Harley Davidson Sportster 1200 Custom 2005 Owner's manual

Safety First

Safe Operating Rules: Sportster Models

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

Know and respect the rules of the road (see RULES OF THE ROAD section). Carefully read and observe the rules contained in the RIDING TIPS booklet accompanying this Owner's Manual. Read and familiarize yourself with the contents of the MOTORCYCLE HANDBOOK for your state. Before starting engine, check for proper operation of brake, clutch, shifter, throttle controls, correct fuel and oil supply.

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

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

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

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

Refuel in a well ventilated area with the engine turned off. Remove fuel filler cap slowly. Do not smoke or allow open flames or sparks when refueling or servicing the fuel system. Always close the fuel supply valve when the engine is not running. This prevents flooding of the carburetor and the surrounding area with gasoline. Do not fill fuel tank above the bottom of the filler neck insert. Leave air space to allow for fuel expansion.

2005 Sportster 1200 Custom - Owner's Manual

Do not store motorcycle with gasoline in tank within the home or garage where open flames, pilot lights, sparks or electric motors are present. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00003a)

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

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

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

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

A new motorcycle must be operated according to the special break-in procedure. See Break-in Riding Rules. Operate motorcycle only at moderate speed and out of traffic until you have become thoroughly familiar with its operation and handling characteristics under all conditions.

NOTE:

We recommend that you obtain information and formal training in the correct motorcycle riding technique. The Motorcycle Safety Foundation® offers beginning and advanced rider safety courses. Call (949)727-3227 for information.

Travel at speeds appropriate for road and conditions and never travel faster than posted speed limit. Excessive

speed can cause loss of vehicle control, which could result in death or serious injury. (00008a)

Do not exceed the legal speed limit or drive too fast for existing conditions. Always reduce speed when poor driving conditions exist. High speed increases the influence of any other condition affecting stability and increases the possibility of loss of control. Pay strict attention to road surfaces and wind conditions. Any two wheeled vehicle may be subject to upsetting forces such as wind blasts from passing trucks, holes in the pavement, rough road surfaces, rider control error, etc. These forces may influence the handling characteristics of your motorcycle. If this happens, reduce speed and guide the motorcycle with a relaxed grip to a controlled condition. Do not brake abruptly or force the handlebar. This may aggravate an unstable condition. Keep cargo weight concentrated close to the motorcycle and as low as possible to minimize the change in the motorcycle's center of gravity. Distribute weight evenly on both sides of the vehicle and do not load bulky items too far behind the rider or add weight to the handlebars or front forks. Do not exceed maximum specified load in each saddlebag.

NOTE:

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

Operate your motorcycle defensively. Remember, a motorcycle does not afford the same protection as an automobile in an accident. One of the most common accident situations occurs when the driver of the other vehicle fails to see or recognize a motorcycle and turns left into the on-coming motorcyclist. Operate only with headlamp on. Wear an approved helmet, clothing, and foot gear suited for motorcycle riding. Bright or light colors are best for greater visibility in traffic, especially at night. Avoid loose, flowing garments and scarves.

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

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

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

Protect your motorcycle against theft. After parking your motorcycle, lock the steering head and remove ignition key from switch. Set security alarm if present. Safe motorcycle operation requires alert mental judgment combined with a defensive driving attitude. Do not allow fatigue, alcohol or drugs to endanger your safety or that of others. Vehicles equipped with a sound system should have the volume adjusted to a nondistracting level before operating vehicle. Maintain your motorcycle in proper operating condition in accordance with Regular Service

Intervals: 2005 Sportster Models. Particularly important to motorcycle stability is proper tire inflation pressure, tread condition, and proper adjustment of wheel bearings and steering head bearings.

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

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

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

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

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

See a Harley-Davidson service manual for proper torque values. Aftermarket fasteners may not have the specific property requirements to perform properly.

883cc and 1200cc Harley-Davidson motorcycles have a plugged carburetor overflow fitting. The fuel supply valve on the vehicle should be turned off when the vehicle is not

operating. Failure to do so may result in fuel drainage into the engine, dilution of the engine oil and engine damage. (00146b)

Be sure tires are properly inflated, balanced and have adequate tread. Inspect your tires regularly and see a Harley-Davidson dealer for replacements. Riding with excessively worn, unbalanced or under-inflated tires can adversely affect stability and handling, which could result in death or serious injury. (00014a)

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

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

GVWR is the sum of the weight of the motorcycle, accessories, and the maximum weight of the rider, passenger and cargo that can be safely carried. The GVWR is shown on the information plate, located on the frame steering head.

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

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

Direct contact of D.O.T. 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)

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

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

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

California vehicles, equipped with Evaporative Emission controls, have a plugged carburetor overflow fitting. The fuel supply valve on the vehicle should be turned off when the vehicle is not operating. Failure to do so may result in fuel drainage into the engine, dilution of the engine oil and engine damage. (00145a)

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

Rules of the Road

Keep to the right side of the road centerline when meeting other vehicles coming in the opposite direction. Ride to left of center of your lane to avoid oily pavement ahead. Always sound your horn, actuate your turn signals, and exercise caution when passing other

vehicles going in the same direction. Never try to pass another vehicle going in the same direction at street intersections, on curves, or when going up or down a hill. At street intersections give the right-of-way to the vehicle on your right. Do not presume you have the right-of-way, as the other driver may not know it is your turn. Always signal when preparing to stop, turn or pass. All traffic signs, including those used for the control of traffic at intersections, should be obeyed promptly. SLOW DOWN signs near schools and CAUTION signs at railroad crossings should always be observed and your actions governed accordingly. When intending to turn to the left, signal at least 100 feet (30.5 meters) before reaching the turning point. Move over to the centerline of the street (unless local rules require otherwise), slow down, enter the intersection of the street and then turn carefully to the left. Never anticipate a traffic light. When a change is indicated from GO to STOP (or vice versa) in the traffic control systems at intersections, slow down and wait for the light to change. Never run through a yellow or red traffic light. While turning either right or left, watch for pedestrians, animals, as well as vehicles. Do not leave the curb or parking area without signaling. Be sure your way is clear to enter moving traffic. A moving line of traffic always has the right-of-way. Be sure your license plate is installed in the position specified by law and is clearly visible at all times. Keep the plate clean. Ride at a safe speed that is consistent with the type of highway you are on. Pay strict attention to whether the road is dry, oily, icy or wet. Watch for debris such as leaves or loose gravel. Weather and traffic conditions on the highway dictate adjusting your speed and driving habits accordingly.

Accessories and Cargo

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

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

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

Accessory and Cargo Guidelines

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

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

Do not exceed the legal speed limit or drive too fast for existing conditions. Always reduce speed when poor driving conditions exist. High speed increases the influence of any other condition affecting stability and increases the possibility of loss of control. Pay strict attention to road surfaces and wind conditions. Any two wheeled vehicle may be subject to upsetting forces such as wind blasts from passing trucks, holes in the pavement, rough road surfaces, rider control error, etc. These forces may influence the handling characteristics of your motorcycle. If this happens, reduce speed and guide the motorcycle with a relaxed grip to a controlled condition. Do not brake abruptly or force the handlebar. This may aggravate an unstable condition. Keep cargo weight concentrated close to the motorcycle and as low as possible. This minimizes the change in the motorcycle's center of gravity. Distribute weight evenly on both sides of the vehicle. Do not load bulky items too far behind the rider or add weight to the handlebars or front forks. Do not exceed maximum specified load in each saddlebag. Luggage racks are designed for lightweight items. Do not overload racks. Be sure cargo is secure and will not shift while riding and recheck the cargo periodically. Accessories that change the operator's riding position may increase reaction time and affect handling of the motorcycle. Additional electrical equipment may overload the motorcycle's electrical system possibly resulting in electrical system and/or component failure.

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

(00022a)

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

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

Identification

2005 Sportster Models

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

NOTE:

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

1. Fuel supply valve

2. Enrichener knob

3. Battery (under left side cover)

4. Fuse block holder

5. Rear master cylinder

6. Rear brake reservoir

7. Clutch inspection cover

8. Primary chain inspection cover

9. Engine oil filter

2005 Sportster XL1200C Custom - Left Side View

1. Engine oil fill plug and dipstick

2. Air cleaner

3. Front brake master cylinder and reservoir

4. Speedometer

5. Fork lock

6. Ignition/headlamp key switch

2005 Sportster XL1200C Custom - Right Side View

1. Fuel supply valve

2. Enrichener knob

3. Battery (under left side cover)

4. Fuse block holder

5. Rear master cylinder

6. Rear brake reservoir

7. Clutch inspection cover

8. Primary chain inspection cover

9. Engine oil filter

2005 Sportster XL1200R Roadster - Left Side View

1. Engine oil fill plug and dipstick

2. Air cleaner

3. Front brake master cylinder and reservoir

4. Speedometer

5. Fork lock

6. Ignition/headlamp key switch

2005 Sportster XL1200R Roadster - Right Side View

1. Fuel supply valve

2. Enrichener knob

3. Battery (under left side cover)

4. Fuse block holder

5. Rear master cylinder

6. Rear brake reservoir

7. Clutch inspection cover

8. Primary chain inspection cover

9. Engine oil filter

2005 Sportster XL883 - Left Side View

1. Engine oil fill plug and dipstick

2. Air cleaner

3. Front brake master cylinder and reservoir

4. Speedometer

5. Fork lock

6. Ignition/headlamp key switch

2005 Sportster XL883 - Right Side View

1. Fuel supply valve

2. Enrichener knob

3. Battery (under left side cover)

4. Fuse block holder

5. Rear master cylinder

6. Rear brake reservoir

7. Clutch inspection cover

8. Primary chain inspection cover

9. Engine oil filter

2005 Sportster XL883R - Left Side View

1. Engine oil fill plug and dipstick

2. Air cleaner

3. Front brake master cylinder and reservoir

4. Speedometer

5. Fork lock

6. Ignition/headlamp key switch

2005 Sportster XL883R - Right Side View

1. Fuel supply valve

2. Enrichener knob

3. Battery (under left side cover)

4. Fuse block holder

5. Rear master cylinder

6. Rear brake reservoir

7. Clutch inspection cover

8. Primary chain inspection cover

9. Engine oil filter

2005 Sportster XL883C Custom - Left Side View

1. Engine oil fill plug and dipstick

2. Air cleaner

3. Front brake master cylinder and reservoir

4. Speedometer

5. Fork lock

6. Ignition/headlamp key switch

2005 Sportster XL883C Custom - Right Side View

1. Fuel supply valve

2. Enrichener knob

3. Battery (under left side cover)

4. Fuse block holder

5. Rear master cylinder

6. Rear brake reservoir

7. Clutch inspection cover

8. Primary chain inspection cover

9. Engine oil filter

2005 Sportster XL883 Low - Left Side View

1. Engine oil fill plug and dipstick

2. Air cleaner

3. Front brake master cylinder and reservoir

4. Speedometer

5. Fork lock

6. Ignition/headlamp key switch

2005 Sportster XL883 Low - Right Side View

Vehicle Identification Number

See V.I.N. Stamping Location. The full 17 digit serial or Vehicle Identification Number (V.I.N.) is stamped on the steering head and on a label located on the right front frame down tube.

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

NOTE:

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

V.I.N. Stamping Location

1. Market designation (1 character)

2. Manufacturer (2 characters)

3. Motorcycle type (1 character)

4. Model (2 characters)

5. Engine type (1 character)

6. Introduction date (1 character)

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

8. Model year (1 character)

9. Assembly plant (1 character)

10. Sequential number (6 characters)

Typical Harley-Davidson Vehicle Identification Number

2005 Harley-Davidson Sportster V.I.N. Breakdown

POSITION DESCRIPTION POSSIBLE VALUES

1 Market designation 1=Domestic

5=International

2 Manufacturer HD=Harley-Davidson

3 Motorcycle type 1=Heavyweight motorcycle

4 Model see model V.I.N. table

5 Engine type M=883cc

P=1200cc

6 Introduction date varies

7 V.I.N. check digit Can be 0-9 or X

8 Model year 5=2005

9 Assembly plant Y=York, PA

K=Kansas City, MO

10 Sequential number varies

2005 Sportster V.I.N. Model Codes

CODE MODEL NAME

CA XL883

CJ XL883C Custom

CM XL883 Low

CK XL883R

CL XL1200R Roadster

CG XL1200C Custom

Specifications

Specifications: 2005 Sportster Models

Ignition System: 2005 Sportster Models

COMPONENT SPECIFICATION

Ignition timing not adjustable

Battery 12 volt, 12 amp/hr,

sealed and maintenance free

Spark plug type HD-6R12

Spark plug size 12 mm

Spark plug gap 0.038-0.043 in. 0.97-1.09 mm

Spark plug torque 12-18 ft-lbs 16.3-24.4 Nm

Transmission Specifications

TRANSMISSION SPECIFICATION

Type Constant mesh, foot shift

Speeds 5 forward

Engine: 2005 Sportster Models

ITEM 883

MODELS

1200

MODELS

Number of cylinders 2

Type 4-cycle, 45 degree

V-Type, air cooled

Compression ratio 8.9-1 9.7-1

Bore 3.00 in.

(76.20 mm)

3.50 in.

(88.85 mm)

Stroke 3.81 in.

(96.82 mm)

3.81 in.

(96.82 mm)

Displacement 53.86 cu. in.

(883 cc)

73.20 cu. in.

(1200 cc)

Torque 51.0 ft-lbs

(69.0 Nm)

@ 4300 RPM

79.0 ft-lbs

(107.0 Nm)

@ 3500 RPM

Sprocket Teeth: 2005 Sportster Models

DRIVE ITEM NUMBER OF TEETH

883 MODELS 1200 MODELS

U.S.

MODELS

WORLD

MODELS

U.S.

MODELS

WORLD

MODELS

Primary Engine 34 38 38 38

Clutch 57 57 57 57

Final Transmission 28 28 29 30

Rear wheel 68 68 68 68

Overall Gear Ratios: 2005 Sportster Models

GEAR 883 MODELS 1200 MODELS

U.S.

MODELS

WORLD

MODELS

U.S.

MODELS

WORLD

MODELS

1st 10.944 9.792 9.454 9.139

2nd 7.524 6.732 6.500 6.283

3rd 5.834 5.220 5.040 4.872

4th 4.806 4.301 4.152 4.014

5th 4.071 3.643 3.517 3.400

Tire Sizes: 2005 Sportster Models

MODEL MOUNT SIZE NUMBER

XL883, XL883R, XL883 Low, XL1200R front 19 in. D401F 100/90-19

XL883C, XL1200C front 21 in. D402F MH90-21

All rear 16 in. D401 150/80B16

Tire Pressures: 2005 Sportster Models

MODEL LOAD TIRE PRESSURE (COLD)

FRONT REAR

PSI kPa PSI kPa

All solo rider 30 206 36 248

rider and passenger 30 206 40 275

2005 vehicles use Dunlop Harley-Davidson tires only.

Bulb Chart: 2005 Sportster Models

LAMP DESCRIPTION

(ALL LAMPS 12 VOLT)

BULBS

REQUIRED

CURRENT

DRAW

(AMPERAGE)

HARLEY-

DAVIDSON

PART NUMBER

Headlamp high beam/low beam 1 4.58/5.0 68329-03

position lamp international

1 0.32 53438-92

Tail and stop lamps

tail lamp 1 0.59 68167-04

stop lamp 1 2.10 68167-88

tail lamp international 1 0.59 68167-88

stop lamp international 1 2.10 68167-88

Turn signal lamp front/running 2 2.25/0.59 68168-89

front international 2 1.75 68163-84

rear 2 2.25 68572-64B

rear international 2 1.75 68163-84

Instrument panel Illuminated with LEDs. Replace entire assembly upon failure.

Dimensions: 2005 Sportster Models

ITEM XL1200C

CUSTOM

XL1200R

ROADSTER

XL883

XL883R

XL883C

CUSTOM

XL883 LOW

IN. MM IN. MM IN. MM IN. MM IN. MM

Wheel base 60.4 1534.2 60.0 1524 60.0 1524 60.4 1534.2 60.0 1524

Overall length 90.3 2293.6 90.1 2288.5 90.1 2288.5 90.3 2293.6 90.1 2288.5

Overall width 32.7 830.6 36.7 932.2 32.7 830.6 32.7 830.6 32.7 830.6

Road clearance 4.4 111.8 5.6 141 5.6 141 4.4 111.8 4.4 111 .8

Overall height 45.7 116 0.8 49.2 1249.7 44.8 113 7.9 45.7 116 0.8 44.8 1137. 9

Saddle height 26.3 668 28.1 713.7 27.3 693.4 26.3 668 26.0 660.4

Capacities: 2005 Sportster Models

ITEM XL1200C

CUSTOM

XL1200R

ROADSTER

XL883

XL883R

XL883C

CUSTOM

XL883 LOW

U.S. LITERS U.S. LITERS U.S. LITERS U.S. LITERS U.S. LITERS

Fuel tank

(total)

4.5 gal.

17.0 3.3 gal.

12.5 3.3 gal.

12.5 4.5 gal

17.0 3.3 gal.

12.5

Fuel tank

(reserve)

1.0 gal.

3.8 0.8 gal.

3.0 0.8 gal.

3.0 1.0 gal.

3.8 0.8 gal.

3.0

Oil tank with filter

3.6 qt. 3.4 3.6 qt. 3.4 3.6 qt. 3.4 3.6 qt. 3.4 3.6 qt.

3.4

Transmission

(approximate)

32 oz. 0.95 32 oz. 0.95 32 oz. 0.95 32 oz. 0.95 32

oz.

0.95

Weights: 2005 Sportster Models

ITEM XL1200C

CUSTOM

XL1200R

ROADSTER

XL883

XL883R

XL883C

CUSTOM

XL883 LOW

LB. KG LB. KG LB. KG LB. KG LB. KG

Weight (as shipped from factory) 575 261 577 262 574 261 579 263 574 261

GVWR 1000 454 1001 454 999 454 1001 454 999 454

GAWR front 329 149 335 152 335 152 335 152 335 152

GAWR rear 671 305 666 302 664 301 666 302 664 301

NOTE:

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

Tire Data

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

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

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

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

Tubeless tires are used on all Harley-Davidson cast and disc wheels.

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

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)

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)

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

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

Gasoline Blends

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

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

Gasoline containing METHYL TERTIARY BUTYL ETHER (MTBE): Gasoline/MTBE blends are a mixture of gasoline and as much as 15% MTBE. Gasoline/MTBE blends can be used in your motorcycle. ETHANOL is a mixture of 10% ethanol (Grain alcohol) and 90% unleaded gasoline. Gasoline/ethanol blends can be used in your motorcycle if the ethanol content does not exceed 10%. REFORMULATED OR OXYGENATED GASOLINES (RFG): Reformulated gasoline is a term used to describe gasoline blends that are specifically designed to burn cleaner than other types of gasoline, leaving fewer tailpipe emissions. They are also formulated to evaporate less when you are filling your tank. Reformulated gasolines use additives to oxygenate the gas. Your motorcycle will run normally using this type of gas and HarleyDavidson recommends you use it when possible, as an aid to cleaner air in our environment.

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

Fuel

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

Avoid spills. Slowly remove filler cap. Do not fill above bottom of filler neck insert, leaving air space for fuel expansion. Secure filler cap after refueling. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00028a)

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

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

Octane Ratings: Sportster Models

VEHICLE PUMP OCTANE

(R + M)/2

883 Models 87 (91 RON)

1200 Models 91 (95 RON)

Catalytic Converters

California and all international motorcycles are equipped with catalytic converters.

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

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

Controls and Indicators

General: Controls and Indicators

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

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

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

Ignition/Headlamp Key Switch: Sportster Models

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)

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

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

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

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

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

Turn the ignition switch to the OFF position and remove the key before locking the motorcycle. Leaving the key in the ACC position will keep the instrument lights on and result in a discharged battery. (00155a)

Turn key counterclockwise to remove from the ignition. Refer to Ignition/Headlamp Switch Positions: 2005 Sportster Models for all key switch functions.

NOTES:

ACC-Accessories and hazard warning flasher can be turned on. Instrument lamps are on. Brake lamp and horn can be activated. Key may not be removed. The lamps work when the switch is in the IGNITION position, as required by law in some localities.

Ignition/Headlamp Key Switch: Sportster Models

Ignition/Headlamp Switch Positions: 2005 Sportster Models

LOCATION

AND

OPERATION

SWITCH

POSITION

FUNCTION

Switch is on right side of steering neck.

Push in and turn key to operate.

OFF Ignition and lamps are off. Key may be removed.

ACC* Accessories and hazard warning flasher can be turned on.

Instrument lamps are on. Brake lamp and horn can be activated. Key may be removed except for international models.

IGNITION* Ignition and lamps are on.

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

Hand Controls: Basic Operation

Electric Starter Switch

NOTE:

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

See Handlebar Controls. The electric starter switch is located on the right handlebar control

group. See Starting the Engine: Carbureted Models for detailed operation procedures.

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

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

Engine OFF/RUN Switch

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

NOTES:

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

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

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

Throttle Control Grip

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

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

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

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

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

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

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

NOTE:

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

Clutch Hand Lever

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

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

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

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

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

Horn Switch

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

Headlamp Dimmer Switch

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

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

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

Turn Signal Switches

Each handlebar control group contains a turn signal switch.

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

NOTE:

Front turn signal lamps also function as running lamps.

1. Clutch hand lever

2. Horn switch

3. Headlamp dimmer switch

4. Left turn signal switch

5. Master cylinder reservoir

6. Electric starter switch

7. Engine off/run switch

8. Brake hand lever

9. Throttle control grip

10. Throttle friction adjusting screw

11. Right turn signal switch

Handlebar Controls

Turn Signal Switch Operation

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

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

NOTES:

If you want the turn signals on longer, hold the switch in. The turn signals will begin flashing immediately, but the microprocessor will not begin computing distance until you release the switch. If you are signaling to turn in one direction and you depress the switch for the opposite turn signal, the first signal is cancelled and the opposite side begins flashing. If you want to stop the lamps from flashing, briefly depress the turn signal switch a second time. The turn signal lamps will stop flashing.

Hazard Warning 4-Way Flasher

Use the following method to activate the four-way flashers.

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

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

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

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

Indicator Lamps

See Indicator Lamps. Five indicator lamps are provided.

The green TURN indicators will flash when turn signals are activated; therefore, flashing indicates the chosen turn direction. When the 4-way hazard flashers are operating, both turn indicators will flash simultaneously. The blue BEAM indicator lamp, when lit, signals high beam headlamp operation. The green NEUTRAL lamp, when lit, signals the transmission is in neutral gear. The red OIL indicator lamp, when lit, signals that oil is not circulating through the engine.

NOTE:

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

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

If the oil pressure indicator lamp does not go off at speeds above idling, it is usually because of an empty oil tank or diluted oil. In freezing weather the oil feed may clog with ice and sludge, preventing oil circulation. A grounded oil signal switch wire. A faulty signal switch. A damaged or improperly installed check valve. Trouble with the pump.

If the oil pressure indicator lamp remains lit, always check the oil supply first. If the oil supply is normal and the lamp is still lit, stop the engine at once and do not ride further until the trouble is located and the necessary repairs are made. Failure to do so may result in engine damage. (00157a)

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