve

5.Rear sprocket and drive

6.Clutch inspection cover

7.Primary chain inspection cover

8.Engine oil filter

2005 Road King (FLHR) ­ Left Side View

1.Ignition module/ECM

2.Battery

3.ACC connector (under seat)

4.Air cleaner

5.Speedometer

6.Front brake master cylinder and reservoir

7.Rear brake master cylinder

8.Transmission fill plug

9.Engine oil fill plug and dipstick

10.Turn signal/security module (under seat)

2005 Road King (FLHR) ­ Right Side View

1.Fork lock

2.Ignition/headlamp key switch

3.Fuses

4.Rear suspension air valve

5.Rear sprocket and drive

6.Clutch inspection cover

7.Primary chain inspection cover

8.Engine oil filter

2005 Road King Classic (FLHRC) ­ Left Side View

1.Ignition module/ECM

2.Battery

3.ACC connector (under seat)

4.Air cleaner

5.Speedometer

6.Front brake master cylinder and reservoir

7.Rear brake master cylinder

8.Transmission fill plug

9.Engine oil fill plug and dipstick

10.Turn signal/security module (under seat)

2005 Road King Classic (FLHRC) ­ Right Side View

1.Fork lock

2.Ignition/headlamp key switch

3.Fuses

4.Saddlebag latch

5.Rear suspension air valve

6.Rear sprocket and drive

7.Clutch inspection cover

8.Primary chain inspection cover

9.Engine oil filter

2005 Road King Custom (FLHRS) ­ Left Side View

1.Ignition module/ECM

2.Battery

3.ACC connector (under seat)

4.Air cleaner

5.Front brake master cylinder and reservoir

6.Speedometer

7.Rear brake master cylinder

8.Transmission fill plug

9.Engine oil fill plug and dipstick

10.Turn signal/security module (under seat)

2005 Road King Custom (FLHRS) ­ Right Side View

1.Fork lock/ignition/headlamp key switch

2.Fuses

3.Rear suspension air valve

4.Rear sprocket and drive

5.Clutch inspection cover

6.Primary chain inspection cover

7.Engine oil filter

2005 Road Glide (FLTRI) ­ Left Side View

1.Ignition module/ECM

2.Battery

3.ACC connector (under seat)

4.Air cleaner

5.Front brake master cylinder and reservoir

6.Speedometer and tachometer

7.Rear brake master cylinder

8.Transmission fill plug

9.Engine oil fill plug and dipstick

10.Turn signal/security module (under seat)

2005 Road Glide (FLTRI) ­ Right Side View

Vehicle Identification Number: Touring Models

The full 17­digit serial or Vehicle Identification Number (V.I.N.) is stamped on the left side of the frame backbone at the rear of the steering head. A label bearing the V.I.N. code is also affixed to the left side of the steering head.

An abbreviated V.I.N. is stamped on the left side crankcase at the base of the rear cylinder.

NOTE:

Always give the full 17­digit Vehicle Identification Number when ordering parts or making any inquiry about your motorcycle.

1.Market designation (1 character)

2.Manufacturer (2 characters)

3.Motorcycle type (1 character)

4.Model (2 characters)

5.Engine type (1 character)

6.Introduction date (1 character)

7.V.I.N. check digit (1 character)

8.Model year (1 character)

9.Assembly plant (1 character)

10.Sequential number (6 characters)

Typical Harley­Davidson Vehicle Identification Number

2005 Harley­Davidson Touring V.I.N. Breakdown

	POSITION		DESCRIPTION		POSSIBLE VALUES
	1		Market designation		1=Domestic
					5=International
	2		Manufacturer		HD=Harley­Davidson
	3		Motorcycle type		1=Heavyweight motorcycle
	4		Model		see model V.I.N. table
	5		Engine type		V=1450cc carbureted
					W=1450cc fuel injected
	6		Introduction date		varies
	7		V.I.N. check digit		Can be 0­9 or X
	8		Model year		5=2005
	9		Assembly plant		Y=York, PA
					K=Kansas City, MO
	10		Sequential number		varies

2005 Touring V.I.N. Model Codes

CODE

MODEL

CODE

MODEL

CODE

MODEL

FD

FLHR

FK

FLHTCI Shrine

FY

FLHRSI

FB

FLHRI

FF

FLHTCI

FS

FLTRI

FR

FLHRCI

FC

FLHTCUI

FV

FLHTI

DD

FLHT

FL

FLHTCUI Shrine

FG

FLHTCUI with sidecar

DJ

FLHTC

FX

FLHRS

FW

FLHRI Shrine

Specifications

Specifications: 2005 Touring Models

Engine: 2005 Touring Models

	ITEM		SPECIFICATION
	Number of cylinders		2
	Type		4­cycle, 45 degree
			V­Type, air cooled
	Compression ratio		8.9­1
	Bore		3.75 in.		95.18 mm
	Stroke		4.00 in.		101.52 mm
	Displacement		88 cu. in.		1450 cc
	Torque		85.0 ft­lbs @ 3000 RPM

Ignition System: 2005 Touring Models

	COMPONENT		SPECIFICATION
	Ignition timing		not adjustable
	Battery		12 volt, 28 amp/hr,
			sealed and maintenance free
	Spark plug type		HD­6R12
	Spark plug size		12 mm
	Spark plug gap		0.038­0.043 in.		0.97­1.09 mm
	Spark plug torque		12­18 ft­lbs		16.3­24.4 Nm

Transmission Specifications

	TRANSMISSION		SPECIFICATION
	Type		Constant mesh, foot shift
	Speeds		5 forward

Sprocket Teeth: 2005 Touring Models

	DRIVE		ITEM		NUMBER OF TEETH
	Primary		Engine		25
			Clutch		36
	Final		Transmission		32
			Rear wheel		70

Capacities: 2005 Touring Models

ITEM		U.S.		LITERS
Fuel tank (total)		5.0 gal		18.9
Fuel tank reserve		1.0 gal		3.8
(carbureted only)
Oil tank with filter		4.0 qt.		3.8
Transmission		20­24 oz.		0.59­0.71
(approximate)
Primary chaincase		32.0 oz.		0.95

(approximate)

Gear Ratios: 2005 Touring Models

	GEAR		RATIO
	1st Gear		10.11
	2nd Gear		6.958
	3rd Gear		4.953
	4th Gear		3.862
	5th Gear		3.150

NOTE:

Gross Vehicle Weight Rating (GVWR) (maximum allowable loaded vehicle weight) and corresponding Gross Axle Weight Ratings (GAWR) are given on a label located on the frame below the steering head.

Weights: 2005 FLHT, FLHTC/U and FLTRI

	ITEM		FLHT				FLHTC				FLHTCU				FLTRI
			LB.		KG		LB.		KG		LB.		KG		LB.		KG
	Weight as shipped from factory		758		344.1		776		352.3		788		357.8		731		331.9
	GVWR		1259		571.6		1259		571.6		1259		571.6		1259		571.6
	GAWR front		500		227		500		227		500		227		500		227
	GAWR rear		827		375		827		375		827		375		827		375

Weights: 2005 FLHR, FLHRC and FLHRS

	ITEM		FLHR				FLHRC				FLHRS
			LB.		KG		LB.		KG		LB.		KG
	Weight as shipped from factory		723		328.2		710		322.3		721		327
	GVWR		1259		571.6		1259		571.6		1259		571.6
	GAWR front		500		227		500		227		500		227
	GAWR rear		827		375		827		375		827		375

Dimensions: 2005 FLHT, FLHTC/U and FLTRI

	ITEM			FLHT					FLHTC				FLHTCU					FLTRI
			IN.			MM		IN.			MM		IN.		MM		IN.			MM
	Wheel base		63.5			1612.9		63.5			1612.9		63.5		1612.9		63.5			1612.9
	Overall length		93.7			2380		97.5			2476.5		98.3		2496.8		93.7			2380
	Overall width		39.0			990.6		39.0			990.6		39.0		990.6		35.8			908.1
	Road clearance		5.1			129.5		5.1			129.5		5.1		129.5		5.1			129.5
	Overall height		61.0			1549.4		61.0			1549.4		61.0		1549.4		55.0			1397
	Saddle height		27.3			693.4		27.3			693.4		27.3		693.4		26.9			683.3

Dimensions: 2005 FLHR, FLHRC and FLHRS

	ITEM			FLHR					FLHRC					FLHRS
			IN.			MM		IN.			MM		IN.			MM
	Wheel base		63.5			1612.9		63.5			1612.9		63.5			1612.9
	Overall length		93.7			2380		93.7			2380		93.7			2380
	Overall width		34.5			875		34.5			875		39.4			1000
	Road clearance		5.1			129.5		5.1			129.5		4.7			119
	Overall height		55.1			1398.5		55.1			1398.5		46.4			1178
	Saddle height		27.3			693.4		26.9			683.3		26.1			662

Tire Pressures: 2005 Touring Models

MODEL		LOAD			TIRE PRESSURE (COLD)
					FRONT					REAR
				PSI			kPa		PSI			kPa
All		solo rider		36			248		36			248
		rider and passenger		36			248		40			276

2005 vehicles use Dunlop Harley­Davidson tires only.

Tire Sizes: 2005 Touring Models

	MODEL		MOUNT		SIZE		NUMBER
	All		front		16 in.		D402F MT90B16
	All		rear		16 in.		D402 MU85B16

Bulb Chart: 2005 Touring Models

LAMP

Headlamp

Tail and stop lamp

Turn signal lamp

Additional lighting

Instrument panel lamps

FLHT/C/U

FLHR/C/S*

FLTRI

Gauge lamps

FLHR/C/S

Gauge lamps

FLHT/C/U

FLTRI

DESCRIPTION		BULBS		CURRENT		HARLEY­
(ALL LAMPS 12 VOLT)		REQUIRED		DRAW		DAVIDSON
				AMPERAGE		PART NUMBER
FLHT/C/U, FLHR, FLTRI (2		1		4.58/5.0		68329­03
bulbs)
position lamp international		1		0.32		53438­92
tail lamp		1		0.59		68167­88
stop lamp		1		2.10		68167­88
tail lamp international		1		0.59		68167­88
stop lamp international		1		2.10		68167­88
front/running		2		2.25/0.59		68168­89
front international		2		1.75		68163­84
rear		2		2.25		68572­64B
rear international		2		1.75		68163­84
Tour­Pak side lamps		8		0.30		53439­79
FLHTC/U
Tour­Pak tail and stop lamp		2		0.59		68168­89A
FLHTCU
Fender tip lamps		2		0.30		53439­79
License plate lamp		1		0.37		53436­97
international
Auxiliary lamps		2		2.1		68351­05
high beam indicator		1		0.15		68024­94
oil pressure indicator		1		0.15		68024­94
neutral indicator		1		0.15		68024­94
turn signal indicator		2		0.08		68024­94
speedometer		N/A		N/A		N/A
odometer		N/A		N/A		N/A
fuel gauge		1		0.19		67136­85
engine		N/A		N/A		N/A
FLHR­I only
speedometer		N/A		N/A		N/A
tachometer		N/A		N/A		N/A
voltmeter		1		0.24		67445­00
oil pressure indicator		1		0.24		67445­00
FLHT/C/U
air temperature gauge		1		0.24		67445­00

			FLHT/C/U
			fuel gauge		1		0.24		67445­00
	Items with *		Illuminated with LEDs. Replace entire assembly upon failure.

Tire Data

Match tires, tubes, air valves and caps to the correct wheel rim. Contact a Harley­Davidson dealer. Mismatching can result in damage to the tire bead, allow tire slippage on the rim or cause tire failure, which could result in death or serious injury. (00023a)

Use only Harley­Davidson approved tires. See a Harley­ Davidson dealer. Using non­approved tires can adversely affect stability, which could result in death or serious injury. (00024a)

Tubeless tires fitted with the correct size inner tubes may be used on all Harley­Davidson laced (wire spoked) wheels. Protective rubber rim strips must be used with tubeless tires (fitted with correct size inner tubes) when mounted on laced (wire spoked) wheels.

Use inner tubes on laced (wire spoked) wheels. Using tubeless tires on laced wheels can cause air leaks, which could result in death or serious injury. (00025a)

Tubeless tires are used on all Harley­Davidson cast and disc wheels.

Tire sizes are molded on the tire sidewall. Inner tube sizes are printed on the tube.

Harley­Davidson front and rear tires are not the same. Interchanging front and rear tires can cause tire failure, which could result in death or serious injury. (00026a)

Do not inflate tire beyond maximum pressure as specified on sidewall. Over inflated tires can blow out, which could result in death or serious injury. (00027a)

Harley­Davidson tires are equipped with wear bars that run horizontally across the tread. When wear bars become visible and only 1/32 in. (0.8 mm) tread depth remains, replace tire immediately. Using a worn tire can adversely affect stability and handling, which could result in death or serious injury. Use only Dunlop Harley­Davidson replacement tires. (00090a)

See Specifications: 2005 Touring Models for tire pressures and sizes.

Gasoline Blends

Your motorcycle was designed to get the best performance and efficiency using unleaded gasoline. Most gasoline is blended with alcohol and/or ether to create oxygenated blends. The type and amount of alcohol or ether added to the fuel is important.

Do not use gasoline that contains methanol. Doing so can result in fuel system component failure, engine damage and/or equipment malfunction. (00148a)

Gasoline containing METHYL TERTIARY BUTYL ETHER (MTBE): Gasoline/MTBE blends are a mixture of gasoline and as much as 15% MTBE. Gasoline/MTBE blends can be used in your motorcycle.

ETHANOL is a mixture of 10% ethanol (Grain alcohol) and 90% unleaded gasoline. Gasoline/ethanol blends can be used in your motorcycle if the ethanol content does not exceed 10%.

REFORMULATED OR OXYGENATED GASOLINES (RFG): Reformulated gasoline is a term used to describe gasoline blends that are specifically designed to burn cleaner than other types of gasoline, leaving fewer tailpipe emissions. They are also formulated to evaporate less when you are filling your tank. Reformulated gasolines use additives to oxygenate the gas. Your motorcycle will run normally using this type of gas and Harley­ Davidson recommends you use it when possible, as an aid to cleaner air in our environment.

You may find that some gasoline blends adversely affect the starting, driveability or fuel efficiency of your motorcycle. If you experience one or more of these problems, it is recommended you operate your motorcycle on straight unleaded gasoline.

Fuel

Refer to Octane Ratings. Always use a good quality unleaded gasoline. Octane ratings are usually found on the pump.

Avoid spills. Slowly remove filler cap. Do not fill above bottom of filler neck insert, leaving air space for fuel

expansion. Secure filler cap after refueling. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00028a)

Use care when refueling. Pressurized air in fuel tank can force gasoline to escape through filler tube. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00029a)

Modern service station pumps dispense a high flow of gasoline into a motorcycle fuel tank making air entrapment and pressurization a possibility.

Octane Ratings

SPECIFICATION

Pump Octane (R+M)/2

RATING

91 (95 RON)

Catalytic Converters

California and all international motorcycles are equipped with catalytic converters.

Do not operate catalytic converter­equipped vehicle with engine misfire or a non­firing cylinder. If you operate the vehicle under these conditions, the exhaust will become abnormally hot, which can cause vehicle damage, including emission control loss. (00149a)

Use only unleaded fuel in catalytic converter­equipped motorcycles. Using leaded fuel will damage the emission control system. (00150b)

Controls and Indicators

General: Controls and Indicators

Read the CONTROLS AND INDICATORS section before riding your motorcycle. Failure to understand the operation of the motorcycle could result in death or serious injury. (00043a)

Some features explained are unique to certain models. These features may be available as accessories for your Harley­Davidson motorcycle. See a Harley­Davidson dealer for a complete list of accessories that will fit your specific motorcycle.

Refer to the side view photographs in the front of the manual to locate the items discussed in this section. See 2005 Touring Models.

Ignition/Headlamp Key Switch: Touring Models

The automatic­on headlamp feature provides increased visibility of the rider to other motorists. Be sure headlamp is on at all times. Poor visibility of rider to other motorists can result in death or serious injury. (00030b)

See YOUR OWNER'S MANUAL section. Be sure to record all your key numbers in the space provided at the front of this book.

See Ignition/Headlamp Key Switch: Touring Models. The ignition/headlamp key switch controls electrical functions of the motorcycle.

Protect your vehicle against theft. After parking your motorcycle, lock the steering head and remove ignition key from switch. Failure to lock your motorcycle may result in theft and/or equipment damage. (00151a)

Do not operate vehicle with forks locked. Locking the forks restricts the vehicle's turning ability, which could result in death or serious injury. (00035a)

Do not lubricate barrel locks with petroleum based lubricants or graphite. Inoperative locks may result. (00152a)

Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed. Use of inferior lubricants can damage the engine. (00184a)

1.To remove the key from the ignition on FLHR models, push the key in and turn it counterclockwise.

2.To remove the key from the ignition on FLHT models, push the key in and turn clockwise.

3.Remove the key.

NOTES:

Harley­Davidson recommends removing key from ignition/fork lock before operating motorcycle. If you do not remove key, it can fall out during operation. ACCESS/ACCESSORY ­ Accessories and hazard warning flasher can be turned on. Instrument lamps are on. Brake lamp and horn can be activated. Key may be removed. The lamps illuminate when the switch is in the IGNITION position, as required by law in some localities.

					Ignition/Headlamp Switch Positions: 2005 Touring Models
	MODEL		LOCATION		SWITCH POSITIONS/FUNCTIONS
	FLHT		At bottom		To unlock the switch and the front fork, push the key in and turn it
	FLHTC		of		counterclockwise. Be sure you push key in to move key to either position.
			instrument		On international models, the switch knob will pop up. Ignition/headlamp
	FLHTCU panel.				key switch can be locked in the accessory position however, forks will
					remain unlocked.
	FLTRI				To lock the fork, move fork to the full left position. Push down on knob and
					turn it to the left, to the FORK LOCK position. Turn key to lock. Remove
					the key. On international models, turn fork to full left position. Turn switch
					knob to fork lock, push knob down and turn key to LOCK. Remove the
					key.
					ACCESS/ACCESSORY ­ Accessories and hazard warning flasher can be
					left on. Instrument lamps are on. Brake lamp and horn can be activated.
					Key may be removed.
					The ignition, lamps and accessories work when the switch is in the
					IGNITION position, as required by law in some localities.*
	FLHR		On fuel		Switch is locked or unlocked by lifting switch cover, inserting key and
	FLHRC		tank		turning key counterclockwise to lock, clockwise to unlock. Key may be
			instrument		removed in any position.

		panel
	FLHRS		OFF ­ Ignition, lamps and accessories are off.
			ACCESS/ACCESSORY ­ Accessories are on. Hazard warning flashers
			can be left on. Instrument lamps are on. Brake lamp and horn can be
			activated.*
			LAMPS and IGNITION ­ Ignition, lamps and accessories are on.*

* International models have an additional function. Position lamp and tail lamp are also on.

1.International and Brazilian FLHT and FLTR models

2.All FLHT (U.S. and Canadian models only)

3.All FLHR models (cover shown closed)

4.All FLHR models (cover shown open)

Ignition/Headlamp Key Switch: Touring Models

Hand Controls: Basic Operation

Electric Starter Switch

NOTE:

Off/Run switch MUST be in RUN position to operate engine.

See Basic Handlebar Controls: FLHRCI Shown (typical). The electric starter switch is located on the right handlebar control group. See Starting the Engine: Carbureted Models for detailed operation procedures.

1.Put the engine off/run switch in the RUN position and the transmission in neutral. Neutral (green) indicator lamp should be illuminated.

2.See Ignition/Headlamp Key Switch: Touring Models. Turn ignition/headlamp key switch to ON and push the START switch to operate starter motor.

Engine OFF/RUN Switch

See Basic Handlebar Controls: FLHRCI Shown (typical). The engine off/run switch (7) turns the ignition power ON or OFF. The engine off/run switch is located on the right handlebar control. Push the top portion of the engine off/run switch to turn off ignition power and shut the engine off. Push the bottom portion of the engine off/run switch to turn on ignition power.

NOTES:

The engine off/run switch must be in the ON position to start or operate the engine. The engine off/run switch should be used to shut the engine off.

1.To shut the engine off, push the top of the off/run switch to the ignition OFF position.

2.See Ignition/Headlamp Key Switch: Touring Models. Turn the ignition key to the OFF position to turn the ignition power completely OFF.

Throttle Control Grip

See Basic Handlebar Controls: FLHRCI Shown (typical). The throttle control grip (9) is located on the right handlebar control and is operated with the right hand.

To reduce rider fatigue on long trips, a spring loaded throttle friction adjustment screw (10) is located at the bottom of the throttle grip clamp on non­cruise equipped models.

1.Slowly turn throttle control grip clockwise (toward the front of the bike) to close the throttle (decelerate).

2.Slowly turn throttle control grip counterclockwise (toward rear of bike) to open the throttle (accelerate).

Do not tighten throttle friction adjustment screw to the point where the engine will not return to idle automatically. Over­tightening can lead to loss of vehicle control, which could result in death or serious injury. (00031b)

3.Unscrew the throttle friction adjustment screw so the throttle returns to the idle position when the hand is removed from the grip.

4.Screw the throttle adjustment screw in to increase friction on grip. This provides a damping effect on throttle motion.

NOTE:

The throttle friction adjustment screw should not be used under normal stop and go operating conditions.

Clutch Hand Lever

Do not position fingers between hand control lever and handlebar grip. Improper hand positioning can impair control lever operation and cause loss of vehicle control, which could result in death or serious injury. (00032a)

The clutch hand lever (1) is located on the left handlebar and is operated with the fingers of the left hand.

1.Slowly pull clutch hand lever in against handlebar grip to fully disengage clutch.

2.Shift to first gear using the gear shifter lever. See Shifting Gears.

3.Slowly release the clutch hand lever to engage clutch.

Horn Switch

The horn is operated by pushing on the horn switch (2) located on the left handlebar control group.

Headlamp Dimmer Switch

The headlamp dimmer switch (3) is located on the left handlebar. The switch has two positions to activate the headlamps high or low beams.

Press the top of the headlamp dimmer beam switch to activate the high beam. Press the bottom of the headlamp dimmer switch to return to the low beam.

See Indicator Lamps. The (blue) high beam indicator lamp will illuminate when the high beam is on.

Turn Signal Switches

Each handlebar control group contains a turn signal switch.

The right turn signal switch (11) operates the right front and right rear flashing lamps. The left turn signal switch (4) operates the left front and left rear flashing lamps.

NOTE:

Front turn signal lamps also function as running lamps.

1.Clutch hand lever

2.Horn switch

3.Headlamp dimmer switch

4.Left turn signal switch

5.Master cylinder reservoir

6.Electric starter switch

7.Engine off/run switch

8.Brake hand lever

9.Throttle control grip

10.Throttle friction adjusting screw (not shown, not used on cruise control models)

11.Right turn signal switch

Basic Handlebar Controls: FLHRCI Shown (typical)

Turn Signal Switch Operation

The turn signal switches are used by the turn signal module to control turn signal operation based on vehicle speed, vehicle acceleration and turn completion.

Momentarily depress the desired turn signal switch. The turn signal lamps will begin and continue flashing until they are manually or automatically cancelled. As long as the motorcycle is stationary, the signals will flash.

NOTES:

If you want the turn signals on longer, hold the switch in. The turn signals will begin flashing immediately, but the microprocessor will not begin computing distance until you release the switch.

If you are signaling to turn in one direction and you depress the switch for the opposite turn signal, the first signal is cancelled and the opposite side begins flashing.

If you want to stop the lamps from flashing, briefly depress the turn signal switch a second time. The turn signal lamps will stop flashing.

Hazard Warning 4­Way Flasher

Use the following method to activate the four­way flashers.

1.With the ignition key ON and security system disarmed (models with security only), press the left and right turn signal switches at the same time.

2.Turn the ignition key OFF and arm the security system if present and desired. The four­way flashers will continue for two hours.

3.To cancel four­way flashing, disarm the security system if necessary, turn the ignition key ON and press the left and right turn signal switches at the same time.

This system allows a stranded vehicle to be left in the four­way flashing mode and secured until help is found.

Indicator Lamps

See Indicator Lamps. Five indicator lamps are provided.

The green TURN indicators will flash when turn signals are activated; therefore, flashing indicates the chosen turn direction. When the 4­way hazard flashers are operating, both turn indicators will flash simultaneously.

The blue BEAM indicator lamp, when lit, signals high beam headlamp operation. The green NEUTRAL lamp, when lit, signals the transmission is in neutral gear.

The red OIL indicator lamp, when lit, signals that oil is not circulating through the engine.

NOTE:

The OIL indicator lamp will glow when the ignition is turned on prior to starting engine. With engine running, lamp should be off when engine speed is above idle.

Several other circumstances that could cause the red oil indicator lamp to signal, include the following:

If the oil pressure indicator lamp does not go off at speeds above idling, it is usually because of an empty oil tank or diluted oil.

In freezing weather the oil feed may clog with ice and sludge, preventing oil circulation. A grounded oil signal switch wire.