Harley Davidson Pre delivery and set up 2005 Harley Davidson Pre delivery and set up 2005

2005

HARLEY-DAVIDSON

MOTORCYCLE

PREDELIVERY

AND SETUP

GENERAL I

TOURING II

MANUAL

The information in this Manual

applies to all 2005 motorcycle

models manufactured by

Harley-Davidson Motor Company.

Printed in the U.S.A.

DYNA III

SOFTAIL IV

SPORTSTER V

VISIT THE HARLEY-DAVIDSON WEB SITE

Binder 99946-88 Contents 99947-05 CMI-4.0M-06/04

VRSC VI

http://www.harley-davidson.com

CVO VII

FOREWORD

INTRODUCTION

This PREDELIVERY AND SETUP MANUAL has been prepared by Harley-Davidson Motor Company to provide the Harley-Davidson dealer with the factory recommended steps needed to prepare our motorcycles for delivery to the customer.

NOTE Harley-Davidson Motor Company considers the predelivery inspections and procedures in this manual necessary to assure customer safety and satisfaction. None of these inspections or procedures should ever be left out, and only qualiﬁed technicians should perform them.

HOW TO USE YOUR PREDELIVERY AND SETUP MANUAL

Your Predelivery and Setup Manual is divided into seven sections:

Section I–General Information: All Models

●

Section ll–Predelivery Inspections: Touring Models

●

Section lll–Predelivery Inspections: Dyna Models

●

Section IV–Predelivery Inspections: Softail Models

●

Section V–Predelivery Inspections: Sportster Models Section VI–Predelivery Inspections: VRSC Models

●

Section VII–Predelivery Inspections: CVO Models

Refer to Section I ﬁrst for general setup instructions pertaining to all current model motorcycles. Then, proceed to the one Section (either II, III, IV, V, VI or VII) which covers the inspection procedures for your speciﬁc model vehicle.

WARNINGS AND CAUTIONS

1WARNING1WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. (00119a)

PRODUCT REFERENCES

All tools mentioned in this manual with “HD” or “J” preceding the part number must be ordered through Kent-Moore.

Direct all mail orders and general correspondence to the following address:

Kent-Moore SPX Corporation 28635 Mound Road Warren, Michigan USA 48092-3499 Telephone: 1-800-345-2233

Sealing and Threadlocking Products

LOCTITE PRODUCTS

Some procedures in this Service Manual call for the use of

®

Loctite product usage or retailer/wholesaler locations, please call Loctite Corp. at 1-800-323-5106.

products. If you have any questions regarding Loctite

ORDERING INFORMATION

Additional binders or contents may be ordered from Parts & Accessories. The binder and the contents must be ordered separately.

●

Binder: Part No. 99946-88 Contents: Part No. 99947-05

●

1CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. (00139a)

CAUTION

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. (00140a)

NOTE Refers to important information, and is placed in italic type.

It is recommended that you take special notice of these items.

iii

iv

TABLE OF CONTENTS

SECTION SUBJECT PAGE NUMBER

IGeneral Information: All Models 1-1

II Predelivery Inspections: Touring Models 2-1

III Predelivery Inspections: Dyna Models 3-1

IV Predelivery Inspections: Softail Models 4-1

VPredelivery Inspections: Sportster Models 5-1

VI Predelivery Inspections: VRSC Models 6-1

VII Predelivery Inspections: CVO* Models 7-1

*Custom Vehicle Operations

v

PREDELIVERY: ALL MODELS

SUBJECT PAGE NO.

1.1 Uncrating and General Setup: All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Vehicle Crate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Uncrating Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Removing Cardboard Carton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Handlebar Installation–FLSTSC, FLSTN and FXDWG Models . . . . . . . . . . . 1-2

Adjusting Handlebars–All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Removing Vehicle From Pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Clutch Hand Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Front Brake Hand Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Front Brake Master Cylinder Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Vehicle Cleanup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Cosmetic Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Returning Steel Pallets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Maintenance-Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Date Of Manufacture Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Voltmeter Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Charging Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Warning Label Placement (All Vehicles Sold Outside of the United States) . 1-18

1.2 System Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

I

10426

8798

1

UNCRATING AND GENERAL SETUP: ALL MODELS 1.1

VEHICLE CRATE INSPECTION

Inspect each crate for external damage while it is still on delivery truck. Open crate and inspect motorcycle for damage before truck leaves your dealership. Refer to HARLEYDAVIDSON/BUELL WARRANTY MANUAL, “SHIPPING DAMAGE PROCEDURE” for complete information on ﬁling claims for damaged and over/short freight.

UNCRATING VEHICLE

CAUTION

Use caution when removing cardboard carton from pallet. DO NOT remove uprights before removing carton. Failure to do so can cause damage to motorcycle.

NOTE All Harley-Davidson motorcycles are shipped in crates using returnable steel pallets. The steel pallets have fork openings 2x7 in. (5.1x17.8 cm) at the front and sides. Crates have widths of 29 in. (73.7 cm) and 43 in. (109.2 cm) and all are 50 in. (127 cm) high. The VRSC, SPORTSTER, DYNA and some SOFTAIL models are shipped with the front wheel turned to the left or right in a “turn-wheel” crate. Removing the shipping crate is similar on all models so the procedure given below is typical for all models. Call your SPOC representative if you have questions regarding steel pallet return.

2. See Figure 1-2. Using a box cutter, cut one end of the cardboard carton. Slide carton away from pallet as shown. Set carton aside for recycling.

Figure 1-2. Remove Cardboard Carton from Pallet.

3. See Figure 1-3. Remove both uprights (VRSC, FLST and FLSTC crates have three uprights) by lifting upward. Set uprights aside for recycling.

REMOVING CARDBOARD CARTON

1. See Figure 1-1. Use a T-20 bit and an electric or air powdered drill/driver to remove all fasteners from cardboard carton. Open top carton ﬂaps.

8796

Figure 1-3. Remove Uprights from Pallet

4. Open plastic bag enclosing motorcycle and push it down off motorcycle. Remove protective tape and elastic protective netting, if present, from chrome and painted parts of motorcycle.

Figure 1-1. Removing Screws

2005 PDI: All Models 1-1

NOTE Always install/adjust handlebars before removing motorcycle from pallet. See HANDLEBAR INSTALLATION–FLSTSC,

FLSTN AND FXDWG MODELS and ADJUSTING HANDLEBARS– ALL MODELS.

5. If uninstalled parts are in crate, verify your receipt of all

separate items by comparing with parts list in shipping crate.

6. If vehicle has damage which appears to have occurred at

the factory, submit warranty claim form. Accurately describe damage and cause. (e.g.–“Found nail in tire; caused tire to go ﬂat.”) Supply proper failure code(s).

1WARNING1WARNING

Do not alter or disable any device or system to circumvent local, state, or federal regulations. All safety and environmental devices or systems must be left intact as designed and built at the factory. Tampering with safety and environmental devices or systems could result in death or serious injury.

1WARNING1WARNING

The automatic-on headlamp feature provides increased visibility for riders. Be sure headlamp is on at all times. Low visibility of rider can result in death or serious injury. (00030a).

1WARNING1WARNING

Some motorcycles are shipped with the hand brake lever wrapped tight against the hand grip. Remove plastic wrap and warning label (see Figure 1-4.) and pump brake lever 3-4 times before moving motorcycle from pallet. Failure to pump brake lever could result in an inoperable front brake which could result in death or serious injury.

HANDLEBAR INSTALLATION– FLSTSC, FLSTN AND FXDWG MODELS

FLSTSC

After removing carton and protective plastic wrap:

1. See Figure 1-5. While holding handlebars, remove the riser bolts (2) securing handlebar shipping cradle (1) to risers. Retain the four bolts, discard washers.

2. While holding the handlebar shipping cradle, cut cable straps (3). Discard cradle and cable straps. Remove and discard protective block (4) from left handlebar grip.

3. Route handlebar switch conduits between and behind risers.

4. Position handlebar on top of risers, secure with riser caps and riser bolts.

5. See ADJUSTING HANDLEBARS– ALL MODELS and

Figure 1-10. Following the Dyna Glide, Softail, XL 883, XL 883L and XL 1200R Models procedure, adjust the

handlebars and tighten the riser bolts to 12-15 ft-lbs (16.3-20.3 Nm) in the sequence given.

6. Push the four plastic wire retainers on the handlebar switch conduits into the holes in the handlebars. Replace any broken wire retainers.

7. Attach hand control and directional wire harnesses to handlebar risers with cable straps (Part No. 10039).

8. Insert the clutch cable into the retaining clip on the left frame downtube.

10612

1

pd0171

WARNING:

PUMP BRAKE LEVER 3-4 TIMES BEFORE USING BRAKES

Figure 1-4. Warning Label

1-2 2005 PDI: All Models

2

4

1. Handlebar shipping cradle

2. Riser bolt (4)

3. Cable strap (4)

4. Protective block

5. Protective pad

Figure 1-5. FLSTSC

3

5

FLSTN

1. Front brake line

2. Clamp (2)

3. Screw (2)

4. Fork stem cover

5. Clamp

6. Screw

1

6

2

10614

3

5

3

4

10615

After removing carton and protective plastic wrap:

1. See Figure 1-6. Remove and discard cloth tie (3) securing handlebar.

2. Remove the riser bolts (2) and shipping clamp (1) from handlebar risers. Retain the bolts. Remove and discard protective block (4) from right handlebar grip.

3. Route handlebar switch conduits between and behind risers.

4. Position handlebar on top of the risers and secure with riser caps, and bolts removed in step 2.

5. See ADJUSTING HANDLEBARS– ALL MODELS and

Figure 1-10. Following the Dyna Glide, Softail, XL 883, XL 883L and XL 1200R Models procedure, adjust the

handlebars and tighten the riser bolts to 12-15 ft-lbs (16.3-20.3 Nm) in the sequence given.

6. Push the four plastic wire retainers on the handlebar switch conduits into the holes in the handlebars. Replace any broken wire retainers.

7. Insert the clutch cable into the retaining clip on the left frame downtube.

10613

1

2

3

4

1. Shipping clamp

2. Riser bolts

3. Cloth tie

4. Protective block

Figure 1-6. FLSTN

8. See Figure 1-7. Install front brake line (1) in clamps (2), inboard of screws (3) and attach to fork stem cover (4). Tighten screws to 30-50

9. Install brake line in clamp (5) in underside of lower fork clamp. Tighten screw (6) to 96-120 Nm).

in-lbs

(3.4-5.7 Nm).

in-lbs

Figure 1-7. Attaching Front Brake Line–FLSTN

(10.9-13.6

2005 PDI: All Models 1-3

FXDWG

After removing carton and protective plastic wrap:

1. See Figure 1-8. Remove and discard cloth tie (1) securing handlebar.

2. Remove the four bolts (2) from the riser. Retain the four bolts.

3. Reroute the left hand switch wire conduit from between the riser to a position in front of the riser.

6052

4. Retrieve riser caps from passenger backrest.

5. Position the handlebar on top of the risers and fasten the riser caps in place using the bolts removed in step 2.

6. See ADJUSTING HANDLEBARS– ALL MODELS and

Figure 1-10. Following the Dyna Glide, Softail, XL 883, XL 883L and XL 1200R Models procedure, adjust the

handlebars and tighten the riser bolts to 12-18 ft-lbs (16.3-24.4 Nm) in the sequence given.

7. See Figure 1-9. Attach brake line (2) and ground wire (3) on upper triple clamp with clamp (1). Position brake line inboard from fastener. Tighten fastener to 30-60 (3.4-6.8 Nm).

6062

in-lbs

1

3

2

4

6053

1. Cloth tie

2. Riser bolts (4)

3. Shipping clamps

4. Protective block

6059

1

2

3

4

1

1. Clamp

2. Brake line

3. Ground wire

2

Figure 1-9. FXDWG Brake Line and Ground Wire

4. Clamp

5. Screw

5

Figure 1-8. FXDWG

1-4 2005 PDI: All Models

CAUTION

pd0031d

1. Lower clamp (2)

2. Cast-in spacers (2)

3. Rear screw (2)

4. Front screw (2)

5. Instrument bracket (if equipped)

6. Upper clamp

3

2

4

1

5

6

Tighten

ﬁrst

FRONT

See Figure 1-9. Attach brake line as shown before removing motorcycle from pallet. If brake line is not secured, it could be pinched and damaged in front fork stop.

8. Attach brake line to bottom of steering stem with clamp (4) and screw (5). Tighten to 96-120 Nm).

9. See Figure 1-8. Remove shipping clamps (3) from the handlebar. Remove protective block (4) on throttle. Discard shipping clamps and protective block.

10. Install clutch cable in clip on left downtube.

11. Install the plastic wire retainers on the handlebar switch conduits and push into the holes in the handlebars. Replace any broken wire retainers.

in-lbs

(10.9-13.6

ADJUSTING HANDLEBARS– ALL MODELS

General

CAUTION

Never adjust handlebars using excessive force. Doing so may result in damage to handlebar or clamp.

NOTE If handlebars are positioned for a rider of normal size, postpone adjustment until customer has checked their position. If customer requests changing handlebar position, perform the adjustment before delivering the motorcycle to the customer. Always center the handlebar laterally (sideways) in the handlebar clamps.

Before removing motorcycle from pallet, adjust handlebars according to the following procedures:

Dyna Glide, Softail, XL 883, XL 883L and XL 1200R Models

1. See Figure 1-10. Loosen four screws (3 and 4) of han-

dlebar upper clamp (6).

2. To be sure handlebars are properly centered, verify that

equal amounts of knurled areas on handlebar protrude from outboard sides of upper handlebar clamp.

Figure 1-10. XL 883, XL 883L, XL 1200R,

Dyna Glide and Some Softail Models

NOTE On some models, knurled areas of handlebar will be completely hidden by upper handlebar clamp and will not be visible at all when handlebar is centered properly.

3. Raise handlebars to normal riding position and hold in

position.

4. Models with cast-in spacers (2) in upper clamp:

a. Tighten two rear screws (3) until cast-in spacers

contact handlebar lower clamps (1).

b. Dyna and Sportster models: tighten front screws (4)

to 12-18 ft-lbs (16.3-24.4 Nm). Softail models: tighten front screws (4) to 12-15 ft-lbs (16.3-20.3 Nm).

c. Dyna and Sportster models: ﬁnal tighten rear

screws to 12-18 ft-lbs (16.3-24.4 Nm). Softail models: ﬁnal tighten rear screws to 12-15 ft-lbs (16.3-

20.3 Nm). Slight gap between upper and lower clamps should exist at front.

5. Models without cast-in spacers in upper clamps:

a. Tighten all four screws ﬁnger-tight, maintaining

equal gaps between upper and lower clamps front to back.

b. Dyna and Sportster models: tighten rear screws to

12-18 ft-lbs (16.3-24.4 Nm). Softail models: tighten rear screws to 12-15 ft-lbs (16.3-20.3 Nm).

c. Dyna and Sportster models: tighten front screws to

12-18 ft-lbs (16.3-24.4 Nm). Softail models: tighten front screws to 12-15 ft-lbs (16.3-20.3 Nm).

2005 PDI: All Models 1-5

XL 883C and XL 1200C Models

1. See Figure 1-11. Loosen four screws (1, 2) of handlebar upper clamp (3).

).

Tighten

2

ﬁrst

1

pd0031f

4

FLHT, FLHTC, FLHTCU and FLHTP

1. Remove ignition switch knob and inner fairing cap according to appropriate Touring Models Service Manual instructions.

2. See Figure 1-12. Loosen two rear screws (3) of handlebar upper clamps (2).

3. If there is a gap between either handlebar lower clamp (1) and upper clamp at front, tighten front screw (4) only enough to close gap. If handlebars do not move up and down freely, loosen rear screws until they do.

pd0021a

4

2

3

1. Front screw (2)

2. Rear screw (2)

3. Upper clamp

4. Lower clamp

Figure 1-11. XL 1200C, XL 883C Custom Models

2. To be sure handlebars are properly centered, verify that equal amounts of knurled areas on handlebar protrude from outboard sides of upper handlebar clamp.

NOTE On some models, knurled areas of handlebar will be completely hidden by upper handlebar clamp and will not be visible at all when handlebar is centered properly.

3. Raise handlebars to normal riding position; hold in posi-

tion. Tighten two front screws (1) to 12-18 ft-lbs (16.3-

24.4 Nm).

4. Tighten rear screws (2) to 12-18 ft-lbs (16.3-24.4 Nm).

FRONT

1

FRONT

1. Lower clamp (2)

2. Upper clamp (2)

3. Rear screw (2)

4. Front screw (2)

Figure 1-12. FLHT/C/U and FLHTP Models

4. Raise handlebars to normal riding position. To be sure handlebars are properly centered, verify that equal amounts of knurled areas on handlebar protrude from outboard sides of both handlebar clamps.

5. Tighten rear screws to 12-16 ft-lbs (16.3-21.7 Nm). Slight gap should exist between upper and lower clamps at rear.

6. Check torque on front handlebar clamp screws. Tighten screws to 12-16 ft-lbs (16.3-21.7 Nm).

7. Reinstall inner fairing cap and ignition switch knob according to appropriate Touring Models Service Manual instructions.

1-6 2005 PDI: All Models

FLHR/C/S/I Road King, FLHP, FLHPE

1. See Figure 1-13. Remove screw (12) securing chrome ring (11) to headlamp nacelle (7). Remove chrome ring.

2. Remove eight screws (10) securing headlamp assembly (9). Squeeze two external tabs (if present) to remove wire connector at back of headlamp bulb. Remove headlamp assembly from vehicle.

3. Remove nut (1) (inside nacelle) securing nacelle trim (2).

4. On Police models, disconnect tachometer lead.

5. Remove nacelle trim. Loosen (but do not remove) front handlebar clamp shroud screw (3), nut and washer (4).

6. Gently pry off fork lock plate (5) at rear of handlebar clamp shroud (8). Remove two screws (6) beneath lock plate.

pd0226

3

6

8

2

5

7

7. Loosen four acorn nuts securing nacelle halves to fork studs. Spread nacelle halves slightly and remove handlebar clamp shroud.

8. Adjust handlebars following steps 2.-6. of the FLHT,

FLHTC, FLHTCU and FLHTP procedure given on previ-

ous page.

9. Reinstall handlebar clamp shroud. Tighten acorn nuts securing nacelle halves to fork studs to 72-108 (8.1-12.2 Nm).

10. Install two screws (6) to handlebar clamp shroud and tighten to 10-20 lock plate (5) into place on handlebar clamp shroud.

11. Tighten front handlebar clamp shroud nut (4) to 10-20

lbs

(1.1-2.3 Nm).

12. On police models, connect tachometer lead.

13. Install nacelle trim (2). Install nut (1) (inside nacelle) securing nacelle trim. Tighten to 15-20

14. Connect wire connector to socket on back of headlamp bulb. Install and secure headlamp assembly to nacelle with eight fasteners.

15. Secure chrome ring (11) to headlamp nacelle with screw (12).

Check clearance between windshield and clutch cable and handlebar position prior to completing assembly of vehicle.

in-lbs

(1.1-2.3 Nm). Gently press fork

in-lbs

(1.7-2.3 Nm).

NOTE

in-lbs

in-

9

1

11

4

10

12

1. Nut

2. Nacelle trim

3. Front handlebar clamp shroud screw

4. Nut and washer

5. Fork lock plate

6. Screw (2)

7. Nacelle

8. Handlebar clamp shroud

9. Headlamp assembly

10. Screw (8)

11. Chrome headlamp ring

12. Screw

Figure 1-13. FLHR/C, FLHP, FLHPE Models

2005 PDI: All Models 1-7

FLTR Road Glide

1. See Figure 1-14. Remove two T25 TORX screws at sides of instrument bezel.

2. Carefully push tab at rear of instrument bezel from slot above ignition switch. Gently raise free side of bezel until tabs at front of instrument nacelle disengage from slot at front of bezel (concealed behind decorative adhesive strip). Move instrument bezel to one side.

3. See Figure 1-15. Loosen two front screws securing handlebar upper clamps (Instrument bezel has been removed in drawing for clarity).

4. Raise handlebars to normal riding position. Tighten front handlebar clamp screws to 12-16 ft-lbs (16.3-21.7 Nm).

5. Verify that left and right sides of instrument nacelle are properly mated. Pins on left side of nacelle must fully engage holes on right.

6. Insert tab at rear of bezel into slot of instrument nacelle just above ignition switch. Holding left and right sides of nacelle together, place bezel over instrument nacelle ﬂange. when properly mated, tabs at front of instrument nacelle engage lip in slot at front of bezel behind decorative adhesive strip.

NOTE If tabs do not properly engage slot at front of bezel, a loose ﬁt will result. Remove decorative adhesive strip by gently prying up outer edges. Using a ﬂat bladed screwdriver, carefully raise tabs so they engage lip in slot. If damaged, install decorative adhesive strip.

new

pd0201

SE SC

2 HRS

3 MIN

4

1 PRO

HARLEY-DAVIDSON MOTOR COMPANY INC.

60

50

70

80

40

90

30

20

100

10

110

MPH

0

120

H

Y

A

N

R

A

L

P

E

M

CERTIFIED

Y

O

-

D

C

A

R

V

O

I

D

T

S

O

M

N

EJECT

R

LO/DX

®

POWER

40

30

50

60

20

70

10

RPM

x100

0

80

H

Y

A

N

R

A

L

P

E

M

Y

O

-

D

C

A

R

V

O

I

D

T

S

O

M

N

Figure 1-14. FLTR Models-Instrument Bezel Screws

pd0195

Figure 1-15. FLTR Models-Front Handlebar Clamp Screws

1-8 2005 PDI: All Models

VRSCB

10059

1. Lower clamp

2. Cast-in spacers (2)

3. Rear screw (2)

4. Front screw (2)

5. Upper clamp

pd0021b

3

2

5

Tighten

ﬁrst

FRONT

1

4

NOTE To gain access to the handlebar adjusting screws, the following steps will be necessary:

1. Remove Maxi-Fuse.

2. See Figure 1-16. Remove instrument cluster screw from

location shown and pivot instrument cluster away from handlebars.

3. Remove wiring harness connector and remove screw on

bottom side of instrument cluster.

4. Remove instrument cluster.

5. To be sure handlebars are properly centered, verify that

equal amounts of knurled areas on handlebar protrude from outboard sides of upper handlebar clamp.

NOTE On some models, knurled areas of handlebar will be completely hidden by upper handlebar clamp and will not be visible at all when handlebar is centered properly.

6. See Figure 1-17. Raise handlebars to normal riding posi-

tion; hold in position. Tighten two front screws (4) until cast-in spacers (2) of upper clamp contact handlebar lower clamp (1).

7. Tighten rear screws (3) to 16-20 Nm (12-15 ft-lbs).

8. Final tighten front screws (4) to 16-20 Nm (12-15 ft-lbs).

Slight gap between upper and lower clamps should exist at rear.

9. Install instrument cluster.

10. Insert instrument cluster screw and tighten to 2.2-2.8 Nm

(20-24

in-lbs

).

11. Install Maxi-Fuse.

Figure 1-16. Instrument Cluster Mounting Screw Location

Figure 1-17. VRSCB Models

2005 PDI: All Models 1-9

REMOVING VEHICLE FROM PALLET

All Models

1WARNING1WARNING

Always have someone steady motorcycle while each strap is being removed to prevent tipping. Motorcycle front suspension is secured in a compressed state by two nylon straps. Releasing strap tension on one side of motorcycle could result in the front of motorcycle rising and leaning abruptly to opposite side, which could result in death or serious injury.

1WARNING1WARNING

b0458xpx

Figure 1-18. Opening Ratchet Lever

Always wear safety glasses and gloves and keep bystanders at a safe distance when uncrating the motorcycle. When released, each strap will unwind rapidly from its ratchet lever, and end of strap could recoil in an outward direction, which could result in death or serious injury.

1. Remove crating straps. a. Have an assistant hold the motorcycle’s handlebars. b. See Figure 1-18. Start with the right side crating

strap. Depress (in opposite direction of spool) and hold down the spring-loaded ratchet release.

c. See Figure 1-19. Swing open the ratchet lever to the

release position; tensioned nylon strap will rapidly unwind. remove strap and any protective padding from pallet.

1CAUTION

On VRSC models, a third strap is located at the left rear. After this rear strap is removed, unscrew the rear eyebolt to prevent tripping and falling over it. Falling could result in minor or moderate injury. Also, if eyebolt is not removed, the left radiator trim or other low-left-side components could be damaged when motorcycle is rolled off pallet.

pd0051

Figure 1-19. Strap Ratchet Lever (Release Position)

1-10 2005 PDI: All Models

2. See Figure 1-20. Place a 2x4 in. (50.8x101.6 mm) board

1WARNING1WARNING

between steel cross braces (see arrow) behind front tire to aid rolling motorcycle rearward off pallet.

3. Carefully roll vehicle off pallet.

7770

Figure 1-20. Vehicle Pallet

1WARNING1WARNING

Always park motorcycle on a level, ﬁrm surface. An unbalanced motorcycle can fall over which could result in death or serious injury. (00039a)

1WARNING1WARNING

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 cause death or serious injury. (00006a)

1WARNING1WARNING

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

Improperly aligned or adjusted handlebars can contact fuel tank when turned to left or right fork stops. Contact with fuel tank while riding can cause loss of vehicle control resulting in death or serious injury.

4. Slowly turn handlebars back and forth to the full right and full left fork stops to be sure handlebars (and/or turn signals on some models) do not contact fuel tank. Also be sure cables and wiring are not pinched or stretched as handlebars are turned back and forth.

a. If contact between handlebars and fuel tank occurs

and handlebars are properly centered, perform handlebar adjustment again (see ADJUSTING HAN-

DLEBARS– ALL MODELS), raising handlebars as

necessary to clear fuel tank.

b. On models with turn signals mounted on handlebar

control housings, if turn signal contacts fuel tank, adjust turn signals and/or handlebar control housings according to appropriate Service Manual instructions.

1WARNING1WARNING

Throttle control must operate freely without binding. Irregular or sticking throttle cables could cause a loss of control, leading to an accident which could result in death or serious injury.

2005 PDI: All Models 1-11

CLUTCH HAND LEVER

NOTE

● See Figure 1-21. All Dyna models have Maxi-Fuse

wrapped in plastic wrapping around clutch hand lever and left handlebar grip.

● See Figure 1-22. See Figure 1-23. All Sportster models

have Maxi-Fuse and headlamp snap cap ﬁtted into protective foam on clutch hand lever and left handlebar grip. Save snap cap for installation after headlamp has been adjusted. Sportster model XL 883L also has righthand mirror ﬁtted into protective foam.

1. Remove plastic wrapping or protective foam from clutch hand lever and left handlebar grip.

2. If handlebar controls need to be adjusted, perform the following procedure.

a. See Figure 1-24. Loosen, but do not remove, clutch

control housing clamp screws (1) and handlebar switch housing clamp screws (2).

b. Rotate clutch control housing and handlebar switch

housing as necessary for correct position and rider comfort.

c. Beginning with the top screw, tighten clutch control

housing clamp screws. All Sportster models: tighten to 108-132 in-lbs (12.2-14.9 Nm). All other models: tighten to 60-80 in-lbs (6.8-9.0 Nm).

d. Tighten handlebar switch housing clamp screws to

35-45 in-lbs (4.0-5.1 Nm).

10702

2

1

3

1. Clutch lever restraining foam

2. Headlamp snap cap (XL 883 and XL 1200R only)

3. 30-amp Maxi-Fuse

Figure 1-22. Location of Maxi-Fuse and Snap Cap on

Clutch Hand Lever–All Sportster Models Except XL 883L

10703

5

1

10616

Figure 1-21. Location of Maxi-Fuse on Clutch

Hand Lever–Dyna Models

4

2

1. Clutch lever restraining foam

2. Headlamp snap cap

3. 30-amp Maxi-Fuse

4. Mirror

5. Package of mirror mounting hardware

Figure 1-23. Location of Maxi-Fuse and Snap Cap on

Clutch Hand Lever–Sportster XL 883L

pd0217

2

1

2

1. Clutch control housing clamp screw (2)

2. Handlebar switch housing clamp screw (2)

3

1-12 2005 PDI: All Models

Figure 1-24. Left Hand Controls (Typical)

FRONT BRAKE HAND LEVER

If handlebar controls need to be adjusted, perform the following procedure.

1. See Figure 1-25. Loosen, but do not remove, front brake master cylinder clamp screws (1) and handlebar switch housing clamp screws (2).

2. Rotate master cylinder housing and handlebar switch housing as necessary for correct position and rider comfort.

3. Beginning with the top screw, tighten front brake master cylinder clamp screws. All Sportster models: tighten to 108-132 in-lbs (12.2-14.9 Nm). All other models: tighten to 60-80 in-lbs (6.8-9.0 Nm).

4. Tighten handlebar switch housing clamp screws to 35-45 in-lbs (4.0-5.1 Nm).

pd0218

4

3

2

1CAUTION

Direct contact of D.O.T. 5 brake ﬂuid with eyes can cause eye irritation, swelling, and redness. 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. 5 brake ﬂuid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a)

1CAUTION

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)

CAUTION

D.O.T. 4 brake ﬂuid will damage painted and molded-in color surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239a)

1

2

1. Front brake master cylinder clamp screw (2)

2. Handlebar switch housing clamp screw (2)

3. Reservoir sightglass (XL models)

4. Reservoir sightglass (all models except XL)

Figure 1-25. Right Hand Controls (Typical)

IMPORTANT NOTE All Touring model motorcycles use D.O.T. 4 HYDRAULIC BRAKE FLUID (Part No. 99953-99A). All Dyna, Softail, VRSC and Sportster models use D.O.T 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. 99902-77: 12 oz., 99901-77: 1 gal.). If it is necessary to top off the brake ﬂuid in the reservoir, make sure you add the correct type.

CAUTION

Cover handlebar switches with a shop towel before adding brake ﬂuid to front master cylinder reservoir. Spilling brake ﬂuid on handlebar switches may render them inoperative.

NOTE AUSTRALIAN MODELS ONLY: Measure from tip of clutch lever to tip of brake lever. Measurement must not exceed 1 meter in length. If it does, re-adjust accordingly.

FRONT BRAKE MASTER CYLINDER RESERVOIR

See Figure 1-25. View reservoir sightglass (3 or 4) and verify ﬂuid presence. Sightglass should appear dark if ﬂuid is present. If sightglass is not dark, add brake ﬂuid. See Service Manual. Use only D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. 99902-77: 12 oz., 99901-77: 1 gal.). for all Dyna, Softail, VRSC and Sportster models. Use only D.O.T. 4 HYDRAULIC BRAKE FLUID (Part No. 99953-99A) for all To uring models. Wash all residue of D.O.T. 4 brake ﬂuid spills off vehicle with water.

2005 PDI: All Models 1-13

VEHICLE CLEANUP

RETURNING STEEL PALLETS

1WARNING1WARNING

Do not let the brakes, engine, mufﬂers or air cleaner get wet when washing your motorcycle. Allowing these components to get too wet can adversely affect their performance, which could result in death or serious injury. Start engine immediately after washing, and make sure brakes and engine are operating properly before riding in trafﬁc. (00078b)

CAUTION

Avoid spraying water directly on handlebar switches. Wet handlebar switches may be inoperative.

Remove protective shipping tape from motorcycle. Wash entire motorcycle before beginning actual predelivery inspection. If vehicle is equipped with frame downtube reﬂectors, remove any plastic cable straps wrapped around reﬂectors (cable straps are used during assembly at factory for retaining reﬂectors to downtubes while reﬂector adhesive cures).

COSMETIC QUALITY

Paint Finish Inspection and Repair

Under good lighting conditions, examine all painted parts for any damage or irregularities in the paint ﬁnish. To aid the dealer network in addressing quality concerns, Harley-Davidson Motor Company has developed a zoning and criteria protocol, which enables us to exceed customer’s expectations. If you discover any condition requiring repair, use Paint Repair Kit (Part No. HD-39994); available through Kent-Moore, at the following address, to correct the condition.

Kent-Moore 28635 Mound Rd Warren, Michigan 48092-3499 (phone) 1-800-345-2233

Instructions covering painted part repair are included with the Paint repair Kit. Additional paint repair information is available from Harley-Davidson on the PHD training videotape No. 136. Additional cosmetic quality information is available in the Harley-Davidson Cosmetic Booklet (Part No. HD-99514-05) and on-line Cosmetic Training located on HDU On-line.

NOTE International Dealers/Distributors should check with their H-D ofﬁce to determine whether or not to return pallets.

1. See Figure 1-26. Remove and discard plastic motor shim

(1).

7770

3

1

2

1. Plastic motor shim

2. Eye-bolts

3. Enclosed area

Figure 1-26. Vehicle Pallet

2. Turn eye-bolts (2) so they are parallel with sides of pallet.

This will allow stacking pallets for shipment.

NOTE On VRSC pallets place eye-bolt from rear in enclosed area (3) of pallet.

3. Place hold-down straps you are returning to factory in

enclosed area (3) of pallets.

CAUTION

Do not mix 29 in. (736.6 mm) width pallets with 43 in. (1.09 m) width pallets on the same 7-pallet stack. Mixing pallets of different width could result in an unstable bundle and pallet damage.

4. Stack seven pallets keeping all eye-bolts on same end.

5. Band pallets by threading hold-down straps through both

end cross members of top and bottom pallets. (If necessary connect two straps together.)

6. Tighten straps to secure pallet bundles.

7. Call, Fax, E-mail or use www.h-dnet.com to arrange

pallet return to Harley-Davidson.

1-14 2005 PDI: All Models

MAINTENANCE-FREE BATTERIES

f1730x8x

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1WARNING1WARNING

Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, rubberized gloves and protective clothing when working with batteries. KEEP BATTERIES AWAY FROM CHILDREN. (00063a)

Table 1-1. Battery Electrolyte Antidote

PHYSICAL LOCATION

External Flush with water Internal Drink large quantities of milk or water,

followed by milk of magnesia, vegetable oil

or beaten eggs. Call doctor immediately

Eyes Flush with water, get immediate

f2180x3x

PROCEDURE

medical attention.

Figure 1-27. Warning Label

1 2 3 4 5 6

1. Contents are corrosive

2. Wear safety glasses

3. Contents are explosive

Figure 1-28. Battery Warning Label

4. Keep ﬂames away

5. Read instructions

6. Keep away from children

2005 PDI: All Models 1-15

DATE OF MANUFACTURE CODE

See Figure 1-29. The battery date code sticker has a number and two letters. The number signiﬁes the year the battery was manufactured.

9 – 1999 0 – 2000 1 – 2001 2 – 2002 3 – 2003 4 – 2004 5 – 2005

The letters signify the month the battery was activated.

JA–January MY–May SE–September

FE–February JU–June OC–October

MA–March JY–July NO–November

AP–April AU–August DE–December

VOLTMETER TEST

Refer to Ta bl e 1-2. The voltmeter test provides a general indi- cator of battery condition. Check the voltage of the battery to make sure it is 12.6 V. If the open circuit (disconnected) voltage reading is below 12.6 V, charge battery and recheck voltage after battery has sat 1-2 hours.

f1742x8x

Battery date of

manufacture code

CHARGING BATTERY

NOTE

The sealed AGM batteries do not need to be removed for charging. Only remove battery if cable connection or marking the Warranty Tag requires it.

1. Connect the red battery charger lead to the positive terminal of the battery and the black charger lead to the negative terminal.

2. Refer to Ta bl e 1-2. Charge battery for time speciﬁed in

Ta bl e 1-2.

3. If battery gets hot, over 110˚F (44˚C) (warm to the touch), discontinue charging and let battery cool down.

1WARNING1WARNING

Unplug or turn OFF battery charger before disconnecting charger cables from battery. Disconnecting clamps with charger ON can cause a spark and battery explosion, which could result in death or serious injury. (00067a)

Figure 1-29. Battery Warranty Tag/Date Code Sticker

4. After the battery is fully charged, disconnect the black battery charger lead to the negative (–) terminal of the battery.

5. Disconnect the red battery charger lead to the positive (+) terminal of the battery.

6. See Figure 1-29. Mark the date on the battery warranty tag by removing the applicable month and year. If the date is after the 15th day of the month, advance the date to the next month. For example, if the battery is put in use July 22, punch out the month of August, which is abbreviated on the tag as “AU.” To determine the correct number to punch out for the year, just reference the last digit of the current year. Therefore, the number “5” is punched to signify the year 2005.

1-16 2005 PDI: All Models

Table 1-2. Battery Charging Rates/Times (Approximate)

BATTERY

AMP HOUR

VRSC,

SPORTSTER

12

DYNA,

SOFTAIL

18

TOURING

28

STATE OF CHARGE

VOLTAGE % OF CHARGE

12.8 100% ----

12.6 75% 70 minutes 34 minutes 20 minutes 10 minutes

12.3 50%

12.0 25%

11.8 0%

12.8 100% ----

12.6 75% 1.75 hours 50 minutes 30 minutes 15 minutes

12.3 50% 3.5 hours 1.75 hours 1 hour 30 minutes

12.0 25% 5 hours 2.5 hours 1.5 hours 45 minutes

11.8 0%

12.8 V 100% - - - -

12.6 V 75% 2.5 hours 1.25 hours 45 minutes 25 minutes

12.3 V 50% 5 hours 2.5 hours 1.5 hours 50 minutes

12.0 V 25% 7.5 hours 3.75 hours 2.25 hours 70 minutes

3 AMP

CHARGER

2 hours,

20 minutes

3 hours,

20 minutes

4 hours,

30 minutes

6 hours,

40 minutes

6 AMP

CHARGER

70 minutes 40 minutes 20 minutes

1 hour,

40 minutes

2 hours,

14 minutes

3 hours,

20 minutes

10 AMP

CHARGER

1 hour 30 minutes

1 hour,

20 minutes

2 hours 1 hour

20 AMP

CHARGER

40 minutes

11.8 V 0% 10 hours 5 hours 3 hours 1.5 hours

NOTE The ﬁgures listed above assume that the battery is charging at room temperature. If warmer than room temperature, use a slightly shorter charging time. If colder, use a slightly longer charging time.

NOTE The use of constant current chargers to charge sealed maintenance-free batteries is not recommended. Any overcharge will cause dry-out and premature battery failure. If a constant current charger is the only type available, do not exceed the charge times listed above and do not continue charging the battery if it gets hot. When charging, never exceed 15 volts for more than 30 minutes.

2005 PDI: All Models 1-17

WARNING LABEL PLACEMENT (ALL VEHICLES SOLD OUTSIDE OF THE UNITED STATES)

All dealers outside of the United States are required to apply a warning label to the vehicle in the local language of the customer. A sheet of warning labels (Part No. 99942-05) is provided in the Owner’s Kit.

Apply the appropriate local language version of the warning label as required to suit your local market. If your local language is not represented on this label sheet, use the English language label.

All EFI Big Twin Models

See Figure 1-30. Peel appropriate label from sheet. Apply label on top of air cleaner cover, centered on cover and lined up with edge of air cleaner back plate.

All Sportster Models

See Figure 1-32. Peel appropriate label from sheet. Apply label on top of air cleaner cover, centered on cover and lined up with edge of air cleaner back plate.

10685

10683

Figure 1-30. Warning Label Placement–

All Big Twin EFI (Typical)

All Carbureted Big Twin Models

See Figure 1-31. Peel appropriate label from sheet. Apply label on top of air cleaner cover, centered on cover and lined up with edge of carburetor cutout in air cleaner back plate.

10684

Figure 1-32. Warning Label Placement–

All Sportster Models (Typical)

All VRSC Models

See Figure 1-33. Open seat. Peel appropriate label from sheet. Apply label centered on rear end of air cleaner cover with bottom edge of label 1.0 in. (25.4 mm) from rear edge of air cleaner cover.

10686

1.0 in

(25.4 mm)

Figure 1-31. Warning Label Placement–

All Big Twin Carbureted (Typical)

1-18 2005 PDI: All Models

Figure 1-33. Warning Label Placement–

All VRSC Models (Typical)

SYSTEM PROBLEMS 1.2

GENERAL

All system problems fall into at least one of three general categories.

No Start

The engine cranks over freely, but will not start. This does not include situations where the engine will not crank, such as a security disabled starter, dead battery, etc. This condition assumes that all obvious checks (fuel in tank, etc.) have been made.

Poor Performance

The engine starts but there are performance problems. These problems may include poor fuel economy, rough idle, engine misﬁre, engine hesitation, severe spark knock, etc.

Check Engine Lamp

The Check Engine lamp indicates the ECM has determined a fault condition exists. There may also be starting or performance problems.

In the event that you encounter any system problems during set-up, see the appropriate Service Manual or Electrical Diagnostic Manual for your model.

2005 PDI: All Models 1-19

NOTES

1-20 2005 PDI: All Models

PREDELIVERY: TOURING MODELS

SUBJECT PAGE NO.

2.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2005 Touring Models Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Initial Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Battery Testing And Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Installing Maxi-Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Installing Fuel Pump Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Installing Data Link Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Installing Tour-Pak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Seats And Passenger Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Installing Sidecovers and Saddlebags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Radio Antenna Mast Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Rear Speaker Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Installing Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Throttle Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Rear Suspension Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.3 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Engine Oil Level (Side Car Equipped Vehicles) . . . . . . . . . . . . . . . . . . . . . . . 2-12

Transmission Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Chaincase Lubricant Level and Clutch Operation . . . . . . . . . . . . . . . . . . . . . 2-13

2.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Checking Quick Connect Fuel Line Fitting–Fuel Injected Models . . . . . . . . . 2-14

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Evaporative Emissions Control System–California Models Only . . . . . . . . . . 2-15

2.5 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Auxiliary Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Directional Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Front Turn Signals (FLHRS Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Indicator Lamps/Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.6 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Front and Rear Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2.7 Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

ABS System (Police Vehicles–Optional Equipment) . . . . . . . . . . . . . . . . . . . 2-19

2.8 Dealer Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Idle Speed: Carbureted Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2.9 Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Notice To Dealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.10 Vehicle PDI Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Prior to Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

At Point of Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

II

1

SPECIFICATIONS 2.1

TORQUE VALUES

The following torque values are included for fasteners that may be loosened and tightened during Predelivery and Setup. Any fasteners that are not loosened/removed do not need to be checked during predelivery and setup.

Table 2-1. Torque Values

ITEM TORQUE NOTES

Handlebar clamp screws (front and rear) 12-16 ft-lbs 16.3-21.7 Nm Must be checked at set-up.

Clutch inspection cover screws 84-108 in-lbs 9.5-12.2 Nm

FLHT windshield screws 25-30 in-lbs 2.8-3.4 Nm

FLTR windshield screws 6-13 in-lbs 0.7-1.5 Nm

Saddlebag mounting bracket bolts 60-96 in-lbs 6.8-10.8 Nm

To ur-Pak

FLHR/ FLHP

®

mounting bolts 96-120 in-lbs 10.8-13.5 Nm

Nacelle acorn nuts 72-108 in-lbs 8.1-12.2 Nm

Handlebar clamp shroud screws 10-20 in-lbs 1.1-2.3 Nm

Handlebar clamp shroud nut 10-20 in-lbs 1.1-2.3 Nm

Nacelle trim nut 15-20 in-lbs 1.7-2.3 Nm

2005 TOURING MODELS SPECIFICATIONS

Table 2-2. Capacities

Component ENGLISH METRIC

Oil tank w/ﬁlter (Dry) 4 qt. 3.79 liter Tr ansmission (Wet) 20-24 oz 591-710 ml Primary Chaincase 32 oz 946 ml

2

All touring models except FLHTCSE 20W50 Harley-Davidson 360 Motor oil. The FLHTCSE model ships with Syn-3® lubricant in the engine, primary and transmission.

are shipped with

Idle Speed: 950 RPM at Operating Temperature

Use 950 RPM during Predelivery and Setup adjustments. Engine idle speed may increase during engine break-in. Use idle speed listed in the Touring Models Service Manual at Initial Maintenance check.

NOTE The idle speed on electronic fuel injected models can only be set using a diagnostic tool such as DIGITAL TECHNICIAN (Part No. HD-44750).

2

2005 PDI: Touring Models 2-1

INITIAL ASSEMBLY 2.2

BATTERY TESTING AND CHARGING

1WARNING1WARNING

Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, rubberized gloves and protective clothing when working with batteries. KEEP BATTERIES AWAY FROM CHILDREN. (00063a)

1WARNING1WARNING

Never remove warning label attached to top of battery. Failure to read and understand all precautions in warning could result in death or serious injury. (00064a)

1WARNING1WARNING

Battery posts, terminals and related accessories contain lead and lead components, chemicals known in the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. (00019a)

NOTE It will be necessary to remove the left saddlebag and left sidecover to gain access to the Maxi-Fuse connector.

1. Check battery voltage at Maxi-Fuse plug. With fuse

removed, place red voltmeter probe on battery side (terminal A) of Maxi-Fuse plug, and black voltmeter probe on a suitable ground.

2. If the open circuit (disconnected) voltage reading is 12.6

VDC or greater the battery is ready for use.

3. See Section 1. Mark the date on the battery warranty tag

by removing the applicable month and year. Month and year punches may be removed with the point of a screwdriver without removing battery.

4. If the open circuit (disconnected) voltage reading is

below 12.6 VDC, refer to Table 1-2, 28 amp-hour battery, in Section 1 and charge battery at rate and time speciﬁed.

5. Recheck battery voltage by repeating step 1 above. If

voltage now is 12.6 VDC or greater, perform steps 2 and 3 above.

6. If the open circuit (disconnected) voltage reading is still

below 12.6 VDC, the battery must be replaced.

INSTALLING MAXI-FUSE

The 40 amp Maxi-Fuse provides battery power to the ignition switch and ECM. The 40 amp Maxi-Fuse is not installed at the factory. It is shipped in the saddlebag of the motorcycle. and is to be installed under the left sidecover. Cut the cable tie securing the Maxi-Fuse wire to the frame. See Service Manual for Maxi-Fuse installation procedure.

INSTALLING FUEL PUMP FUSE

NOTE It will be necessary to remove the right saddlebag and right sidecover to gain access to the fuel pump fuse.

For fuel-injected vehicles, it will be necessary to install the 15amp fuel pump fuse that is located in the spare fuse slot of the fuse-block located under the right sidecover. See Service Manual.

2-2 2005 PDI: Touring Models

INSTALLING DATA LINK

5029

CONNECTOR

See Figure 2-1. The data link connector [91] (2) mounts in a clip on the electrical bracket (1) under the right side cover. Cut the cable tie securing the data link connector harness to the frame and snap the connector into its clip on the electrical bracket.

pd0215

1

2

INSTALLING TOUR-PAK

NOTE The seat screw is not factory installed on models with TourPaks. The seat screw is in the Parts Kit, Part No. 53318-99.

On Ultra models, see Figure 2-2. Remove map pouch and molded Tour-Pak liner from Tour-Pak prior to performing the following procedures. Install both after work is completed.

®

Carbureted

pd0216

1

1. Electrical bracket

2. Data link connector [91]

Figure 2-1. Data Link Connector

2

Fuel injected

Figure 2-2. Tour-Pak Liner and Map Pouch

Five Bolt Mounting

Note that Tour-Pak has seven mounting holes which allow it to be positioned forward on luggage rack for shipping only. Mount Tour-Pak in the rearward position (front four holes and rear center hole) so seat access screw can be reached.

1. To avoid dropping or scratching the Tour-Pak, disconnect

the radio antenna cable and Tour-Pak lights connectors and feed wiring out through hole at front of Tour-Pak (after removing grommet). On Ultra models, repeat the procedure to release the CB antenna cable and connector.

2. If not already removed, remove seat.

3. Place a protective blanket across the frame tubes in the

seat area.

4. From inside Tour-Pak, remove the nuts and oversized

shipping washers and then lift the Tour-Pak off the mounting bolts setting it on the blanket. Retain nuts for use later, discard large shipping washers.

2005 PDI: Touring Models 2-3

5. See Figure 2-3. Remove and discard the pushnuts (5) from the mounting bolts (1), and pull the bolts (1) and washers (2) from the luggage rack (although the spacers (4) may be left in place between the top support tube (3) and the license plate bracket).

6. Locate Parts kit, Part no. 53318-99 in Tour-Pak or saddlebag. The plastic bag contains three spacers, bolts, nuts and ﬁve washers used to mount Tour-Pak. Also in parts kit is the seat retaining screw.

7. See Figure 2-4. Move Tour-Pak to rear so ﬁve mounting holes align with ﬁve holes in top support tube.

NOTE Make certain bolts are installed with threaded end down. Bolt head and washer must be inside Tour-Pak.

8. From inside Tour-Pak, install right rear bolt (1) and

washer (2) through bottom of Tour-Pak, hole in top support tube (3), luggage rack spacer (4), and hole in license plate bracket (5).

9. Install washer (2) and locknut (6) on right rear bolt and

tighten “ﬁnger-tight”. (This fastener will keep Tour-Pak in position while remaining four bolts are installed.)

10. Install antenna ground lead ring terminal under washer

of rear mounting bolt and install rear bolt as shown in

Figure 2-4.

11. Install remaining bolts, washers, spacers and nuts as

shown in Figure 2-4.

12. Tighten ﬁve nuts and bolts to 96-120 in-lbs (10.8-13.5

Nm).

pd0188

1

5

3

SEATS AND PASSENGER STRAP

Refer to Touring Models Owner’s Manual for seat and passenger strap removal and installation instructions. Road Glide models must have the seat strap installed per the appropriate Service Manual.

INSTALLING SIDECOVERS AND SADDLEBAGS

Check that each saddlebag is ﬁrmly seated on its saddlebag bottom support rail. Check that adequate clearance exists between saddlebags and sidecovers. The front and rear mounting brackets of each saddlebag have slotted mounting holes (on the bracket ends which attach to the motorcycle) to allow for vertical adjustment of the saddlebag. If adjustment is necessary, loosen the bolts which secure the saddlebag mounting brackets to the motorcycle. Press down and to the rear ﬁrmly on closed saddlebag, and then tighten the bolts to 60-96 in-lbs (6.8-10.8 Nm) torque.

NOTE

It is essential that the Tour-Pak be installed in the rearward position or seat removal/installation will not be possible due to interference with the forward-mounted Tour-Pak.

On Ultra models, see Figure 2-5. Check that AM/FM/WB antenna (left side) cable is in its two clips on left side of TourPak floor. Also check that CB antenna (right side) cable is in two clips on right side of Tour-Pak floor. Verify that ground strap of AM/FM/WB antenna is securely fastened to base plate in Tour-Pak with rear mounting screw.

4

2

1. Bolt, 1/4-20 x 2-1/4 in. (2)

2. Washer 1/4 in. inside dia. (2) (under bolt head)

3. Top support tube

4. Luggage rack spacer (2)

5. Pushnuts (2)

Figure 2-3. Tour-Pak Shipping Fasteners

2-4 2005 PDI: Touring Models

pd0187e

Bottom view showing spacer (4) between license plate bracket (5) and top support tube (3).

1

2

4

f1467b2x

3

5

6

2

4

3

5

2

6

1. Bolt, 1/4-20 x 2-1/4 in. (5)

2. Washer 1/4 in. inside dia. (7)

3. Top support tube

4. Luggage rack spacer (5)

5. License plate bracket

6. Locknut, Nylon cap, 1/4-20 (5)

Figure 2-4. Tour-Pak Mounting

Figure 2-5. Antenna Cable Clip

(CB Antenna Cable Shown)

2005 PDI: Touring Models 2-5

RADIO ANTENNA MAST INSTALLATION

Open the Tour-Pak lid. FLHTC models are equipped with one antenna mast. Thread

the mast securely over the antenna mounting stud and tighten the set screw.

FLHTCU models are equipped with two antenna masts — one with loading coil for CB radio for right side mounting, the other for AM/FM radio for left side.

On Ultra models only, use soapy water as a lubricant to install a protective rubber boot (provided with vehicle) over tip of AM/FM antenna mast; slide boot down mast and over springloaded base. Repeat for CB antenna, but, loosen upper setscrew in base, slide mast from base and slide boot onto mast below loading coil. Reassemble mast to base and adjust distance between bottom of loading coil to top of base to 1 in.

Thread each mast securely over its antenna mounting stud. Tighten the two (3 on CB) set screws (one for antenna mast,

the other for antenna mounting stud) located in the springloaded base of each antenna and one at top of loading coil.

NOTE Standing Wave Ratio (SWR) will be checked later in these procedures.

REAR SPEAKER HARNESSES

1. See Figure 2-6. Cut cable straps securing rear speaker harnesses to passenger handrail (both right and left sides). Locate plastic grommets packed in Tour-Pak.

2. Press down on seat cushion, slide harness and connector into speaker box.

3. Install split plastic grommet on harness and push grommet into hole in speaker box.

4. Repeat steps 2 and 3 for left side.

6712

1

6711

2

1. Right speaker harness

2. Plastic grommet (shown partially installed)

Figure 2-6. Rear Speaker Harness Grommets

(Seat removed for clarity)

2-6 2005 PDI: Touring Models

INSTALLING WINDSHIELD

f2280x2x

1. Windshield

2. Outer fairing

3. Screw (5)

4. Flat washer (plastic) (5)

5. Wellnut (5)

6. Flat washer (rubber) (5)

1

2

3

4

5

6

FLHTC, FLHTCU, FLHTCSE2 (Wind Deﬂector) and FLHTP (Fairing)

1. See Figure 2-7. Loosen the three fasteners along the top of the outer fairing. It is not necessary to remove the fasteners.

2. Slide windshield down between the inner and outer fairing over the fasteners. Position on the raised boss on the inner fairing.

pd0173x

Windshield Installation: FLTR

1. See Figure 2-8. Place black plastic washers (4) on the ﬁve mounting screws (3). Position rubber trim along bottom of windshield. Insert screws through windshield holes and thread loosely into ﬁve Wellnuts (5) with rubber washers (6).

2. Push Wellnuts with rubber washers into holes in fairing.

3. Beginning with the center screw and working outward toward the rear edges of windshield, tighten all screws to 6-13 in-lbs (0.7-1.5 Nm). Make certain that the four outer screws are located at the upper end of the slots in the windshield.

Figure 2-7. Windshield Installation–FLHT Models

Overtightening windshield fasteners may crack windshield and/or fairing.

3. Tighten fasteners to 25-30 in-lbs (2.8-3.4 Nm).

CAUTION

Figure 2-8. Windshield Installation–FLTR Models

2005 PDI: Touring Models 2-7

Windshield Installation: FLHR/C and FLHP (Windshield)

CAUTION

pd0227

16

15

6

Be sure you position the windshield bracket between the rubber grommets. Incorrect mounting could result in damage to the windshield.

See Figure 2-9. Insert your ﬁngers into the wireform latch springs at either side of the windshield and slide the BOTTOM windshield bracket notches onto the bottom grommets. Slide the TOP bracket notches onto the top grommets.

NOTE

If windshield contacts clutch cable, reposition handlebars.

OMF53

Figure 2-9. FLHR/C and FLHP Windshield Installation

Seat Adjustment: FLHTP

Before applying load to the seat, refer to the Police Models Owner’s Manual for adjustment procedures of the FLHTP airsuspension seat. Conﬁrm that air bladder is inﬂated to 10-psi (69 kPa) minimum.

Instrument Mounting Bracket Installation: FLHP

The FLHP is provided with an instrument mounting bracket. The bracket relocates the tachometer to allow the addition of a radio speaker, and control panel.

1. See Figure 2-10. Remove screw (13) securing chrome ring (12) to headlamp nacelle (8). Remove chrome ring.

2. Remove eight fasteners (11) securing headlamp assembly (10). Squeeze two external tabs (if present) to remove wire connector at back of headlamp bulb. Remove headlamp assembly from vehicle.

3

2

1

10

5

12

11

13

1. Nut

2. Nacelle trim

3. Screw

4. Nut

5. Flat washer

6. Fork lock plate

7. Screw (2)

8. Nacelle

9. Handlebar clamp shroud

10. Headlamp assembly

11. Screw (8)

12. Chrome headlamp ring

13. Screw

14. Stud plate

15. Acorn nut (2)

16. Tachometer bracket

Figure 2-10. FLHP Headlamp Nacelle

7

14

9

8

4

2-8 2005 PDI: Touring Models

p0044x5x

1. Nut (2)

2. Instrument mounting bracket

3. Handlebar clamp shroud

4. Stud plate

5. Screw

6. Nut

3

2

4

6

1

5

5530

3. Remove nut (1) (inside nacelle) securing nacelle trim (2).

4. Disconnect tachometer connector [108] inside headlamp nacelle.

5. Remove nacelle trim. Loosen (but do not remove) front handlebar clamp shroud screw (3), nut (4) and washer (5).

6. Gently pry off fork lock plate (6) at rear of handlebar clamp shroud. Remove two screws (7) beneath lock plate.

7. Loosen four acorn nuts securing nacelle halves to fork studs. Spread nacelle halves slightly and remove handlebar clamp shroud.

8. Remove two acorn nuts (15) and ﬂat washers securing Ta chometer and bracket (16) to handlebar clamp shroud.

9. See Figure 2-11. A peel and stick foam tape holds the stud plate (4) in place inside the handlebar clamp shroud (3). Position instrument mounting bracket (2) on studs of stud plate and secure in position using hardware provided by radio manufacturer (1).

10. Using screw (5) and nut (6) provided, secure front tab of instrument mounting bracket on handlebar clamp shroud.

11. Reinstall handlebar clamp shroud. Tighten acorn nuts securing nacelle halves to fork studs to 72-108 in-lbs (8.1-12.2 Nm).

12. See Figure 2-12. Mount tachometer on bracket with acorn nuts and ﬂat washers as shown.

13. See Figure 2-10. Install two screws (7) to handlebar clamp shroud and tighten to 10-20 in-lbs (1.1-2.3 Nm). Gently press fork lock plate (6) into place on handlebar clamp shroud.

14. Tighten front handlebar clamp shroud nut (4) to 10-20 in- lbs (1.1-2.3 Nm).

15. Connect tachometer lead [108].

16. Install nacelle trim (2). Install nut (1) (inside nacelle) securing nacelle trim. Tighten to 15-20 in-lbs (1.7-2.3 Nm).

17. Connect wire connector to socket on back of headlamp bulb. Install and secure headlamp assembly to nacelle with eight fasteners.

18. Secure chrome ring (12) to headlamp nacelle with screw (13).

NOTE Check for adequate clearance between windshield and clutch cable and handlebar position prior to completing assembly of vehicle.

Figure 2-11. FLHP Instrument Bracket

Figure 2-12. FLHP Tachometer Mount

2005 PDI: Touring Models 2-9

MIRRORS

THROTTLE CONTROL CABLES

See Figure 2-13. Adjust mirrors for proper rear view. Verify that mirror fasteners are properly tightened.

pdoo72b

Figure 2-13. Mirror Installation

All Non-Ultra Models

Check throttle cable adjustment in accordance with procedure given in Section 1 of Touring Models Service Manual.

Ultra Models

Check throttle cable adjustment in accordance with procedure given in Section 8 of Touring Models Service Manual.

2-10 2005 PDI: Touring Models

REAR SUSPENSION

8472

AIR PRESSURE

CAUTION

Do not exceed maximum air pressure for rear suspension. Air components ﬁll rapidly. Therefore, use low air line pressure. Failure to do so may result in possible damage to components. (00165a)

IMPORTANT NOTE

Maximum air pressure of rear suspension system is 50 psi (345 kPa).

See Figure 2-14. Check rear suspension air pressure at air valve located on the left side of the motorcycle below the frame cover, above the left saddlebag. Refer to Ta ble 2-3. These are recommended starting points, adjust to suit load conditions, riding style and comfort desired. Less initial pressure does not necessarily result in a softer ride. Use a no-loss gauge, add 3-5 psi (20.68-34.48 kPa) to clear line and adjust for application.

Table 2-3. Rear Suspension Air Pressure (All Models Except FLHRS)

Figure 2-14. Rear Suspension Air Pressure Valve

Loading

psi kPa

Solo rider -150 lbs (68.0 kg) maximum 0 0 Solo rider 150-200 lbs (68.0-90.7 kg) 0-10 0-69 Solo rider 200-250 lbs (90.7-113.4 kg) 5-15 35-103 Rider and 150 lbs (68.0 kg) passenger 10-15 69-103 Rider and 200 lbs (90.7 kg) passenger 20-25 138-172 Gross vehicle weight rating (GVWR) 20-35 138-241

Pressure

Table 2-4. Rear Suspension Air Pressure (FLHRS and FLHTCSE2 Only)

Loading

psi kPa

Solo rider -160 lbs (73.0 kg) maximum 0-5 0-35 Solo rider 160-200 lbs (73.0-90.7 kg) 0-10 0-69 Solo rider 200-250 lbs (90.7-113.4 kg) 5-10 35-69 Rider and 150 lbs (68.0 kg) passenger 20-30 138-207 Rider and Over 150 lbs (68 kg) passenger 25-35 172-241 Gross vehicle weight rating (GVWR) 40-50 276-345

Pressure

2005 PDI: Touring Models 2-11

LUBRICATION SYSTEM 2.3

ENGINE OIL LEVEL

CAUTION

2

The FLHTCSE

®

SYN-3 transmission. If there is a need to top off lubricants, DO NOT use standard lubricants in the FLHTCSE do not mix lubricants as damage to the motorcycle can result.

Oil level cannot be accurately measured on a cold engine. For preride inspection with motorcycle leaning on jiffy stand on level ground, oil should register on dipstick between arrows when engine is cold. Do NOT add oil to bring the level to the FULL mark on a COLD engine.

Perform engine oil level COLD CHECK as follows:

1. With the vehicle resting on the jiffy stand on level ground,

2. Remove the dipstick and note the level of the oil. Oil level

Once the predelivery inspection procedure is complete and the vehicle has been road-tested, the engine oil level should be checked again as described in the following procedure.

Perform engine oil level HOT CHECK as follows:

1. With the vehicle resting on the jiffy stand on level ground,

2. Remove the dipstick, wipe it off and insert it back into the

lubricant exclusively in the engine, primary and

remove the dipstick, wipe it off and insert it back into the oil pan with the plug pushed completely into the ﬁll spout.

should register on the dipstick. See Figure 2-15. If oil level is at or below the lower arrow, add only enough oil to bring the level to the add arrow on the dipstick.

allow engine to idle for 1-2 minutes. Turn engine off.

oil pan with the plug pushed completely into the ﬁll spout.

model is shipped from the factory with

2

model and

IMPORTANT NOTE

NOTE

3. Remove the dipstick and note the level of the oil. Add only enough oil to bring the level to the FULL mark on the dipstick. See Figure 2-15. Do not overﬁll.

4. Start engine and carefully check for oil leaks around drain plug and oil ﬁlter.

ENGINE OIL LEVEL (SIDE CAR EQUIPPED VEHICLES)

NOTE Since a motorcycle equipped with a sidecar is ﬁxed in an upright position, the engine oil level reading must be adjusted in this case; the actual FULL engine oil level will be about 1/2 inch above the original FULL mark on the oil tank dipstick.

To insure the correct oil level with sidecar attached perform the following:

1. Without sidecar attached, check engine oil level with

engine at normal operating temperature. See HOT CHECK procedure above.

2. Verify oil level is at FULL mark on dipstick (add oil if

needed).

3. With sidecar attached, ride until engine is at normal

operating temperature.

4. On a level surface, note engine oil level on dipstick.

5. Scribe a line on dipstick at the oil level noted in step 4

above. The scribed line is the FULL mark for sidecar operation.

COLD CHECK

2-12 2005 PDI: Touring Models

HOT CHECK

f1254b3x

Figure 2-15. Engine Oil Dipstick

TRANSMISSION LUBRICANT

pd0206

NOTE

Allow vehicle to stand upright for a moment before checking transmission lubricant level. This will allow lubricant level to normalize.

Check the transmission lubricant level with the motorcycle standing upright in accordance with the procedure given in the Touring Models Service Manual.

CHAINCASE LUBRICANT LEVEL AND CLUTCH OPERATION

NOTE

Do not remove the clutch cover on the FLHTCSE necessary to check the primary chaincase lubricant level on this vehicle. Also, the hydraulic clutch is not adjustable.

1. Remove ﬁve screws, clutch inspection cover and cover gasket.

2. See Figure 2-16. The primary chaincase lubricant level is acceptable when lubricant is visible in bottom of chaincase with motorcycle standing upright (not resting on jiffy stand).

2

. It is not

Figure 2-16. Chaincase Lubricant Level

3. Check clutch action. Clutch lever should move freely and smoothly through its entire range of travel.

4. Check clutch adjustment according to the procedures given in the Touring Models Service Manual.

NOTE The clutch inspection cover gasket may be reused ONLY when checking chaincase lubricant level and reinstalling clutch inspection cover at PDI.

5. Reinstall cover gasket and clutch inspection cover, and

secure with ﬁve screws. Tighten to 84-108 in-lbs (9.5-

12.2 Nm).

2005 PDI: Touring Models 2-13

FUEL SYSTEM 2.4

GENERAL

CAUTION

Some fuel suppliers sell gasoline which has been blended with an alcohol or an ether. The type and amount of alcohol or ether added to the fuel is important.

CAUTION

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

● Gasolines containing ETHANOL (ethyl alcohol or grain

alcohol) can be used. Gasoline/ethanol blends are a mixture of 10% ethanol and 90% unleaded gasoline. They are identiﬁed as “gasohol,” “ethanol enhanced,” or “contains ethanol.”

● Gasolines containing METHYL TERTIARY BUTYL

ETHER (MTBE) can also be used. Gasoline/MTBE blends are a mixture of gasoline and as much as 15% MTBE.

● 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

Because of their different chemical properties (which affect fuel volatility and ignition characteristics), these blends may adversely affect the starting, drivability, and fuel efﬁciency of the motorcycle. If you experience these problems, HarleyDavidson recommends using straight, unleaded gasoline.

CHECKING QUICK CONNECT FUEL LINE FITTING–FUEL INJECTED MODELS

1WARNING1WARNING

To avoid an uncontrolled discharge or spray of gasoline, always be sure the quick-connect ﬁtting (under left side of fuel tank) is properly mated. A slight tug on the fuel line will verify this condition. Gasoline is extremely ﬂammable and highly explosive. Inadequate safety precautions could result in death or serious injury.

1. Tug on fuel supply line (under left side of fuel tank) to be sure quick connect ﬁtting is properly mated.

2. If fuel line comes free, push up on sleeve of quick-connect ﬁtting and insert neck of fuel supply line ﬁtting. While pushing up on bottom of fuel supply line ﬁtting, pull down on sleeve until it “clicks” into the locked position.

FUEL TANK

Make sure engine stop switch on the handlebar is switched to the OFF position. Turn the ignition/light switch to the IGNITION position. Fuel injected models: verify that Low Fuel lamp is lit. Partially ﬁll fuel tank with gasoline. Follow FUEL recommendations found in the Owner’s Manual. Use unleaded gasoline, 91 octane or higher. Verify function of fuel gauge as fuel tank is ﬁlling, then turn ignition/light switch OFF. Inspect fuel lines for leaks.

Carbureted Models

See Figure 2-17. After adding gasoline, check for smooth operation of the fuel valve. Inspect fuel valve for leaks.

o0046box

CAUTION

Use only unleaded fuel in California model catalytic converter-equipped motorcycles. Using leaded fuel will damage the emission control system. (00150a).

2-14 2005 PDI: Touring Models

Figure 2-17. Fuel Supply Valve

EVAPORATIVE EMISSIONS CONTROL SYSTEM–CALIFORNIA MODELS ONLY

See Figure 2-18. See Figure 2-19. Ve rify correct evaporative emissions control system hose routing, connections, and fuel tank venting to canister (if equipped).

1. Carburetor (induction module on fuel-injected models)

2. Vacuum tube

3. Fuel valve

4. Filler neck ﬁtting (Top of canopy on FLHR/C/S)

5. Fuel tank

6. Fuel vapor vent tube

7. Vapor valve

8. Charcoal canister

9. Purge tube

10. Clean air inlet tube (not used on fuel-injected models)

11. Air cleaner backplate

f1706x4x

Figure 2-18. Evaporative Emissions Control System Hose Connections

f1884x4x

2

1

4

5

3

7

10

9

11

1

3

6

8

2

1. Clean air inlet tube from air cleaner backplate (carbureted models only)

2. Purge tube to carburetor or induction module

3. Fuel vapor vent tube from fuel tank

4. Fuel vapor vent tube from vapor valve

Figure 2-19. Evaporative Emissions Control System Hose Routing

4

2005 PDI: Touring Models 2-15

ELECTRICAL SYSTEM 2.5

HEADLAMP

Check headlamp beam for proper height and lateral alignment in accordance with procedures given in Section 8 of the Touring Models Service Manual.

1WARNING1WARNING

The automatic-on 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)

AUXILIARY LAMPS

On models equipped with auxiliary lamps, check lamp beam for proper height and lateral alignment in accordance with procedures given in the Touring Models Service Manual.

DIRECTIONAL LAMPS

Adjust front directional lamps so lenses are aimed directly forward. Verify that directional lamp fasteners are properly tightened.

FRONT TURN SIGNALS (FLHRS ONLY)

Adjust and tighten. Ensure that directionals do not contact fuel tank.

INSTRUMENT PANEL

See Figure 2-20. The instrument panel has a Low Fuel, Check Engine, Security (if equipped) Battery, Cruise Control (if equipped) and ABS (if equipped) warning lamps.

● The Low Fuel Warning lamp comes on when approxi-

mately 0.9 gallon (3.4 liter) of gasoline remains.

● The Check Engine lamp illuminates brieﬂy (4 seconds) at

start-up and should then remain off unless an error code is present.

f2185xax

1

40

30

20

10

0

7

H

A

50

C

R

MPH

E

R

T

L

E

Y

8

60

70

80

90 100

110

120

D

E

I

F

I

N

O

S

D

I

V

-

A

D

2

20

10

0

H

6

5

FLHT and FLTR Models

1. Speedometer

2. Security system lamp

3. Tachometer

4. Cruise lamp

5. Odometer/trip-odometer

6. Low fuel warning lamp

7. Engine check lamp

8. Battery discharge lamp

9. ABS lamp (optional police equipment)

10. Pursuit lamp indicator (police)

d0715x8x

3

40

30

50

60

x100

A

RPM

R

L

70

80

N

O

S

D

I

E

V

Y

-

A

D

7

4

10

1

6

4

FLHR Models

40

30

20

10

0

H

RPM

A

R

50

x100

P

N

O

S

L

D

I

E

V

Y

-

A

D

5

60

70

80

2

8

pd0221

9

FLHTP/FLHP Models Tachometer

2-16 2005 PDI: Touring Models

Figure 2-20. Instrument Panel Warning Lamps

INDICATOR LAMPS/CONTROLS

1. See Figure 2-21. Turn ignition/light switch to IGNITION position, and check that Oil pressure indicator lamp turns on (before engine is started). The Check Engine lamp and if TSSM EQUIPPED, THE SECURITY LAMP will illuminate for approximately four seconds and then turn off.

NOTES For any Systems problems, refer to the appropriate Electrical Diagnostic manual for your model.

2. Shift transmission to neutral position, and verify that neu-

tral indicator lamp turns on.

3. Start engine; check operation of starter.

NOTE On Police models, the clutch lever must be depressed to operate the starter.

4. Check that oil pressure indicator lamp turns off when

engine is running above 1000 RPM.

5. Check operation of tachometer (if equipped).

6. Disengage clutch (depress clutch lever), and verify that

neutral indicator lamp turns off when transmission is shifted to any forward gear. Shift transmission to neutral position, and verify that neutral indicator lamp turns on again.

7. Check horn operation.

8. Check operation of all remaining lamps:

● Headlamp–low and high beams

● Headlamp high beam indicator lamp

● Passing/pursuit lamps

● Pursuit lamp indicator lamp (FLHTP)

● Left directional (turn signal) lamps–front and rear

● Left directional (turn signal) indicator lamp

● Right directional (turn signal) lamps–front and rear

● Right directional (turn signal) indicator lamp

● Left front running lamp

● Right front running lamp

● Ta il lamp–running lamp and brake lamp ﬁlaments

● Speedometer illumination lamp

● Ta chometer illumination lamp (if equipped)

● License plate lamp (HDI only)

● Sound System Operation (if equipped)

9. After engine has reached normal operating temperature, turn engine off.

10. Check engine oil level in manner previously speciﬁed. This time, ﬁll oil tank to upper mark on ﬁller cap/dipstick.

pd0192

3

1

1. Ignition switch unlocked

2. Ignition switch locked

3. “Key ON” Ignition position

2

Figure 2-21. Ignition Switches

1

2

2005 PDI: Touring Models 2-17

TIRES 2.6

FRONT AND REAR TIRES

1WARNING1WARNING

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

1WARNING1WARNING

Harley-Davidson 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)

1. Check for proper front and rear tire pressures when tires are cold. Compare results against Tab le 2-5.

Table 2-5. Tire Pressures

Front Rear

Tires

PSI kPA PSI kPA

Solo rider 36 248 36 248 Rider & passenger 36 248 40 276

2-18 2005 PDI: Touring Models

BRAKE SYSTEM 2.7

6628

BRAKES

1CAUTION

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)

CAUTION

D.O.T. 4 brake ﬂuid will damage painted and molded-in color surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239a)

CAUTION

Cover handlebar switches with a shop towel before adding brake ﬂuid to front master cylinder reservoir. Spilling brake ﬂuid on handlebar switches may render them inoperative.

See Figure 2-22. View reservoir sightglass and verify ﬂuid presence. Sightglass should appear dark if ﬂuid is present. If sightglass is not dark, add brake ﬂuid. See Service Manual. Use only D.O.T. 4 HYDRAULIC BRAKE FLUID (Part No. 99953-99A). Wash all residue of D.O.T. 4 brake ﬂuid spills off vehicle with water.

Figure 2-22. Rear Brake Reservoir/Master Cylinder Sight-

glass (typical)

ABS SYSTEM (POLICE VEHICLES– OPTIONAL EQUIPMENT)

The ABS indicator lamp in the tachometer will ﬂash when the ignition switch is turned on, and remains ﬂashing until the motorcycle reaches 6 MPH (9.7 KPH). The lamp will then turn off.

If the ABS lamp turns on solid at ignition-ON, or does not turn off when vehicle exceeds 6 MPH (9.7 KPH), it is an indication of a current fault condition in the ABS system. See the Police Models Service Manual Supplement for instructions on placing the ABS system into test mode and extracting diagnostic trouble codes from the ABS system computer.

2005 PDI: Touring Models 2-19

DEALER ROAD TEST 2.8

ROAD TEST

After you complete motorcycle inspection, take motorcycle for a road test. Check all systems and overall operation of motorcycle: engine, transmission, clutch, brakes, handling, etc. On Ultra models, check Cruise Control, rear speakers and rider/ passenger sound system controls. Refer to Touring Models Owner’s Manual to check for proper operation.

After road test, return motorcycle to shop and thoroughly clean off any road dirt. Check and correct any problems you may have found during road test.

Before You Begin

Check the following items before road test of vehicle:

● Lamps and indicators.

● Check amount of gasoline in tank and add (if

needed).

● Adjust mirrors to proper riding positions.

● Check tire condition and pressure (adjust if neces-

sary).

● Check controls to verify proper function.

● Check all electrical equipment and switches includ-

ing stop lamp, turn signals and horn for proper operation.

Road Test of Vehicle: Low Speed

1. Shift from ﬁrst through third gear, checking clutch operation, throttle control, and transmission operation.

2. Verify low-speed braking for front and rear brakes.

3. Handling under braking conditions.

4. Low speed handling. Verify that vehicle does not pull to left or right.

5. Check for any abnormal vibrations.

6. Check electrical lamps, indicators.

IDLE SPEED: CARBURETED ONLY

NOTE The idle speed on fuel injected models can only be set using a diagnostic tool such as DIGITAL TECHNICIAN (Part No. HD-44750).

See Figure 2-23. Set engine slow idle speed of 950 RPM with engine running at normal operating temperature and with enrichment control knob pushed in fully. Turn carburetor idle speed adjusting screw (5) clockwise to increase speed, or counterclockwise to decrease speed.

NOTE The C.V. carburetor has an enrichment circuit that will cause the engine to idle above the normal idle range (950-1050 RPM) with the engine at normal operating temperature and the enrichment knob pulled out fully. The increase in idle speed is intended to alert the rider that the engine is warmed up to normal operating temperature and that the enrichment knob should be pushed in all the way. Continuing to use the enrichener when the engine is at full operating temperature will cause fouled plugs.

Be sure the engine is warmed up to normal operating temperature and the enrichment knob is pushed all the way in before adjusting engine idle speed. Be aware that, because there are variations in individual components, it is possible for a properly warmed-up engine to idle above the normal idle range (950-1050 RPM) with the enrichment knob pulled out partially.

f1381a2x

5

Road Test of Vehicle: Highway Speed

1. Shift from ﬁrst through ﬁfth gear, checking clutch operation, throttle control and transmission operation.

2. Verify highway-speed braking operation of front and rear brakes.

3. Verify proper handling at highway speeds.

4. Check for any abnormal vibrations.

● Program Security System (if equipped)

● Engine Oil:

Check and correct hot level.

● Clean Vehicle

NOTE Be sure to submit a Dealer Product Quality Audit (DPQA) on ANY adjustments and/or warranty work performed required to deliver the vehicle to the customer.

2-20 2005 PDI: Touring Models

2

3

4

1

1. Carburetor stop plate

2. Cable housing

3. Spring

4. Throttle cam stop

5. Idle speed adjusting screw

Figure 2-23. Carburetor Adjustments

CUSTOMER DELIVERY 2.9

NOTICE TO DEALER

Before delivering motorcycle to owner, perform the following:

1. Make sure vehicle owner receives, and is aware of importance of reading Owner’s Manual, safety booklets and viewing Welcome To The Family video included with owner’s kit.

2. Review warranties with vehicle owner. Make sure owner understands warranties. California dealers must give customer a copy of Emissions Control System Warranty.

3. Give IMPORTANT sheet and other printed material in literature kit to vehicle owner.

4. Complete and sign warranty registration form. Have vehicle owner sign it.

5. Explain operation of vehicle controls to vehicle owner.

6. Explain how turn signals and emergency ﬂashers operate.

7. If motorcycle is equipped with a Sound System, explain to customer that the Touring Models Owner’s Manual contains detailed operating instructions for the system. In addition, a video has been prepared to give the customer operating instructions for the Sound System. On Ultra models, tell customer helmet headset is shipped in saddlebag.

8. Inform vehicle owner about changing TSM/TSSM to sidecar or solo conﬁguration as appropriate.

IMPORTANT NOTE Make sure vehicle owner understands how to arm and disarm security system. Explain how to disarm security system with personal code if key fob is lost or not functioning. Personal code should be written on the tear-out card in Touring Models Owner’s Manual and kept on the owner’s person. Also, verify both key fobs operate properly.

9. Whenever possible, introduce dealer Service Manager to

vehicle owner, and involve Service Manager in delivery process. Supply owner with name(s) of dealer Service/ Parts Department personnel who should be contacted regarding vehicle service/parts questions.

10. Inform vehicle owner about checking engine oil level,

checking tire pressure, and performing other basic maintenance functions. Review the Initial Scheduled Main- tenance requirement with owner. Depending on owner’s anticipated frequency of operating motorcycle, you may wish to schedule the Initial Scheduled Maintenance service appointment at this time.

2005 PDI: Touring Models 2-21

VEHICLE PDI CHECKLIST 2.10

PRIOR TO CUSTOMER DELIVERY

NOTE Use this checklist for performing tasks related to this model motorcycle setup.

❒ Uncrate:

Check for damaged or missing parts.

❒ Handlebars:

Verify proper position; tighten clamps to proper torque.

❒ Jiffy Stand:

Verify proper function.

❒ Note Any Additional Problems

(including cosmetic quality):

Perform Warranty repairs.

❒ Battery:

Perform required voltmeter test on Maxi Fuse (main fuse) and battery.

❒ Install Maxi Fuse (main fuse). ❒ Install Fuel Pump Fuse (EFI vehicles only). ❒ Install Data Link Connector. ❒ Position Tour-Pak and Install Seat and Seat Strap:

If equipped

❒ Install Saddlebags and Side Covers:

Verify adequate saddlebag/side cover clearance.

❒ Install Antenna Mast(s):

If equipped

❒ Position Rear Speaker Harness. ❒ Install Windshield. ❒ Verify Proper Police Seat Air Bladder Pressure

(Police models).

❒ Install Instrument Bracket (FLHP models). ❒ Mirrors:

Inspect and adjust as necessary.

❒ Throttle Control Cables:

Inspect and adjust as necessary.

❒ Rear Air Suspension:

Inspect and adjust pressure as necessary.

❒ Engine Oil:

Verify oil is present (cold level).

❒ Lubrication System:

Inspect condition of oil lines and ﬁttings.

❒ Tr ansmission Lubricant:

Check and verify correct lubricant level.

❒ Primary Chaincase:

Check and verify lubricant is present.

❒ Clutch Operation:

Verify proper adjustment.

❒ Fuel System:

a. Inspect fuel system for leaks. b. Fill, verify sender operation. c. Verify low fuel light operation (if equipped).

2-22 2005 PDI: Touring Models

❒ Fuel Outlet (valve or quick connect ﬁtting)

and Hoses:

Verify operation and connections.

❒ Evaporative Control System:

Inspect hose routings, connections and fuel tank venting to canister (if equipped).

❒ Lighting, Gauges, Electrical Systems:

a. Verify correct operation. b. Verify adequate directional-to-fuel tank clearance

(FLHRS only).

❒ Tires:

Inspect condition and air pressure.

❒ Brake Systems (front and rear):

a. Correct ﬂuid level (if necessary). Use DOT 4 ﬂuid

only for 2005 FL models.

b. Verify proper ABS indicator function (Police models

only, if equipped).

❒ Road Test Vehicle: Low Speed.

a. Shift from ﬁrst through third gear, checking clutch

operation, throttle control and transmission operation. b. Verify low-speed braking for front and rear brakes. c. Verify handling under braking conditions. d. Verify low-speed handling. Verify that vehicle does

not pull to left or right. e. Check for any abnormal vibrations. f. Check electrical lamps, indicators.

❒ Road Test Vehicle: Highway Speed.

a. Shift from ﬁrst through ﬁfth gear, checking clutch

operation, throttle control and transmission operation. b. Verify highway speed braking operation of front and

rear brakes. c. Verify proper handling at highway speeds. d. Check for any abnormal vibrations.

❒ Engine Oil:

Check and correct hot level.

❒ Create Vehicle Birth-Certiﬁcate Using

Digital Technician (optional).

❒ Clean Vehicle. ❒ Program Security System.

AT POINT OF CUSTOMER DELIVERY

❒ Suspension Adjustments. ❒ Shift Linkage Adjustment. ❒ Brake Hand Lever Adjustment. ❒ Review Vehicle Care and Maintenance Requirements.

NOTE

Be sure to submit a Dealer Product Quality Audit (DPQA) on ANY adjustments and/or warranty work performed required to deliver the vehicle to the customer.

PREDELIVERY: DYNA MODELS

SUBJECT PAGE NO.

3.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

2005 Dyna Models Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Initial Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Battery Testing And Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Installing Maxi-Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Installing Fuel Pump Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Idle Speed: Carbureted Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Throttle Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Suspension Adjustment for FXDX Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Seats And Passenger Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Transmission Lubricant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Chaincase Lubricant Level and Clutch Operation . . . . . . . . . . . . . . . . . . . . . 3-5

3.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Checking Quick Connect Fuel Line Fitting–Fuel Injected Models . . . . . . . . . 3-6

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.5 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Indicator Lamps/Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Mirrors and Directional Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.6 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Front and Rear Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.7 Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.8 Dealer Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.9 Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Notice To Dealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.10 Vehicle PDI Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Prior to Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

At Point of Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

III

1

SPECIFICATIONS 3.1

TORQUE VALUES

The following torque values are included for fasteners that may be loosened and tightened during Predelivery and Setup. Any fasteners that are not loosened/removed do not need to be checked during predelivery and setup.

Table 3-1. Torque Values

ITEM TORQUE NOTES

Battery terminal screws 60-96 in-lbs 6.8-10.9 Nm

Front brake master cylinder cover screws 6-8 in-lbs 0.7-0.9 Nm

Handlebar clamp screws (front and rear) 12-18 ft-lbs 16.3-24.4 Nm

Mirror fasteners 12 ft-lbs 16.3 Nm

Clutch inspection cover screws 84-108 in-lbs 9.5-12.2 Nm

2005 DYNA MODELS SPECIFICATIONS

Table 3-2. Capacities

Component ENGLISH METRIC

Oil tank w/ﬁlter (Dry) 3 qt. 2.84 liter Tr ansmission (Wet) 20-24 oz 591-710 ml Primary Chaincase 26 oz 769 ml All motorcycles are shipped with 20W50 Harley-Davidson

360 Motor oil

Idle Speed: 950 RPM at Operating Temperature

Use 950 RPM during Predelivery and Setup adjustments. Engine idle speed may increase during engine break-in. Use idle speed listed in the Dyna Models Service Manual at Initial Maintenance check.

NOTE The idle speed on electronic fuel injected models can only be set using a diagnostic tool such as DIGITAL TECHNICIAN (Part No. HD-44750).

2005 PDI: Dyna Models 3-1

INITIAL ASSEMBLY 3.2

BATTERY TESTING AND CHARGING

1WARNING1WARNING

Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, rubberized gloves and protective clothing when working with batteries. KEEP BATTERIES AWAY FROM CHILDREN. (00063a)

1WARNING1WARNING

Never remove warning label attached to top of battery. Failure to read and understand all precautions in warning could result in death or serious injury. (00064a)

1WARNING1WARNING

Battery posts, terminals and related accessories contain lead and lead components, chemicals known in the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. (00019a)

NOTE It will be necessary to remove the battery sidecover to gain access to the battery.

1. Place test probes of voltmeter on battery terminals and

check the voltage of the battery to make sure it is at least

12.6 VDC.

2. If the open circuit (disconnected) voltage reading is 12.6

VDC or greater the battery is ready for use.

3. See Section 1. Mark the date on the battery warranty tag

by removing the applicable month and year. Month and year punches may be removed with the point of a screwdriver without removing battery.

4. If the open circuit (disconnected) voltage reading is

below 12.6 VDC, refer to Table 1-2, 12 amp-hour battery, in Section 1 and charge battery at rate and time speciﬁed.

5. Recheck battery voltage by repeating step 1 above. If

voltage now is 12.6 VDC or greater, perform steps 2 and 3 above.

6. If the open circuit (disconnected) voltage reading is still

below 12.6 VDC, the battery must be replaced.

INSTALLING MAXI-FUSE

The 40 amp Maxi-Fuse provides battery power to the ignition switch and ECM. The 40 amp Maxi-Fuse is not installed at the factory. It is shipped attached to the motorcycle. See Service Manual.

INSTALLING FUEL PUMP FUSE

For non-carbureted vehicles, install the 15-amp fuel pump fuse that is located in the spare fuse slot in the fuse block per procedure in the appropriate Service Manual.

IDLE SPEED: CARBURETED ONLY

NOTE The idle speed on fuel injected models can only be set using a diagnostic tool such as DIGITAL TECHNICIAN (Part No. HD-44750).

See Figure 3-1. Set engine slow idle speed of 950 RPM with engine running at normal operating temperature and with enrichment control knob pushed in fully. Turn carburetor idle speed adjusting screw (5) clockwise to increase speed, or counterclockwise to decrease speed.

NOTE The C.V. carburetor has an enrichment circuit that will cause the engine to idle above the normal idle range (950-1050 RPM) with the engine at normal operating temperature and the enrichment knob pulled out fully. The increase in idle speed is intended to alert the rider that the engine is warmed up to normal operating temperature and that the enrichment knob should be pushed in all the way. Continuing to use the enrichener when the engine is at full operating temperature will cause fouled plugs.

Be sure the engine is warmed up to normal operating temperature and the enrichment knob is pushed all the way in before adjusting engine idle speed. Be aware that, because there are variations in individual components, it is possible for a properly warmed-up engine to idle above the normal idle range (950-1050 RPM) with the enrichment knob pulled out partially.

3-2 2005 PDI: Dyna Models

5428

1. Throttle friction screw

2. Throttle control cable

3. Idle control cable

4. Adjuster

5. Jam nut

3

1

2

4

5

f1381a2x

5

2

3

4

1

1. Carburetor stop plate

2. Cable housing

3. Spring

4. Throttle cam stop

5. Idle speed adjusting screw

Figure 3-1. Carburetor Adjustments

THROTTLE CABLES

Tw ist and release throttle control grip a few times to verify proper operation of throttle control system. With throttle friction screw loosened, carburetor throttle must return to idle position each time throttle control grip is released.

1WARNING1WARNING

Throttle cables must not pull tight when handlebars are turned fully to left or right fork stops. Be sure wires and throttle cables are clear of fork stops at steering head so they will not be pinched when fork is turned against stops. Steering must be smooth and free with no binding or interference. Interference with steering could cause loss of vehicle control which could result in death or serious injury.

Check throttle cable adjustment. With engine running, turn handlebars through full range of travel. If engine speed changes during this maneuver, adjust throttle cables as follows:

1. See Figure 3-2. Slide rubber boot (if applicable) off each cable adjuster.

2. Loosen jam nut (5) on each adjuster (4).

3. Turn adjusters in direction which will shorten cable housings to minimum length.

4. Point front wheel straight ahead. Twist throttle control grip to fully open position; hold in position.

5. See Figure 3-1. Tu rn adjuster on throttle control cable

6. See Figure 3-2. Tighten jam nut (5) on throttle control

7. See Figure 3-1. Tu rn handlebars fully to right. Turn

8. See Figure 3-2. With throttle friction screw (1) loosened,

9. Tighten jam nut (5) on idle control cable (3) adjuster (4).

10. Slide rubber boot (if applicable) over each cable adjuster

Figure 3-2. Throttle Cable Adjustment

until throttle cam stop (4) touches carburetor stop plate (1).

cable (2) adjuster (4); release throttle control grip.

adjuster on idle control cable until end of cable housing (2) just touches spring (3) within carburetor cable guide.

twist and release throttle control grip a few times. Carburetor throttle must return to idle position each time throttle grip is released. If this is not the case, turn adjuster (4) on idle control cable (3) (shortening cable housing) until throttle control functions properly.

Recheck operation of throttle control (Step 7).

(4). Recheck engine slow idle speed; adjust if required.

2005 PDI: Dyna Models 3-3

SUSPENSION ADJUSTMENT FOR FXDX MODEL

Refer to the Dyna Models Owner’s Manual for suspension adjustment instructions for FXDX model.

SHIFT LEVER

Inspect shift linkage for free movement. Check shift lever adjustment; rider’s foot must be able to ﬁt easily under shift lever. Adjust shift lever if required.

SEATS AND PASSENGER STRAP

Refer to the Dyna Models Owner’s Manual for seat and passenger strap removal and installation instructions.

3-4 2005 PDI: Dyna Models

LUBRICATION SYSTEM 3.3

pd0206

ENGINE OIL LEVEL

Check engine oil level with engine turned off and motorcycle resting on jiffy stand on level surface.

1. Remove ﬁller cap with attached dipstick. Wipe dipstick clean.

2. Install ﬁller cap. Make sure cap is fully seated in oil pan ﬁller neck.

3. See Figure 3-3. Remove ﬁller cap, and check oil level on dipstick. If oil level in pan is below lower mark on dipstick, add enough Harley-Davidson oil to bring level up between lower mark (1) and cold check level (2) on dipstick. Refer to the Dyna Models Service Manual for recommended viscosity.

NOTE Do not ﬁll oil tank to full (upper) mark on ﬁller cap/dipstick at this time. Ordinarily, you would ﬁll a Dyna oil pan (with warm engine) to this level. In this situation, however, if any oil has ﬂowed from oil pan to crankcase during shipping, ﬁlling oil pan to full mark might result in overﬁlling of oil pan when engine is started. Final check of oil level must be made with engine off, after engine has reached normal operating temperature.

d0386x1x

For cold check level do not exceed

2

1

this point when ﬁlling with oil.

3

NOTE

CHAINCASE LUBRICANT LEVEL AND CLUTCH OPERATION

1. Remove ﬁve screws, clutch inspection cover and cover gasket.

2. See Figure 3-4. The primary chaincase lubricant level is acceptable when lubricant is visible in bottom of chaincase with motorcycle standing upright (not resting on jiffy stand).

1. Lower arrow (add oil)

2. Cold check level

3. Upper arrow (hot check level)

Figure 3-3. Engine Oil Dipstick

TRANSMISSION LUBRICANT LEVEL

NOTE Allow vehicle to stand upright for a moment before checking transmission lubricant level. This will allow lubricant level to normalize.

Check the transmission lubricant level with the motorcycle standing upright in accordance with the procedure given in the Dyna Models Service Manual.

Figure 3-4. Chaincase Lubricant Level

3. Check clutch action. Clutch lever should move freely and smoothly through its entire range of travel.

4. Check clutch adjustment according to the procedures given in the Dyna Models Service Manual.

NOTE The clutch inspection cover gasket may be reused ONLY when checking chaincase lubricant level and reinstalling clutch inspection cover at PDI.

5. Reinstall cover gasket and clutch inspection cover, and

secure with ﬁve screws. Tighten to 84-108 in-lbs (9.5-

12.2 Nm).

2005 PDI: Dyna Models 3-5

FUEL SYSTEM 3.4

GENERAL

CAUTION

Some fuel suppliers sell gasoline which has been blended with an alcohol or an ether. The type and amount of alcohol or ether added to the fuel is important.

CAUTION

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

● Gasolines containing ETHANOL (ethyl alcohol or grain

alcohol) can be used. Gasoline/ethanol blends are a mixture of 10% ethanol and 90% unleaded gasoline. They are identiﬁed as “gasohol,” “ethanol enhanced,” or “contains ethanol.”

● Gasolines containing METHYL TERTIARY BUTYL

ETHER (MTBE) can also be used. Gasoline/MTBE blends are a mixture of gasoline and as much as 15% MTBE.

● 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

Because of their different chemical properties (which affect fuel volatility and ignition characteristics), these blends may adversely affect the starting, drivability, and fuel efﬁciency of the motorcycle. If you experience these problems, HarleyDavidson recommends using straight, unleaded gasoline.

CAUTION

CHECKING QUICK CONNECT FUEL LINE FITTING–FUEL INJECTED MODELS

1WARNING1WARNING

To avoid an uncontrolled discharge or spray of gasoline, always be sure the quick-connect ﬁtting (under left side of fuel tank) is properly mated. A slight tug on the fuel line will verify this condition. Gasoline is extremely ﬂammable and highly explosive. Inadequate safety precautions could result in death or serious injury.

1. Tug on fuel supply line (under left side of fuel tank) to be sure quick connect ﬁtting is properly mated.

2. If fuel line comes free, push up on sleeve of quick-connect ﬁtting and insert neck of fuel supply line ﬁtting. While pushing up on bottom of fuel supply line ﬁtting, pull down on sleeve until it “clicks” into the locked position.

FUEL TANK

Make sure engine stop switch on the handlebar is switched to the OFF position. Turn the ignition/light switch to the IGNITION position. Fuel injected models: verify that Low Fuel lamp is lit. Partially ﬁll fuel tank with gasoline. Follow FUEL recommendations found in the Owner’s Manual. Use unleaded gasoline, 91 octane or higher. Verify function of fuel gauge as fuel tank is ﬁlling, then turn ignition/light switch OFF. Inspect fuel lines for leaks.

Carbureted Models

See Figure 3-5. After adding gasoline, check for smooth operation of the fuel valve. Inspect fuel valve for leaks.

o0046b

Use only unleaded fuel in California model catalytic converter-equipped motorcycles. Using leaded fuel will damage the emission control system. (00150a).

3-6 2005 PDI: Dyna Models

Figure 3-5. Fuel Supply Valve

1. Speedometer

2. Odometer and trip odometer

3. Left directional (turn signal) indicator lamp

4. High beam indicator lamp

5. Neutral indicator lamp

6. Oil pressure indicator lamp

7. Right directional (turn signal) indicator lamp

8. Tachometer

9. Check engine lamp

10648

1

2

3

4

5

6

7

8

9

ELECTRICAL SYSTEM 3.5

HEADLAMP

Check headlamp beam for proper height and lateral alignment in accordance with procedures given in the Dyna Models Service Manual

1WARNING1WARNING

The automatic-on 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)

NOTE All FXDX/I models with a black-painted mounting bracket above the headlamp have a snap cap taped to right rear turn signal. Install snap cap after headlamp has been adjusted. All other models are shipped in position.

INDICATOR LAMPS/CONTROLS

NOTE See Figure 3-6. This ﬁgure shows instruments and indicators on FXDX models. Instruments and indicators on remaining Dyna models are located as follows:

● FXD Speedometer and indicators in handlebar bracket.

● FXDWG Speedometer and indicators in panel on gas

tank.

FXDL Speedometer and tachometer in console on gas tank, indicators in headlamp bracket.

1. Turn ignition switch to “IGNITION” position, check that oil

pressure indicator lamp turns on (before engine is started) and check engine lamp illuminates for about four seconds and goes off.

2. Shift transmission to neutral position, and verify that neu-

tral indicator lamp turns on.

3. Start engine; check operation of starter.

4. Check that oil pressure indicator lamp turns off when

engine is running above 1000 RPM.

5. Check operation of tachometer, if equipped.

6. Disengage clutch (depress clutch lever), and verify that

neutral indicator lamp turns off when transmission is shifted to any forward gear. Shift transmission to neutral position, and verify that neutral indicator lamp turns on again.

Figure 3-6. Instruments & Indicator Lamps FXDX (typical)

7. Check horn operation.

8. Check operation of all remaining lamps:

● headlamp–low and high beams

● headlamp high beam indicator lamp

● left directional (turn signal) lamps–front and rear

● Ieft directional (turn signal) indicator lamp

● right directional (turn signal) lamps–front and rear

● right directional (turn signal) indicator lamp

● Ieft front running lamp

● right front running lamp

● tail lamp–running lamp and brake lamp ﬁlaments

● speedometer illumination lamp

● tachometer illumination lamp

9. After engine has reached normal operating temperature, turn engine off.

10. Check engine oil level in manner previously speciﬁed. This time, ﬁll oil tank to upper mark on ﬁller cap/dipstick.

2005 PDI: Dyna Models 3-7

MIRRORS AND DIRECTIONAL LAMPS

See Figure 3-7. Adjust mirrors for proper rear view. Adjust front directional lamps so lenses are aimed directly forward; adjust rear directional lamps so lenses are aimed directly rearward. Verify that mirror and directional lamp fasteners are properly tightened. Tighten mirror fasteners to 12 ft-lbs (16.3 Nm).

pd0104c

3-8 2005 PDI: Dyna Models

1. Mirror

2. Star washer

3. Acorn nut

4. Front directional lamp

Figure 3-7. Mirror and Directional Lamp Mounting

TIRES 3.6

FRONT AND REAR TIRES

1WARNING1WARNING

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)

1WARNING1WARNING

Harley-Davidson 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)

1. Check for proper front and rear tire pressures when tires

are cold. Compare results against Table 3-3.

Table 3-3. Tire Pressures

TIRES

SOLO RIDER

PSI kPA PSI kPA

Front 30 207 30 207

Rear 36 248 40 276

RIDER & ONE

PASSENGER

2005 PDI: Dyna Models 3-9

BRAKE SYSTEM 3.7

BRAKES

1CAUTION

Direct contact with D.O.T. 5 brake ﬂuid can cause eye irritation, swelling, and redness. Avid eye contact. In case of eye contact ﬂush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake ﬂuid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a)

See Figure 3-8. View reservoir sightglass and verify ﬂuid presence. Sightglass should appear dark if ﬂuid is present. If sightglass is not dark, add brake ﬂuid. See Service Manual. Use only D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID.

4934

Figure 3-8. Rear Master Cylinder Shown

3-10 2005 PDI: Dyna Models

DEALER ROAD TEST 3.8

ROAD TEST

After you complete motorcycle inspection, take motorcycle for a road test. Check all systems and overall operation of motorcycle: engine, transmission, clutch, brakes, handling, etc.

After road test, return motorcycle to shop, and thoroughly clean off any road dirt. Check and correct any problems you may have found during road test.

Before You Begin

Check the following items before road test of vehicle:

● Lamps and indicators.

● Check amount of gasoline in tank and add (if

needed).

● Adjust mirrors to proper riding positions.

● Check tire condition and pressure (adjust if neces-

sary).

● Check controls to verify proper function.

● Check all electrical equipment and switches includ-

ing stop lamp, turn signals and horn for proper operation.

Road Test of Vehicle: Low Speed

1. Shift from ﬁrst through third gear, checking clutch operation, throttle control, and transmission operation.

2. Verify low speed braking for front and rear brakes.

3. Handling under braking conditions.

4. Low speed handling. Verify that vehicle does not pull to left or right.

5. Check for any abnormal vibrations.

6. Check electrical lamps, indicators.

Road Test of Vehicle: Highway Speed

1. Shift from ﬁrst through ﬁfth gear, checking clutch operation, throttle control, and transmission operation.

2. Verify highway speed braking operation of front and rear brakes.

3. Verify proper handling at highway speeds.

4. Check for any abnormal vibrations.

● Program Security System (if equipped)

● Engine Oil:

Check and correct hot level

● Clean Vehicle:

NOTE Be sure to submit a Dealer Product Quality Audit (DPQA) on ANY adjustments and/or warranty work performed required to deliver the vehicle to the customer.

2005 PDI: Dyna Models 3-11

CUSTOMER DELIVERY 3.9

NOTICE TO DEALER

Before delivering motorcycle to owner, perform the following:

1. Make sure vehicle owner receives, and is aware of importance of reading Owner’s Manual, safety booklets and viewing Welcome To The Family video included with owner’s kit.

2. Review warranties with vehicle owner. Make sure owner understands warranties. California dealers must give customer a copy of Emissions Control System Warranty.

3. Give IMPORTANT sheet and other printed material in literature kit to vehicle owner.

4. Complete and sign warranty registration form. Have vehicle owner sign it.

5. Explain operation of vehicle controls to vehicle owner.

6. Explain how turn signals and emergency ﬂashers operate.

IMPORTANT NOTE Make sure vehicle owner understands how to arm and disarm security system. Explain how to disarm security system with personal code if key fob is lost or not functioning. Personal code should be written on the tear-out card in the Dyna Models Owner’s Manual and kept on the owner’s person. Also, verify both key fobs operate properly.

7. Whenever possible, introduce dealer Service Manager to

vehicle owner, and involve Service Manager in delivery process. Supply owner with name(s) of dealer Service/ Parts Department personnel who should be contacted regarding vehicle service/parts questions.

8. Inform vehicle owner about checking engine oil level,

checking tire pressure, and performing other basic maintenance functions. Review the Initial Scheduled Main- tenance requirement with owner. Depending on owner’s anticipated frequency of operating motorcycle, you may wish to schedule the Initial Scheduled Maintenance service appointment at this time.

3-12 2005 PDI: Dyna Models

VEHICLE PDI CHECKLIST 3.10

PRIOR TO CUSTOMER DELIVERY

NOTE Use this checklist for performing tasks related to this model motorcycle setup.

❒ Uncrate:

Check for damaged or missing parts.

❒ Jiffy Stand:

Verify proper function.

❒ Note Any Additional Problems

(including cosmetic quality):

Perform Warranty repairs.

❒ Battery:

Perform required voltmeter test on Maxi Fuse (main fuse) and battery.

❒ Install Maxi Fuse (main fuse). ❒ Lubrication System:

Inspect condition of oil lines.

❒ Engine Oil:

Verify oil is present (cold level).

❒ Primary Chaincase:

Check and verify lubricant is present.

❒ Fuel System:

a. Inspect fuel system for leaks. b. Fill, verify sender operation. c. Verify low fuel light operation (if equipped).

❒ Evaporative Control System:

Inspect hose routings, connections and fuel tank venting to canister (if equipped).

❒ Lighting, Gauges, Electrical Systems:

Verify correct operation.

❒ Tires:

Inspect condition and air pressure.

❒ Brake Systems (front and rear):

Correct ﬂuid level (if necessary).

❒ Headlamps:

Inspect and adjust as necessary.

❒ Mirrors:

Inspect and adjust as necessary.

❒ Fuel Outlet (valve or quick connect ﬁtting)

and Hoses:

Verify operation and connections.

❒ Road Test Vehicle: Low Speed

a. Shift from ﬁrst through third gear, checking clutch

operation, throttle control, and transmission opera-

tion. b. Verify low-speed braking for front and rear brakes. c. Verify handling under braking conditions. d. Verify low-speed handling. Verify that vehicle does

not pull to left or right. e. Check for any abnormal vibrations. f. Check electrical lamps, indicators.

❒ Road Test Vehicle: Highway Speed

a. Shift from ﬁrst through ﬁfth gear, checking clutch

operation, throttle control, and transmission opera-

tion. b. Verify highway speed braking operation of front and

rear brakes. c. Verify proper handling at highway speeds. d. Check for any abnormal vibrations.

❒ Engine Oil:

Check and correct hot level.

❒ Create Vehicle Birth-Certiﬁcate Using

Digital Technician (optional).

❒ Clean Vehicle.

AT POINT OF CUSTOMER DELIVERY

❒ Suspension Adjustments. ❒ Shift Linkage Adjustment. ❒ Brake Hand Lever Adjustment. ❒ Review Vehicle Care and Maintenance Requirements.

NOTE Be sure to submit a Dealer Product Quality Audit (DPQA) on ANY adjustments and/or warranty work performed required to deliver the vehicle to the customer.

2005 PDI: Dyna Models 3-13

NOTES

3-14 2005 PDI: Dyna Models

PREDELIVERY: SOFTAIL MODELS

SUBJECT PAGE NO.

4.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

2005 Softail Models Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Initial Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Battery Testing And Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Installing Fuel Pump Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Idle Speed: Carbureted Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Seats And Passenger Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.3 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Transmission Lubricant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Chaincase Lubricant Level and Clutch Operation . . . . . . . . . . . . . . . . . . . . . 4-5

4.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Checking Quick Connect Fuel Line Fitting–Fuel Injected Models . . . . . . . . . 4-6

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.5 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Auxiliary Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Mirrors and Directional Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.6 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Front and Rear Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.7 Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.8 Dealer Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.9 Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Notice To Dealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.10 Vehicle PDI Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Prior to Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

At Point of Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

IV

1

SPECIFICATIONS 4.1

TORQUE VALUES

The following torque values are included for fasteners that may be loosened and tightened during Predelivery and Setup. Any fasteners that are not loosened/removed do not need to be checked during predelivery and setup.

Table 4-1. Torque Values

ITEM TORQUE NOTES

Handlebar clamp screws (front and rear) 12-15 ft-lbs 16.3-20.3 Nm

Brake master cylinder cover screws (front and rear)

Battery terminal screws 60-96 in-lbs 6.8-10.9 Nm

Mirror fasteners 60-96 in-lbs 6.8-10-9 Nm

Clutch inspection cover screws 84-108 in-lbs 9.5-12.2 Nm

6-8 in-lbs 0.7-0.9 Nm

2005 SOFTAIL MODELS SPECIFICATIONS

Table 4-2. Capacities

Component ENGLISH METRIC

Oil tank w/ﬁlter (Dry) 3.5 qt. 3.31 liter Tr ansmission (Wet) 20-24 oz 591-710 ml Primary Chaincase 26 oz 769 ml All Softail models except FLSTFSE are shipped with

20W50 Harley-Davidson 360 Motor oil. The FLSTFSE model ships with Syn-3® lubricant in the engine, primary and transmission.

Idle Speed: 950 RPM at Operating Temperature

Use 950 RPM during Predelivery and Setup adjustments. Engine idle speed may increase during engine break-in. Use idle speed listed in the Softail Models Service Manual at Initial Maintenance check.

NOTE The idle speed on electronic fuel injected models can only be set using a diagnostic tool such as DIGITAL TECHNICIAN (Part No. HD-44750).

2005 PDI: Softail Models 4-1

INITIAL ASSEMBLY 4.2

BATTERY TESTING AND CHARGING

1WARNING1WARNING

Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, rubberized gloves and protective clothing when working with batteries. KEEP BATTERIES AWAY FROM CHILDREN. (00063a)

1WARNING1WARNING

Never remove warning label attached to top of battery. Failure to read and understand all precautions in warning could result in death or serious injury. (00064a)

1WARNING1WARNING

Battery posts, terminals and related accessories contain lead and lead components, chemicals known in the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. (00019a)

NOTE It will be necessary to remove the seat to perform required battery tests. Remove seat according to procedure in appropriate Service Manual.

Battery Testing and Charging

1. Place test probes of voltmeter on battery terminals and

check the voltage of the battery to make sure it is at least

12.6 VDC.

2. If the open circuit (disconnected) voltage reading is 12.6

VDC or greater the battery is ready for use.

3. See Section 1. Mark the date on the battery warranty tag

by removing the applicable month and year. Month and year punches may be removed with the point of a screwdriver without removing battery.

4. If the open circuit (disconnected) voltage reading is

below 12.6 VDC, refer to Ta bl e 1-2., 12 amp-hour battery, in Section 1 and charge battery at rate and time speciﬁed.

5. Recheck battery voltage by repeating step 1 above. If

voltage now is 12 VDC or greater, perform steps 2 and 3 above.

6. If the open circuit (disconnected) voltage reading is still

below 12.6 VDC, the battery must be replaced.

Connecting Battery

NOTE One battery terminal bolt is attached to red plastic terminal cover covering positive battery terminal. The second battery terminal bolt is in negative battery terminal.

1. Attach positive battery cable ﬁrst. Orient terminal so

cable is oriented away from oil tank and tighten terminal bolt to 60-96 in-lbs (6.8-10.9 Nm).

2. Attach negative battery cable and tighten terminal bolt to

60-96 in-lbs (6.8-10.9 Nm).

INSTALLING FUEL PUMP FUSE

For non-carbureted vehicles, it will also be necessary to install the fuel pump fuse that is located in the spare fuse slot of the fuse-block. See Service Manual.

INDICATOR LAMPS

NOTE All Softail models have an electronic speedometer with selfdiagnostic capabilities. Refer to the Softail Models Service Manual for service instructions.

1. See Figure 4-1. Tu rn ignition switch to “IGNITION” posi-

tion, and check that oil pressure indicator lamp turns on (before engine is started). Speedometer needle will “vibrate” and speedometer amber backlight will be visible. The Check Engine indicator will illuminate for about four seconds and then go off. If vehicle is equipped with optional Security System (TSSM), a key icon (9) (security lamp) will illuminate for about four seconds and then go off.

NOTE For any systems problems, please refer to the appropriate Electrical Diagnostic manual for your model.

2. Shift transmission to neutral position, and verify that neu-

tral indicator lamp turns on.

NOTE See 4.3 LUBRICATION SYSTEM and perform initial engine oil level check prior to starting engine.

3. Start engine; check operation of starter.

4. Check that oil pressure indicator lamp turns off when

engine is running above 1000 RPM.

5. Disengage clutch and verify that neutral indicator lamp

turns off when transmission is shifted to any forward gear. Shift transmission to neutral position, and verify that neutral indicator lamp turns on again.

6. Check horn operation.

4-2 2005 PDI: Softail Models

7. Check operation of all remaining lamps:

f1381a2x

2

3

5

1

1. Carburetor stop plate

2. Cable housing

3. Spring

4. Throttle cam stop

5. Idle speed adjusting screw

4

● headlamp–low and high beams

● headlamp high beam indicator lamp

● left directional (turn signal) lamps–front and rear

● Ieft directional (turn signal) indicator lamp

● right directional (turn signal) lamps–front and rear

● right directional (turn signal) indicator lamp

● Ieft front running lamp

● right front running lamp

● tail lamp–running lamp and brake lamp ﬁlaments

8. After engine has reached normal operating temperature, turn engine off.

9. Check engine oil level per instructions in 4.3 LUBRICA-

TION SYSTEM. This time, ﬁll oil tank to upper mark on

ﬁller cap/dipstick.

pd0189

7

1

8

60

50

70

EF

40

30

20

10

0

H

A

MPH

C

E

R

L

80

90 100

110

120

D

R

E

I

T

F

I

N

O

S

D

E

I

Y

V

-

A

D

IDLE SPEED: CARBURETED ONLY

NOTE The idle speed on fuel injected models can only be set using a diagnostic tool such as DIGITAL TECHNICIAN (Part No. HD-44750).

See Figure 4-2. Set engine slow idle speed of 950 RPM with engine running at normal operating temperature and with enrichener control knob pushed in fully. Turn carburetor idle speed adjusting screw (5) clockwise to increase speed, or counterclockwise to decrease speed.

NOTE The C.V. carburetor has an enrichener circuit that will cause the engine to idle at approximately 2000 RPM with the engine at normal operating temperature and the enrichener knob pulled fully out. The increase in idle speed is intended to alert the rider that the engine is warmed up to normal operating temperature and that the enrichener knob should be pushed in all the way. Continuing to use the enrichener circuit when the engine is at normal operating temperature will cause fouled plugs.

Be sure the engine is warmed up to normal operating temperature and the enrichener knob is pushed all the way in before adjusting engine idle speed. Be aware that, because there are variations in individual components, it is possible for a properly warmed-up engine to idle at 2000 RPM with the enrichener knob pulled out partially.

9

2

3

4

6

5

1. Speedometer

2. Left turn signal

3. High beam

4. Neutral

5. Oil pressure

6. Right turn signal

7. Check engine lamp

8. Fuel gauge

9. Security lamp

Figure 4-1. Indicator Lamps

IGNITION TIMING

Ignition timing is not adjustable on The Twin Cam 88B™ engine.

Figure 4-2. Carburetor Adjustments

2005 PDI: Softail Models 4-3

Windshield Installation: FLSTC

CAUTION

Be sure you position the windshield bracket notches in the grooves in the mounting bushings. Incorrect mounting could result in damage to the windshield.

1. See Figure 4-3. Lower the windshield into position carefully inserting the side brackets between the headlamp and the passing lamp supports until the bottom notches are seated in the lower bushing grooves.

2. Standing at the front of the vehicle, gently push the top of the windshield toward the rear until the upper notches fully engage the upper bushings.

SEATS AND PASSENGER STRAP

Refer to the Softail Models Owner’s Manual for seat and passenger strap removal and installation instructions.

o0138xox

Figure 4-3. Windshield Mounting

4-4 2005 PDI: Softail Models

LUBRICATION SYSTEM 4.3

pd0206

ENGINE OIL LEVEL

CAUTION

The FLSTFSE model is shipped from the factory with

®

SYN-3 transmission. If there is a need to top off lubricants, DO NOT use standard lubricants in the FLSTFSE model and do not mix lubricants as damage to the motorcycle can result.

Check engine oil level with engine turned off and motorcycle resting on side stand on level surface.

1. Remove ﬁller cap (with attached dipstick) from oil tank.

2. Install ﬁller cap onto oil tank. Make sure cap is fully

3. See Figure 4-4. Remove ﬁller cap, and check oil level on

Do not ﬁll oil tank to full (upper) mark on ﬁller cap/dipstick at this time. Ordinarily, you would ﬁll a Softail oil tank (with warm engine) to this level. In this situation, however, if any oil has ﬂowed from tank to crankcase during shipping, ﬁlling oil tank to full mark might result in overﬁlling of oil tank when engine is started. Final check of oil level must be made with engine off, after engine has reached normal operating temperature.

lubricant exclusively in the engine, primary and

Wipe dipstick clean.

seated on tank.

dipstick. If oil level in tank is below lower mark on dipstick, add 3/4 quart (0.7 liter) of Harley-Davidson oil to tank. Refer to the Softail Models Service Manual for recommended viscosity.

NOTE

CHAINCASE LUBRICANT LEVEL AND CLUTCH OPERATION

NOTE Do not remove the clutch cover on the FLSTFSE. It is not necessary to check the primary chaincase lubricant level on this vehicle. Also, the hydraulic clutch is not adjustable.

1. Remove ﬁve screws, clutch inspection cover and cover

gasket.

2. See Figure 4-5. The primary chaincase lubricant level is

acceptable when lubricant is visible in bottom of chaincase with motorcycle standing upright (not resting on jiffy stand).

pd0219

Add 1 quart mark

Full mark with engine

at normal operating

temperature

Figure 4-4. Engine Oil Dipstick

TRANSMISSION LUBRICANT LEVEL

NOTE Allow vehicle to stand upright for a moment before checking transmission lubricant level. This will allow lubricant level to normalize.

Check the transmission lubricant level with the motorcycle standing upright in accordance with the procedure given in the Softail Models Service Manual.

Figure 4-5. Chaincase Lubricant Level

3. Check clutch action. Clutch lever should move freely and smoothly through its entire range of travel.

4. Check clutch adjustment according to the procedures given in the Softail Models Service Manual.

NOTE The clutch inspection cover gasket may be reused ONLY when checking chaincase lubricant level and reinstalling clutch inspection cover at PDI.

5. Reinstall cover gasket and clutch inspection cover, and

secure with ﬁve screws. Tighten to 84-108 in-lbs (9.5-

12.2 Nm).

2005 PDI: Softail Models 4-5

FUEL SYSTEM 4.4

GENERAL

CAUTION

Some fuel suppliers sell gasoline which has been blended with an alcohol or an ether. The type and amount of alcohol or ether added to the fuel is important.

CAUTION

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

● Gasolines containing ETHANOL (ethyl alcohol or grain

alcohol) can be used. Gasoline/ethanol blends are a mixture of 10% ethanol and 90% unleaded gasoline. They are identiﬁed as “gasohol,” “ethanol enhanced,” or “contains ethanol.”

● Gasolines containing METHYL TERTIARY BUTYL

ETHER (MTBE) can also be used. Gasoline/MTBE blends are a mixture of gasoline and as much as 15% MTBE.

● 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

Because of their different chemical properties (which affect fuel volatility and ignition characteristics), these blends may adversely affect the starting, drivability, and fuel efﬁciency of the motorcycle. If you experience these problems, HarleyDavidson recommends using straight, unleaded gasoline.

CHECKING QUICK CONNECT FUEL LINE FITTING–FUEL INJECTED MODELS

1WARNING1WARNING

To avoid an uncontrolled discharge or spray of gasoline, always be sure the quick-connect ﬁtting (under left side of fuel tank) is properly mated. A slight tug on the fuel line will verify this condition. Gasoline is extremely ﬂammable and highly explosive. Inadequate safety precautions could result in death or serious injury.

1. Tug on fuel supply line (under left side of fuel tank) to be sure quick connect ﬁtting is properly mated.

2. If fuel line comes free, push up on sleeve of quick-connect ﬁtting and insert neck of fuel supply line ﬁtting. While pushing up on bottom of fuel supply line ﬁtting, pull down on sleeve until it “clicks” into the locked position.

FUEL TANK

Make sure engine stop switch on the handlebar is switched to the OFF position. Turn the ignition/light switch to the IGNITION position. Fuel injected models: verify that Low Fuel lamp is lit. Partially ﬁll fuel tank with gasoline. Follow FUEL recommendations found in the Owner’s Manual. Use unleaded gasoline, 91 octane or higher. Verify function of fuel gauge as fuel tank is ﬁlling, then turn ignition/light switch OFF. Inspect fuel lines for leaks.

Carbureted Models

See Figure 4-6. After adding gasoline, check for smooth operation of the fuel valve. Inspect fuel valve for leaks.

o0046box

CAUTION

Use only unleaded fuel in California model catalytic converter-equipped motorcycles. Using leaded fuel will damage the emission control system. (00150a).

4-6 2005 PDI: Softail Models

Figure 4-6. Fuel Supply Valve

ELECTRICAL SYSTEM 4.5

1. Mirror

2. Star washer

3. Acorn nut

4. Front directional lamp

pd0104c

HEADLAMP

Check headlamp beam for proper height and lateral alignment in accordance with procedures given in the Softail Models Service Manual.

1WARNING1WARNING

The automatic-on 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)

AUXILIARY LAMPS

On models equipped with auxiliary lamps, check lamp beam for proper height and lateral alignment in accordance with procedures given in the Softail Models Service Manual.

MIRRORS AND DIRECTIONAL LAMPS

See Figure 4-7. Adjust mirrors for proper rear view. Adjust front directional lamps so lenses are aimed directly forward; adjust rear directional lamps so lenses are aimed directly rearward. Verify that mirror and directional lamp fasteners are properly tightened.

Figure 4-7. Mirrors And Turn Signals

2005 PDI: Softail Models 4-7

TIRES 4.6

FRONT AND REAR TIRES

1WARNING1WARNING

Do not alter or modify front suspension/fender/tire type on FXSTS models. The motorcycle handling characteristics and front end structural integrity might be adversely affected. This may cause loss of control, which could result in death or serious injury.

1WARNING1WARNING

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)

1WARNING1WARNING

Harley-Davidson 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)

1. Check for proper front and rear tire pressures when tires are cold. Compare results against Tab le 4-3.

Table 4-3. Tire Pressures

TIRES SOLO RIDER

MODEL TIRE PSI kPA PSI kPA

FLSTC/F/N/SC Front 36 248 36 248 FXST/D/S/B Front 30 207 30 207 All models Rear 36 248 40 276

RIDER AND

PASSENGER

4-8 2005 PDI: Softail Models

BRAKE SYSTEM 4.7

BRAKES

1CAUTION

Direct contact with D.O.T. 5 brake ﬂuid can cause eye irritation, swelling, and redness. Avid eye contact. In case of eye contact ﬂush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake ﬂuid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a)

View reservoir sightglass and verify ﬂuid presence. Sightglass should appear dark if ﬂuid is present. If sightglass is not dark, add brake ﬂuid. See Softail Models Service Manual. Use only D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. 99902-77: 12 oz., 99901-77: 1 gal.).

2005 PDI: Softail Models 4-9

DEALER ROAD TEST 4.8

ROAD TEST

After you complete motorcycle inspection, take motorcycle for a road test. Check all systems and overall operation of motorcycle: engine, transmission, clutch, brakes, handling, etc.

After road test, return motorcycle to shop, and thoroughly clean off any road dirt. Check and correct any problems you may have found during road test.

Before You Begin

Check the following items before road test of vehicle:

● Lamps and indicators.

● Check amount of gasoline in tank and add (if

needed).

● Adjust mirrors to proper riding positions.

● Check tire condition and pressure (adjust if neces-

sary).

● Check controls to verify proper function.

● Check all electrical equipment and switches includ-

ing stop lamp, turn signals and horn for proper operation.

Road Test of Vehicle: Low Speed

1. Shift from ﬁrst through third gear, checking clutch operation, throttle control, and transmission operation.

2. Verify low speed braking for front and rear brakes.

3. Handling under braking conditions.

4. Low speed handling. Verify that vehicle does not pull to left or right.

5. Check for any abnormal vibrations.

6. Check electrical lamps, indicators.

Road Test of Vehicle: Highway Speed

1. Shift from ﬁrst through ﬁfth gear, checking clutch operation, throttle control, and transmission operation.

2. Verify highway speed braking operation of front and rear brakes.

3. Verify proper handling at highway speeds.

4. Check for any abnormal vibrations.

● Program Security System (if equipped)

● Engine Oil:

Check and correct hot level.

● Clean Vehicle:

NOTE Be sure to submit a Dealer Product Quality Audit (DPQA) on ANY adjustments and/or warranty work performed required to deliver the vehicle to the customer.

4-10 2005 PDI: Softail Models

CUSTOMER DELIVERY 4.9

NOTICE TO DEALER

Before delivering motorcycle to owner, perform the following:

1. Make sure vehicle owner receives, and is aware of importance of reading Owner’s Manual, safety booklets and viewing Welcome To The Family video included with owner’s kit.

2. Review warranties with vehicle owner. Make sure owner understands warranties. California dealers must give customer a copy of Emissions Control System Warranty.

3. Give IMPORTANT sheet and other printed material in literature kit to vehicle owner.

4. Complete and sign warranty registration form. Have vehicle owner sign it.

5. Explain operation of vehicle controls to vehicle owner.

6. Explain how turn signals and emergency ﬂashers operate.

IMPORTANT NOTE Make sure vehicle owner understands how to arm and disarm security system. Explain how to disarm security system with personal code if key fob is lost or not functioning. Personal code should be written on the tear-out card in the Softail Models Owner’s Manual and kept on the owner’s person. Also, verify both key fobs operate properly.

7. Whenever possible, introduce dealer Service Manager to

vehicle owner, and involve Service Manager in delivery process. Supply owner with name(s) of dealer Service/ Parts Department personnel who should be contacted regarding vehicle service/parts questions.

8. Inform vehicle owner about checking engine oil level,

checking tire pressure, and performing other basic maintenance functions. Review the Initial Scheduled Main- tenance* requirement with owner. Depending on owner’s anticipated frequency of operating motorcycle, you may wish to schedule the Initial Scheduled Maintenance* service appointment at this time.

Initial Scheduled Maintenance is required as follows:

● All Softails, except FLSTSC and FXSTS @ 1000 mi.

(1600 km)

● FLSTSC and FXSTS @ 500 mi. (800 km)

2005 PDI: Softail Models 4-11

VEHICLE PDI CHECKLIST 4.10

PRIOR TO CUSTOMER DELIVERY

NOTE Use this checklist for performing tasks related to this model motorcycle setup.

❒ Uncrate:

Check for damaged or missing parts.

❒ Jiffy Stand:

Verify proper function.

❒ Note Any Additional Problems

(including cosmetic quality):

Perform Warranty repairs.

❒ Battery:

Perform required voltmeter test on battery.

❒ Connect negative battery cable to battery. ❒ Lubrication System:

Inspect condition of oil lines.

❒ Engine Oil:

Verify oil is present (cold level).

❒ Primary Chaincase:

Check and verify lubricant is present.

❒ Fuel System:

a. Inspect fuel system for leaks. b. Fill, verify sender operation. c. Verify low fuel light operation (if equipped).

❒ Evaporative Control System:

Inspect hose routings, connections and fuel tank venting to canister (if equipped).

❒ Lighting, Gauges, Electrical Systems:

Verify correct operation.

❒ Tires:

Inspect condition and air pressure.

❒ Brake Systems (front and rear):

Correct ﬂuid level (if necessary).

❒ Headlamps:

Inspect and adjust as necessary.

❒ Mirrors:

Inspect and adjust as necessary.

❒ Fuel Outlet (valve or quick connect ﬁtting)

and Hoses:

Verify operation and connections.

❒ Road Test Vehicle: Low Speed

a. Shift from ﬁrst through third gear, checking clutch

operation, throttle control, and transmission opera-

tion. b. Verify low-speed braking for front and rear brakes. c. Verify handling under braking conditions. d. Verify low-speed handling. Verify that vehicle does

not pull to left or right. e. Check for any abnormal vibrations. f. Check electrical lamps, indicators.

❒ Road Test Vehicle: Highway Speed

a. Shift from ﬁrst through ﬁfth gear, checking clutch

operation, throttle control, and transmission opera-

tion. b. Verify highway speed braking operation of front and

rear brakes. c. Verify proper handling at highway speeds. d. Check for any abnormal vibrations.

❒ Engine Oil:

Check and correct hot level.

❒ Create Vehicle Birth-Certiﬁcate Using

Digital Technician (optional).

❒ Clean Vehicle.

AT POINT OF CUSTOMER DELIVERY

❒ Suspension Adjustments. ❒ Brake Pedal Height Adjustment. ❒ Shift Linkage Adjustment. ❒ Brake Hand Lever Adjustment. ❒ Review Vehicle Care and Maintenance Requirements.

NOTE Be sure to submit a Dealer Product Quality Audit (DPQA) on ANY adjustments and/or warranty work performed required to deliver the vehicle to the customer.

4-12 2005 PDI: Softail Models

PREDELIVERY: SPORTSTER MODELS

SUBJECT PAGE NO.

5.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

2005 Sportster Models Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 Initial Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Battery Testing And Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Installing Maxi-Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Directional Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Throttle Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Seats And Passenger Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.3 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Clutch Operation and Primary Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.5 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Headlamp Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Indicator Lamps/Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5.6 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Front and Rear Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.7 Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Rear Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.8 Dealer Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.9 Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Notice To Dealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.10 Vehicle PDI Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Prior to Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

At Point of Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

V

1

SPECIFICATIONS 5.1

TORQUE VALUES

The following torque values are included for fasteners that may be loosened and tightened during Predelivery and Setup. Any fasteners that are not loosened/removed do not need to be checked during predelivery and setup.

Table 5-1. Torque Values

ITEM TORQUE NOTES

Handlebar clamp screws (front and rear) 12-18 ft-lbs 16.3-24.4 Nm

Front brake master cylinder cover screws 9-17 in-lbs 1.0-2.0 Nm

Mirror fasteners 96-144 in-lbs 10.9-16.3 Nm

Battery terminal screw (positive and negative) 40-50 in-lbs 4.5-5.7 Nm

2005 SPORTSTER MODELS SPECIFICATIONS

Table 5-2. Capacities

Component ENGLISH METRIC

Oil tank w/ﬁlter (Dry) 3.6 qt. 3.4 liters Tr ansmission/Primary

Chaincase All motorcycles are shipped with 20W50 Harley-Davidson

360 Motor oil

32 oz 946 ml

Idle Speed: 950 RPM at Operating Temperature

Use 950 RPM during Predelivery and Setup adjustments. Engine idle speed may increase during engine break-in. Use idle speed listed in the Sportster Models Service Manual at Initial Maintenance check.

2005 PDI: Sportster Models 5-1

INITIAL ASSEMBLY 5.2

BATTERY TESTING AND CHARGING

1WARNING1WARNING

Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, rubberized gloves and protective clothing when working with batteries. KEEP BATTERIES AWAY FROM CHILDREN. (00063a)

1WARNING1WARNING

Never remove warning label attached to top of battery. Failure to read and understand all precautions in warning could result in death or serious injury. (00064a)

1WARNING1WARNING

Battery posts, terminals and related accessories contain lead and lead components, chemicals known in the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. (00019a)

1. Grasp left side cover at upper corners and gently pull away from plastic mounting clips on frame.

2. Lift cover up slightly so mounting grommet clears mounting tab on battery tray. Remove cover.

3. Place test probes of voltmeter on battery terminals and check the voltage of the battery to make sure it is at least

12.6 VDC.

4. If the open circuit (disconnected) voltage reading is 12.6 VDC or greater the battery is ready for use.

5. See Section 1. Mark the date on the battery warranty tag by removing the applicable month and year. Month and year punches may be removed with the point of a screwdriver without removing battery.

6. If the open circuit (disconnected) voltage reading is below 12.6 VDC, refer to Table 1-2, 12 amp-hour battery, in Section 1 and charge battery at rate and time speciﬁed.

7. Recheck battery voltage by repeating step 2 above. If voltage now is 12 VDC or greater, perform steps 2 and 3 above.

8. If the open circuit (disconnected) voltage reading is still below 12.6 VDC, the battery must be replaced.

9. Place bottom of side cover with grommet onto mounting tab on battery tray.

10. Line up top of side cover with mounting clips aligning with front clip ﬁrst. Press top of side cover into clips until snug.

x0628x1x

1

1. Mounting slots (top)

2. Mounting grommet (bottom)

Figure 5-1. Left Side Cover

2

5-2 2005 PDI: Sportster Models

INSTALLING MAXI-FUSE

1. Throttle cam stop

2. Cable housing

3. Spring

4. Throttle cam

5. Idle speed adjusting screw

1

5

2

x0505a1x

4

3

IDLE SPEED

The 30 amp Maxi-Fuse provides battery power to the ignition switch and ICM. The Maxi-Fuse is not installed at the factory. It is mounted in protective foam attached to the left handlebar grip of the motorcycle in the crate.

See Figure 5-2. The Maxi-Fuse holder is located under the left side cover, attached to the battery strap. See the Sportster Models Service Manual for the proper installation procedure.

8946

8948a

See Figure 5-3. Set engine slow idle speed of 950 RPM with engine running at normal operating temperature and with enrichment control knob pushed in fully. Turn carburetor idle speed adjusting screw (5) clockwise to increase speed, or counterclockwise to decrease speed.

NOTE The C.V. carburetor has an enrichment circuit that will cause the engine to idle above the normal idle range (950-1050 RPM) with the engine at normal operating temperature and the enrichment knob pulled out fully. The increase in idle speed is intended to alert the rider that the engine is warmed up to normal operating temperature and that the enrichment knob should be pushed in all the way. Continuing to use the enrichener when the engine is at full operating temperature will cause fouled plugs.

Be sure the engine is warmed up to normal operating temperature and the enrichment knob is pushed all the way in before adjusting engine idle speed. Be aware that, because there are variations in individual components, it is possible for a properly warmed-up engine to idle above the normal idle range (950-1050 RPM) with the enrichment knob pulled out partially.

Figure 5-2. Installing Maxi-Fuse

Figure 5-3. Carburetor adjustments

2005 PDI: Sportster Models 5-3

MIRRORS

REAR SUSPENSION

NOTE XL 883L model: righthand mirror is shipped in protective foam on left hand grip and must be installed.

1. XL 883L models:

a. See Figure 5-4. Insert mirror (1) stem into hole in

master cylinder assembly (2).

b. Install lock washer (3) and lock nut (4). Tighten to

96-144 in-lbs (10.9-16.3 Nm).

pd0225

1

2

1. Righthand mirror

2. Front brake master cylinder assembly

3. Lock washer

4. Lock nut

3

4

See Figure 5-5. Check that spring preload is set the same on both rear shock absorbers. For a solo rider of average weight, adjust spring preload to softest setting using SPANNER TOOL (Part No. HD-94820-75A) for all models.

10628

Figure 5-5. Adjusting Spring Preload

DIRECTIONAL LAMPS

Adjust rear directional lamps so lenses are aimed directly rearward. Verify that directional lamp fasteners are properly tightened.

Figure 5-4. Installing Righthand Mirror on XL 883L

2. Adjust mirrors for proper rear view.

3. Adjust front directional lamps so lenses are aimed directly forward.

4. Verify that mirror and directional lamp fasteners are properly tightened.

NOTE A 4 mm allen wrench will be needed to perform the front directional adjustments.

THROTTLE CONTROL CABLES

1WARNING1WARNING

Throttle cables must not pull tight when handlebars are turned fully to left or right fork stops. Be sure wires and throttle cables are clear of fork stops at steering head so they will not be pinched when fork is turned against stops. Steering must be smooth and free with no binding or interference. Interference with steering could cause loss of vehicle control which could result in death or serious injury.

Check throttle cable adjustment in accordance with procedure given in Section 1 of Sportster Models Service Manual.

SEATS AND PASSENGER STRAP

Refer to Sportster Models Owner’s Manual for seat and passenger strap removal and installation instructions.

5-4 2005 PDI: Sportster Models

LUBRICATION SYSTEM 5.3

10100 10099

ENGINE OIL LEVEL

Check engine oil level in oil tank at least once every 500 miles (800 km). Check level more frequently if engine uses more oil than normal or if vehicle is operated under harsh conditions. Oil tank capacity is 3.6 quarts (U.S.) (3.4 liters). Refer to Owner’s Manual for recommended engine oil viscosity.

NOTE It will be necessary to check engine oil with motorcycle leaning on jiffy stand.

1. Run engine until engine oil is at normal operating tem-

perature. Turn engine off.

2. Remove ﬁller cap from oil tank on right side of vehicle.

a. Press straight down on ﬁller cap and release. Cap

will pop up.

b. Pull up on ﬁller cap while turning counterclockwise

one-quarter turn as if unscrewing ﬁller cap.

3. Wipe attached dipstick clean.

NOTE See Figure 5-6. Note that dipstick has a wide slot and a narrow slot and can only be inserted in oil tank one way.

4. Insert dipstick into tank. Press down on ﬁller cap while

turning clockwise one-quarter turn as if screwing ﬁller cap into tank. When ﬁller cap “snaps” slightly, it is fully seated.

5. See Figure 5-7. Remove ﬁller cap again and check warm

oil level on dipstick. Dipstick has two marks. If oil level in tank is at or below lower mark, add one quart (0.946 liter) of Harley-Davidson oil to tank.

6. Repeat step 4 to replace ﬁller cap.

7. If you added oil in step 5, remove ﬁller cap and verify cor-

rect engine oil level in oil tank. Do not ﬁll oil tank to the level above upper mark on dipstick. Repeat step 4 to replace ﬁller cap.

8. Press down on ﬁller cap until it clicks in place.

Figure 5-6. Filler Cap/Dipstick Slots

Figure 5-7. Oil Level Marks

CLUTCH OPERATION AND PRIMARY CHAINCASE

1. Check clutch action. Clutch lever should move freely and

smoothly through its entire range of travel.

2. Check clutch adjustment and primary chaincase lubri-

cant level according to the procedures in Chapter 1 of the Sportster Models Service Manual.

2005 PDI: Sportster Models 5-5

FUEL SYSTEM 5.4

GENERAL

CAUTION

Some fuel suppliers sell gasoline which has been blended with an alcohol or an ether. The type and amount of alcohol or ether added to the fuel is important.

CAUTION

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

● Gasolines containing ETHANOL (ethyl alcohol or grain

alcohol) can be used. Gasoline/ethanol blends are a mixture of 10% ethanol and 90% unleaded gasoline. They are identiﬁed as “gasohol,” “ethanol enhanced,” or “contains ethanol.”

● Gasolines containing METHYL TERTIARY BUTYL

ETHER (MTBE) can also be used. Gasoline/MTBE blends are a mixture of gasoline and as much as 15% MTBE.

● 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

Because of their different chemical properties (which affect fuel volatility and ignition characteristics), these blends may adversely affect the starting, drivability, and fuel efﬁciency of the motorcycle. If you experience these problems, HarleyDavidson recommends using straight, unleaded gasoline.

FUEL TANK

Partially ﬁll fuel tank with gasoline. Follow FUEL recommendations found in the Owner’s Manual. Use unleaded gasoline, 91 octane or higher on all 1200 Roadster and Custom models, and 87 octane or higher on 883 Standard and Custom models.

See Figure 5-8. After adding gasoline, check for smooth operation of the fuel valve. Inspect fuel valve and fuel lines for leaks.

o0046box

Figure 5-8. Fuel Supply Valve

CAUTION

Use only unleaded fuel in California model catalytic converter-equipped motorcycles. Using leaded fuel will damage the emission control system. (00150a).

5-6 2005 PDI: Sportster Models

1. Speedometer

2. Odometer and trip odometer

3. Left directional (turn signal) indicator lamp

4. High beam indicator lamp

5. Neutral indicator lamp

6. Oil pressure indicator lamp

7. Right directional (turn signal) indicator lamp

8. Tachometer (1200 Roadster only)

1200 Roadster shown, other Sportster models not originally equipped with tachometer.

1

2

4

5

7

6

8

4911

3

ELECTRICAL SYSTEM 5.5

HEADLAMP ALIGNMENT

Check headlamp beam for proper height and lateral alignment in accordance with procedures given in Section 1 of the Sportster Models Service Manual.

1WARNING1WARNING

The automatic-on 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)

INDICATOR LAMPS/CONTROLS

1. See Figure 5-9. Tu rn ignition switch to IGNITION posi-

tion, and check that oil pressure indicator lamp (6) turns on (before engine is started).

2. Shift transmission to neutral position, and verify that neu-

tral indicator lamp (5) turns on.

3. Start engine; check operation of starter.

4. Check that oil pressure indicator lamp (6) turns off when

engine is running above 1000 RPM.

5. Disengage clutch (depress clutch lever), and verify that

neutral indicator lamp (5) turns off when transmission is shifted to any forward gear.

6. Shift transmission to neutral position, and verify that neu-

tral indicator lamp turns on again.

7. Check operation of tachometer (8) (1200 Roadster only).

8. Check horn operation.

9. Check operation of all remaining lamps:

● Headlamp–low and high beams

● Headlamp high beam indicator lamp (4)

● Left directional (turn signal) lamps–front and rear

● Left directional (turn signal) indicator lamp (3)

● Right directional (turn signal) lamps–front and rear

● Right directional (turn signal) indicator lamp (7)

● Left front running lamp

● Right front running lamp

● Ta il lamp–running lamp and brake lamp ﬁlaments

● Speedometer (1) illumination lamp

● Ta chometer (8) illumination lamp (1200 Roadster

only)

10. After engine has reached normal operating temperature, turn engine off.

11. Check engine oil level in manner previously speciﬁed. This time, ﬁll oil tank to upper mark on ﬁller cap/dipstick.

Figure 5-9. Instruments (Typical)

2005 PDI: Sportster Models 5-7

TIRES 5.6

FRONT AND REAR TIRES

1WARNING1WARNING

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)

1WARNING1WARNING

Harley-Davidson 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)

1. Check for proper front and rear tire pressures when tires are cold. Compare results against Tab le 5-3.

Table 5-3. Tire Pressures

TIRES SOLO RIDER

MODEL TIRE PSI kPA PSI kPA

All models Front 30 207 30 207 All models Rear 36 248 40 276

RIDER &

PASSENGER

5-8 2005 PDI: Sportster Models

BRAKE SYSTEM 5.7

8967

REAR BRAKE

1CAUTION

Direct contact with D.O.T. 5 brake ﬂuid can cause eye irritation, swelling, and redness. Avid eye contact. In case of eye contact ﬂush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake ﬂuid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a)

1. With vehicle upright (not on sidestand), check that ﬂuid level is between the upper and lower marks on reservoir. If brake ﬂuid level is low, add brake ﬂuid. See Sportster Models Service Manual. Use only D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. 99902-77: 12 oz., 99901-77: 1 gal.).

Figure 5-10. Rear Brake Master Cylinder

Remote Reservoir

2005 PDI: Sportster Models 5-9

DEALER ROAD TEST 5.8

ROAD TEST

After you complete motorcycle inspection, take motorcycle for a road test. Check all systems and overall operation of motorcycle: engine, transmission, clutch, brakes, handling, etc.

After road test, return motorcycle to shop, and thoroughly clean off any road dirt. Check and correct any problems you may have found during road test.

Before You Begin

Check the following items before road test of vehicle:

● Lamps and indicators.

● Check amount of gasoline in tank and add (if

needed).

● Adjust mirrors to proper riding positions.

● Check tire condition and pressure (adjust if neces-

sary).

● Check controls to verify proper function.

● Check all electrical equipment and switches includ-

ing stop lamp, turn signals and horn for proper operation.

Road Test of Vehicle: Low Speed

1. Shift from ﬁrst through third gear, checking clutch operation, throttle control, and transmission operation.

2. Verify low speed braking for front and rear brakes.

3. Handling under braking conditions.

4. Low speed handling. Verify that vehicle does not pull to left or right.

5. Check for any abnormal vibrations.

6. Check electrical lamps, indicators.

Road Test of Vehicle: Highway Speed

1. Shift from ﬁrst through ﬁfth gear, checking clutch operation, throttle control, and transmission operation.

2. Verify highway speed braking operation of front and rear brakes.

3. Verify proper handling at highway speeds.

4. Check for any abnormal vibrations.

● Program Security System (if equipped)

● Engine Oil:

Check and correct hot level.

● Clean Vehicle:

NOTE Be sure to submit a Dealer Product Quality Audit (DPQA) on ANY adjustments and/or warranty work performed required to deliver the vehicle to the customer.

5-10 2005 PDI: Sportster Models

CUSTOMER DELIVERY 5.9

NOTICE TO DEALER

Before delivering motorcycle to owner, perform the following:

1. Make sure vehicle owner receives, and is aware of importance of reading Owner’s Manual, safety booklets and viewing Welcome To The Family video included with owner’s kit.

2. Review warranties with vehicle owner. Make sure owner understands warranties. California dealers must give customer a copy of Emissions Control System Warranty.

3. Give IMPORTANT sheet and other printed material in literature kit to vehicle owner.

4. Complete and sign warranty registration form. Have vehicle owner sign it.

5. Explain operation of vehicle controls to vehicle owner.

6. Explain how turn signals and emergency ﬂashers operate.

IMPORTANT NOTE Make sure vehicle owner understands how to arm and disarm security system. Explain how to disarm security system with personal code if key fob is lost or not functioning. Personal code should be written on the tear-out card in the Sportster Models Owner’s Manual and kept on the owner’s person. Also, verify both key fobs operate properly.

7. Whenever possible, introduce dealer Service Manager to

vehicle owner, and involve Service Manager in delivery process. Supply owner with name(s) of dealer Service/ Parts Department personnel who should be contacted regarding vehicle service/parts questions.

8. Inform vehicle owner about checking engine oil level,

checking tire pressure, and performing other basic maintenance functions. Review the Initial Scheduled Main- tenance requirement with owner. Depending on owner’s anticipated frequency of operating motorcycle, you may wish to schedule the Initial Scheduled Maintenance service appointment at this time.

2005 PDI: Sportster Models 5-11

VEHICLE PDI CHECKLIST 5.10

PRIOR TO CUSTOMER DELIVERY

NOTE Use this checklist for performing tasks related to this model motorcycle setup.

❒ Uncrate:

Check for damaged or missing parts.

❒ Jiffy Stand:

Verify proper function.

❒ Note Any Additional Problems

(including cosmetic quality):

Perform Warranty repairs.

❒ Battery:

Perform required voltmeter test on Maxi-Fuse (main fuse) and battery.

❒ Install Maxi Fuse (main fuse). ❒ Install righthand mirror (XL 883L only). ❒ Lubrication System:

Inspect condition of oil lines.

❒ Engine Oil:

Verify oil is present (cold level).

❒ Primary Chaincase:

Check and verify lubricant is present.

❒ Fuel System:

Inspect fuel system for leaks.

❒ Evaporative Control System:

Inspect hose routings, connections and fuel tank venting to canister (if equipped).

❒ Lighting, Gauges, Electrical Systems:

Verify correct operation.

❒ Tires:

Inspect condition and air pressure.

❒ Brake Systems (front and rear):

Correct ﬂuid level (if necessary).

❒ Headlamps:

Inspect and adjust as necessary.

❒ Mirrors:

Inspect and adjust as necessary.

❒ Fuel Outlet valve and Hoses:

Verify operation and connections.

❒ Road Test Vehicle: Low Speed

a. Shift from ﬁrst through third gear, checking clutch

operation, throttle control, and transmission opera-

tion. b. Verify low-speed braking for front and rear brakes. c. Verify handling under braking conditions. d. Verify low-speed handling. Verify that vehicle does

not pull to left or right. e. Check for any abnormal vibrations. f. Check electrical lamps, indicators.

❒ Road Test Vehicle: Highway Speed

a. Shift from ﬁrst through ﬁfth gear, checking clutch

operation, throttle control, and transmission opera-

tion. b. Verify highway speed braking operation of front and

rear brakes. c. Verify proper handling at highway speeds. d. Check for any abnormal vibrations.

❒ Engine Oil:

Check and correct hot level.

❒ Create Vehicle Birth-Certiﬁcate Using

Digital Technician (optional).

❒ Clean Vehicle.

AT POINT OF CUSTOMER DELIVERY

❒ Suspension Adjustments. ❒ Shift Linkage Adjustment. ❒ Brake Hand Lever Adjustment. ❒ Review Vehicle Care and Maintenance Requirements.

NOTE Be sure to submit a Dealer Product Quality Audit (DPQA) on ANY adjustments and/or warranty work performed required to deliver t he vehicle to the customer.

5-12 2005 PDI: Sportster Models

PREDELIVERY: VRSC MODELS

SUBJECT PAGE NO.

6.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

2005 VRSC Models Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 Initial Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Battery Testing And Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Installing Maxi-Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Seats And Passenger Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.3 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6.5 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Indicator Lamps/Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6.6 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Front and Rear Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6.7 Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Rear Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6.8 Dealer Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6.9 Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Notice To Dealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6.10 Vehicle PDI Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Prior to Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

At Point of Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

VI

1

SPECIFICATIONS 6.1

TORQUE VALUES

The following torque values are included for fasteners that may be loosened and tightened during Predelivery and Setup. Any fasteners that are not loosened/removed do not need to be checked during Predelivery and Setup.

ITEM TORQUE NOTES

Front axle nut 68-75 Nm 50-55 ft-lbs

Rear axle nut 129-142.36 Nm 95-105 ft-lbs

All master cylinder cover screws 0.7-0.90 Nm 6-8 in-lbs

Battery terminal screws 6.8-10.9 Nm 60-96 in-lbs

Coolant air bleed plug 9-11 Nm 80-97 in-lbs

Radiator drain plug – – Hand-tighten

2005 VRSC MODELS SPECIFICATIONS

Table 6-1. Capacities

Component Metric English

Fuel tank total 14.0 liters 3.7 gal. Oil sump 4.3 liters 4.5 qt. Coolant 2.4 liters 2.54 qt.

2005 PDI: VRSC Models 6-1

INITIAL ASSEMBLY 6.2

BATTERY TESTING AND CHARGING

1WARNING1WARNING

Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, rubberized gloves and protective clothing when working with batteries. KEEP BATTERIES AWAY FROM CHILDREN. (00063a)

1WARNING1WARNING

Never remove warning label attached to top of battery. Failure to read and understand all precautions in warning could result in death or serious injury. (00064a)

1WARNING1WARNING

Battery posts, terminals and related accessories contain lead and lead components, chemicals known in the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. (00019a)

NOTES

● The engine is equipped with a compression release, so a

smaller (12 amp hour) battery provides adequate starting current.

● It will be necessary to remove the airbox cover to gain

access to the battery.

1. Place test probes of voltmeter on battery terminals and check the voltage of the battery to make sure it is at least

12.6 VDC.

2. If the open circuit (disconnected) voltage reading is 12.6 VDC or greater the battery is ready for use.

3. See Section 1. Mark the date on the battery warranty tag by removing the applicable month and year. Month and year punches may be removed with the point of a screwdriver without removing battery.

4. If the open circuit (disconnected) voltage reading is below 12.6 VDC, refer to Table 1-2, 12 amp-hour battery, in Section 1 and charge battery at rate and time speciﬁed.

5. Recheck battery voltage by repeating step 1 above. If voltage now is 12 VDC or greater, perform steps 2 and 3 above.

6. If the open circuit (disconnected) voltage reading is still below 12.6 VDC, the battery must be replaced. To

remove battery, air cleaner and air cleaner bottom must be removed. See appropriate Service Manual for

procedure.

IMPORTANT NOTE Only remove air cleaner and air cleaner bottom if battery could not be charged to 12.6 VDC and battery must be removed and replaced.

6-2 2005 PDI: VRSC Models