2005 HARLEY-DAVIDSON MOTORCYCLE PREDELIVERY AND SETUP MANUAL

GENERAL

I

TOURING

II

DYNA

III

The information in this Manual applies to all 2005 motorcycle models manufactured by Harley-Davidson Motor Company.

SOFTAIL

IV

SPORTSTER
© 2004 H-D All RIGHTS RESERVED Printed in the U.S.A.

V

VRSC
VISIT THE HARLEY-DAVIDSON WEB SITE http://www.harley-davidson.com

VI

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

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.

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® products. If you have any questions regarding Loctite product usage or retailer/wholesaler locations, please call Loctite Corp. at 1-800-323-5106.

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

CONTENTS
All photographs, illustrations and procedures may not necessarily depict the most current model or component, but are based on the latest production information available at the time of publication. Since product improvement is our continual goal, HarleyDavidson reserves the right to change specifications, equipment or designs at any time without notice and without incurring obligation.

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.

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

WARNINGS AND CAUTIONS 1WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. (00119a)

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

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TABLE OF CONTENTS SECTION I II III IV V VI VII SUBJECT General Information: All Models Predelivery Inspections: Touring Models Predelivery Inspections: Dyna Models Predelivery Inspections: Softail Models Predelivery Inspections: Sportster Models Predelivery Inspections: VRSC Models Predelivery Inspections: CVO* Models *Custom Vehicle Operations PAGE NUMBER 1-1 2-1 3-1 4-1 5-1 6-1 7-1 v .

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. . . . . . . . . . . . . . Removing Vehicle From Pallet . . . . .2 System Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handlebar Installation–FLSTSC. . . . . . . . . . . . . . . . . . .I PREDELIVERY: ALL MODELS SUBJECT PAGE NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltmeter Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Brake Hand Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Hand Lever . . . . . . Uncrating Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date Of Manufacture Code . . . . . . . . . . . . . . . . . . . . . . . Adjusting Handlebars–All Models . . . . . . . . . . . . . . . . Cosmetic Quality . . . Front Brake Master Cylinder Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. . . . . . . . Removing Cardboard Carton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Cleanup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning Label Placement (All Vehicles Sold Outside of the United States) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Returning Steel Pallets . . . . . . . . . . . . . . . . . Charging Battery . . . . . . . . . . Vehicle Crate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance-Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . .1 Uncrating and General Setup: All Models . . . . . . . . 1-1 1-1 1-1 1-1 1-2 1-5 1-10 1-12 1-13 1-13 1-14 1-14 1-14 1-15 1-16 1-16 1-16 1-18 1-19 1-19 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLSTN and FXDWG Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Using a box cutter. Remove Uprights from Pallet 4. Figure 1-2. Failure to do so can cause damage to motorcycle.1 UNCRATING AND GENERAL SETUP: ALL MODELS VEHICLE CRATE INSPECTION Inspect each crate for external damage while it is still on delivery truck. Open top carton flaps. 8796 Figure 1-3. DO NOT remove uprights before removing carton. NOTE All Harley-Davidson motorcycles are shipped in crates using returnable steel pallets. Remove both uprights (VRSC. Open plastic bag enclosing motorcycle and push it down off motorcycle. Refer to HARLEYDAVIDSON/BUELL WARRANTY MANUAL. DYNA and some SOFTAIL models are shipped with the front wheel turned to the left or right in a “turn-wheel” crate. 2. FLST and FLSTC crates have three uprights) by lifting upward. 10426 UNCRATING VEHICLE CAUTION Use caution when removing cardboard carton from pallet. Crates have widths of 29 in. Set uprights aside for recycling. See Figure 1-1. Removing the shipping crate is similar on all models so the procedure given below is typical for all models.7 cm) and 43 in. SPORTSTER. The steel pallets have fork openings 2x7 in. Call your SPOC representative if you have questions regarding steel pallet return. cut one end of the cardboard carton. “SHIPPING DAMAGE PROCEDURE” for complete information on filing claims for damaged and over/short freight. 3. The VRSC.8 cm) at the front and sides. Open crate and inspect motorcycle for damage before truck leaves your dealership. Use a T-20 bit and an electric or air powdered drill/driver to remove all fasteners from cardboard carton. Figure 1-1. Slide carton away from pallet as shown.2 cm) and all are 50 in. Removing Screws 2005 PDI: All Models 1-1 . Set carton aside for recycling. (5.1 See Figure 1-2. (127 cm) high. (109. Remove protective tape and elastic protective netting. 8798 REMOVING CARDBOARD CARTON 1. from chrome and painted parts of motorcycle. Remove Cardboard Carton from Pallet. (73. See Figure 1-3.1x17. if present. 1.

HANDLEBAR INSTALLATION– FLSTSC.NOTE Always install/adjust handlebars before removing motorcycle from pallet. submit warranty claim form.g. 10039). 4. 2. Retain the four bolts. Failure to pump brake lever could result in an inoperable front brake which could result in death or serious injury.) and pump brake lever 3-4 times before moving motorcycle from pallet. 1WARNING Some motorcycles are shipped with the hand brake lever wrapped tight against the hand grip. 1WARNING The automatic-on headlamp feature provides increased visibility for riders. secure with riser caps and riser bolts. verify your receipt of all separate items by comparing with parts list in shipping crate. 6. FLSTN AND FXDWG MODELS and ADJUSTING HANDLEBARS– ALL MODELS. or federal regulations. remove the riser bolts (2) securing handlebar shipping cradle (1) to risers. 5. While holding the handlebar shipping cradle. 6. 8. 7. 1WARNING Do not alter or disable any device or system to circumvent local. Insert the clutch cable into the retaining clip on the left frame downtube. If vehicle has damage which appears to have occurred at the factory. Remove and discard protective block (4) from left handlebar grip. 3. 2. cut cable straps (3). FLSTSC 3 5 1-2 2005 PDI: All Models .3 Nm) in the sequence given. adjust the handlebars and tighten the riser bolts to 12-15 ft-lbs (16. discard washers. Accurately describe damage and cause. XL 883L and XL 1200R Models procedure. Softail. 5. FLSTN AND FXDWG MODELS FLSTSC After removing carton and protective plastic wrap: 1. 3. Position handlebar on top of risers. Push the four plastic wire retainers on the handlebar switch conduits into the holes in the handlebars. See HANDLEBAR INSTALLATION–FLSTSC. Low visibility of rider can result in death or serious injury. Replace any broken wire retainers. Be sure headlamp is on at all times. XL 883. 10612 1 pd0171 WARNING: PUMP BRAKE LEVER 3-4 TIMES BEFORE USING BRAKES Figure 1-4. While holding handlebars. Route handlebar switch conduits between and behind risers. All safety and environmental devices or systems must be left intact as designed and built at the factory.–“Found nail in tire.3-20. See Figure 1-5. Discard cradle and cable straps. 2 4 Handlebar shipping cradle Riser bolt (4) Cable strap (4) Protective block Protective pad Figure 1-5. Tampering with safety and environmental devices or systems could result in death or serious injury.”) Supply proper failure code(s). Attach hand control and directional wire harnesses to handlebar risers with cable straps (Part No. Following the Dyna Glide. caused tire to go flat. 5. See ADJUSTING HANDLEBARS– ALL MODELS and Figure 1-10. Remove plastic wrap and warning label (see Figure 1-4. (00030a). Warning Label 1. state. (e. 4. If uninstalled parts are in crate.

FLSTN 8.7 Nm). Install front brake line (1) in clamps (2). 6. Following the Dyna Glide. Retain the bolts. See Figure 1-6. 3. 5. Front brake line Clamp (2) Screw (2) Fork stem cover Clamp Screw Figure 1-7.6 Nm). 7. Remove and discard cloth tie (3) securing handlebar. Install brake line in clamp (5) in underside of lower fork clamp. Shipping clamp Riser bolts Cloth tie Protective block Figure 1-6. 10614 3 1 4 3. Attaching Front Brake Line–FLSTN 9. XL 883L and XL 1200R Models procedure. Insert the clutch cable into the retaining clip on the left frame downtube. Tighten screws to 30-50 in-lbs (3.3-20. 5 10613 1 6 2 10615 3 4 1. 2.9-13. Position handlebar on top of the risers and secure with riser caps. inboard of screws (3) and attach to fork stem cover (4). 2. 5. Remove the riser bolts (2) and shipping clamp (1) from handlebar risers. 4. XL 883. 4. Replace any broken wire retainers. 2005 PDI: All Models 1-3 . Softail.4-5. Push the four plastic wire retainers on the handlebar switch conduits into the holes in the handlebars.3 Nm) in the sequence given. Tighten screw (6) to 96-120 in-lbs (10. adjust the handlebars and tighten the riser bolts to 12-15 ft-lbs (16. 4. Remove and discard protective block (4) from right handlebar grip. 3. 3 2 6. 2. See ADJUSTING HANDLEBARS– ALL MODELS and Figure 1-10. 1. See Figure 1-7. Route handlebar switch conduits between and behind risers.FLSTN After removing carton and protective plastic wrap: 1. and bolts removed in step 2.

XL 883. 4.FXDWG After removing carton and protective plastic wrap: 1. 6. Softail. 5.4 Nm) in the sequence given. See Figure 1-9. 5. 2. adjust the handlebars and tighten the riser bolts to 12-18 ft-lbs (16. Position brake line inboard from fastener.4-6. Remove and discard cloth tie (1) securing handlebar. Following the Dyna Glide. FXDWG Brake Line and Ground Wire 1. Remove the four bolts (2) from the riser. Retrieve riser caps from passenger backrest. 7. Cloth tie Riser bolts (4) Shipping clamps Protective block Figure 1-8.8 Nm). 6052 6062 1 3 2 6059 1 4 2 6053 3 4 1 1. XL 883L and XL 1200R Models procedure. 2. See Figure 1-8. Position the handlebar on top of the risers and fasten the riser caps in place using the bolts removed in step 2. Clamp Screw 5 2 Figure 1-9. Retain the four bolts. Tighten fastener to 30-60 in-lbs (3. 4.3-24. Attach brake line (2) and ground wire (3) on upper triple clamp with clamp (1). Clamp Brake line Ground wire 4. See ADJUSTING HANDLEBARS– ALL MODELS and Figure 1-10. 3. Reroute the left hand switch wire conduit from between the riser to a position in front of the riser. 2. 3. FXDWG 1-4 2005 PDI: All Models . 3.

4 Nm). Attach brake line as shown before removing motorcycle from pallet.3 Nm). 3. Doing so may result in damage to handlebar or clamp. Replace any broken wire retainers. XL 883L and XL 1200R Models 1. Softail models: tighten front screws (4) to 12-15 ft-lbs (16. 5. Remove shipping clamps (3) from the handlebar. If customer requests changing handlebar position.3-24. Remove protective block (4) on throttle. XL 883L. b. 11. Lower clamp (2) Cast-in spacers (2) Rear screw (2) Front screw (2) Instrument bracket (if equipped) Upper clamp Figure 1-10.3-24. maintaining equal gaps between upper and lower clamps front to back. Softail models: tighten rear screws to 12-15 ft-lbs (16. See Figure 1-10.3 Nm). postpone adjustment until customer has checked their position. 3.CAUTION See Figure 1-9. c. Raise handlebars to normal riding position and hold in position. verify that equal amounts of knurled areas on handlebar protrude from outboard sides of upper handlebar clamp. 8. 4.9-13.3-20. See Figure 1-8.4 Nm). 5. Install clutch cable in clip on left downtube. Install the plastic wire retainers on the handlebar switch conduits and push into the holes in the handlebars. ADJUSTING HANDLEBARS– ALL MODELS General CAUTION Never adjust handlebars using excessive force. c. XL 1200R. 2. To be sure handlebars are properly centered. Before removing motorcycle from pallet. Models without cast-in spacers in upper clamps: a.3-24. Softail models: final tighten rear screws to 12-15 ft-lbs (16. Loosen four screws (3 and 4) of handlebar upper clamp (6). Dyna and Sportster models: tighten front screws to 12-18 ft-lbs (16. Discard shipping clamps and protective block. b.3 Nm). Tighten two rear screws (3) until cast-in spacers contact handlebar lower clamps (1).320. Dyna and Sportster models: final tighten rear screws to 12-18 ft-lbs (16. Tighten to 96-120 in-lbs (10. pd0031d Tighten first 4 5 3 6 9. Dyna Glide. NOTE If handlebars are positioned for a rider of normal size. Dyna and Sportster models: tighten front screws (4) to 12-18 ft-lbs (16.4 Nm). it could be pinched and damaged in front fork stop. knurled areas of handlebar will be completely hidden by upper handlebar clamp and will not be visible at all when handlebar is centered properly. Softail.3 Nm). Softail models: tighten front screws to 12-15 ft-lbs (16. Slight gap between upper and lower clamps should exist at front. perform the adjustment before delivering the motorcycle to the customer.3-20. 6. If brake line is not secured. Models with cast-in spacers (2) in upper clamp: a. 2.4 Nm). 2 1 FRONT 1. 4. Dyna and Sportster models: tighten rear screws to 12-18 ft-lbs (16.3-24. Dyna Glide and Some Softail Models 10. adjust handlebars according to the following procedures: NOTE On some models.6 Nm).3-20. XL 883. Attach brake line to bottom of steering stem with clamp (4) and screw (5). Always center the handlebar laterally (sideways) in the handlebar clamps. Tighten all four screws finger-tight. 2005 PDI: All Models 1-5 . XL 883.

XL 1200C. Lower clamp (2) Upper clamp (2) Rear screw (2) Front screw (2) Figure 1-12. Check torque on front handlebar clamp screws. Loosen two rear screws (3) of handlebar upper clamps (2). To be sure handlebars are properly centered. 7. FLHTCU and FLHTP 1. 6. Remove ignition switch knob and inner fairing cap according to appropriate Touring Models Service Manual instructions.4 Nm).7 Nm). If there is a gap between either handlebar lower clamp (1) and upper clamp at front. Tighten screws to 12-16 ft-lbs (16. 4. See Figure 1-12. pd0021a See Figure 1-11. 3. 5.4 Nm). Tighten rear screws to 12-16 ft-lbs (16. 2 4 4 2 3 3 1 FRONT 1. 3. ). verify that equal amounts of knurled areas on handlebar protrude from outboard sides of upper handlebar clamp. Tighten first 1 pd0031f 2. knurled areas of handlebar will be completely hidden by upper handlebar clamp and will not be visible at all when handlebar is centered properly. hold in position. NOTE On some models. Tighten two front screws (1) to 12-18 ft-lbs (16. Raise handlebars to normal riding position. FLHT/C/U and FLHTP Models 4. To be sure handlebars are properly centered.324. tighten front screw (4) only enough to close gap. 2. 3.3-24. Loosen four screws (1. 2. Raise handlebars to normal riding position. Front screw (2) Rear screw (2) Upper clamp Lower clamp FRONT 1. verify that equal amounts of knurled areas on handlebar protrude from outboard sides of both handlebar clamps. loosen rear screws until they do. 2) of handlebar upper clamp (3). Slight gap should exist between upper and lower clamps at rear. 3. FLHT.XL 883C and XL 1200C Models 1. Tighten rear screws (2) to 12-18 ft-lbs (16. Reinstall inner fairing cap and ignition switch knob according to appropriate Touring Models Service Manual instructions.3-21.3-21. If handlebars do not move up and down freely. 1-6 2005 PDI: All Models .7 Nm). 4. Figure 1-11. 4. XL 883C Custom Models 2. FLHTC.

Reinstall handlebar clamp shroud.1-12. 10. 4. connect tachometer lead.7-2. Secure chrome ring (11) to headlamp nacelle with screw (12). Gently pry off fork lock plate (5) at rear of handlebar clamp shroud (8). Remove nacelle trim. nut and washer (4). On Police models. pd0226 3 8 6 5 2 7 NOTE Check clearance between windshield and clutch cable and handlebar position prior to completing assembly of vehicle. On police models. Install two screws (6) to handlebar clamp shroud and tighten to 10-20 in-lbs (1. 8. 8. 15. 10. Spread nacelle halves slightly and remove handlebar clamp shroud. 6. 12. 3. 2.-6. FLHPE Models 2005 PDI: All Models 1-7 .FLHR/C/S/I Road King. Nut Nacelle trim Front handlebar clamp shroud screw Nut and washer Fork lock plate Screw (2) Nacelle Handlebar clamp shroud Headlamp assembly Screw (8) Chrome headlamp ring Screw Figure 1-13. 13.3 Nm). Install nut (1) (inside nacelle) securing nacelle trim. 14. 7. Remove two screws (6) beneath lock plate. 9. Loosen (but do not remove) front handlebar clamp shroud screw (3). FLHR/C. Remove screw (12) securing chrome ring (11) to headlamp nacelle (7). 3. Install and secure headlamp assembly to nacelle with eight fasteners. Tighten to 15-20 in-lbs (1. Tighten front handlebar clamp shroud nut (4) to 10-20 inlbs (1.1-2. of the FLHT. Remove chrome ring. Connect wire connector to socket on back of headlamp bulb. 9. Loosen four acorn nuts securing nacelle halves to fork studs. Squeeze two external tabs (if present) to remove wire connector at back of headlamp bulb. Tighten acorn nuts securing nacelle halves to fork studs to 72-108 in-lbs (8. 4. 5.1-2. See Figure 1-13. 9 11 1 4 10 12 1. Remove nut (1) (inside nacelle) securing nacelle trim (2). Adjust handlebars following steps 2. 2. Install nacelle trim (2). FLHTC. FLHP.3 Nm). 7. FLHPE 1. Gently press fork lock plate (5) into place on handlebar clamp shroud. 6. Remove eight screws (10) securing headlamp assembly (9). FLHTCU and FLHTP procedure given on previous page. FLHP. 12.3 Nm). 5. 11. 11.2 Nm). Remove headlamp assembly from vehicle. disconnect tachometer lead.

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. FLTR Models-Instrument Bezel Screws 6. R LO/DX ® POWER 40 30 20 10 0 H 50 60 70 MPH 80 90 100 110 120 30 20 10 0 H AR LE 40 50 60 70 RPMx100 80 Y N PA M CO Y AR N LE PA M Y-D CERTIFIED CO AVI DSON MOTOR Y-D AVI DSON MOTOR 3. carefully raise tabs so they engage lip in slot. FLTR Models-Front Handlebar Clamp Screws 1-8 2005 PDI: All Models . Remove two T25 TORX screws at sides of instrument bezel.FLTR Road Glide 1. pd0195 NOTE If tabs do not properly engage slot at front of bezel. See Figure 1-14. Remove decorative adhesive strip by gently prying up outer edges. pd0201 1 PRO 2 HRS 3 MIN 4 SE SC EJECT HARLEY-DAVIDSON MOTOR COMPANY INC. 5. Raise handlebars to normal riding position. place bezel over instrument nacelle flange. install new decorative adhesive strip. Figure 1-15. tabs at front of instrument nacelle engage lip in slot at front of bezel behind decorative adhesive strip. Insert tab at rear of bezel into slot of instrument nacelle just above ignition switch. Using a flat bladed screwdriver. when properly mated. If damaged. a loose fit will result.7 Nm). Loosen two front screws securing handlebar upper clamps (Instrument bezel has been removed in drawing for clarity). Tighten front handlebar clamp screws to 12-16 ft-lbs (16. 4. See Figure 1-15. Pins on left side of nacelle must fully engage holes on right. Carefully push tab at rear of instrument bezel from slot above ignition switch. 2. Verify that left and right sides of instrument nacelle are properly mated.3-21. Holding left and right sides of nacelle together. Figure 1-14.

Lower clamp Cast-in spacers (2) Rear screw (2) Front screw (2) Upper clamp Figure 1-17. Insert instrument cluster screw and tighten to 2. Tighten first 4 3 2 7. Instrument Cluster Mounting Screw Location pd0021b NOTE On some models. Tighten rear screws (3) to 16-20 Nm (12-15 ft-lbs). 4. Install Maxi-Fuse. See Figure 1-17. the following steps will be necessary: 1. Remove Maxi-Fuse. FRONT 1. Remove instrument cluster screw from location shown and pivot instrument cluster away from handlebars. 8. 10059 3. 6. verify that equal amounts of knurled areas on handlebar protrude from outboard sides of upper handlebar clamp. knurled areas of handlebar will be completely hidden by upper handlebar clamp and will not be visible at all when handlebar is centered properly. VRSCB Models 10. 5.8 Nm (20-24 in-lbs). 5. 2005 PDI: All Models 1-9 . Remove instrument cluster. Raise handlebars to normal riding position. Install instrument cluster. 11. 2. Slight gap between upper and lower clamps should exist at rear. Remove wiring harness connector and remove screw on bottom side of instrument cluster.2-2. Figure 1-16. 4. 5 1 9. To be sure handlebars are properly centered.VRSCB NOTE To gain access to the handlebar adjusting screws. 3. 2. hold in position. Tighten two front screws (4) until cast-in spacers (2) of upper clamp contact handlebar lower clamp (1). See Figure 1-16. Final tighten front screws (4) to 16-20 Nm (12-15 ft-lbs).

unscrew the rear eyebolt to prevent tripping and falling over it. When released. a third strap is located at the left rear. See Figure 1-19. Falling could result in minor or moderate injury. each strap will unwind rapidly from its ratchet lever. pd0051 c. Releasing strap tension on one side of motorcycle could result in the front of motorcycle rising and leaning abruptly to opposite side. Have an assistant hold the motorcycle’s handlebars. Also. a. Opening Ratchet Lever 1WARNING Always wear safety glasses and gloves and keep bystanders at a safe distance when uncrating the motorcycle. the left radiator trim or other low-left-side components could be damaged when motorcycle is rolled off pallet. which could result in death or serious injury. if eyebolt is not removed. Depress (in opposite direction of spool) and hold down the spring-loaded ratchet release. which could result in death or serious injury.REMOVING VEHICLE FROM PALLET All Models b0458xpx 1WARNING Always have someone steady motorcycle while each strap is being removed to prevent tipping. Figure 1-18. Strap Ratchet Lever (Release Position) 1CAUTION On VRSC models. Figure 1-19. tensioned nylon strap will rapidly unwind. Motorcycle front suspension is secured in a compressed state by two nylon straps. Swing open the ratchet lever to the release position. 1-10 2005 PDI: All Models . 1. After this rear strap is removed. See Figure 1-18. Remove crating straps. remove strap and any protective padding from pallet. and end of strap could recoil in an outward direction. Start with the right side crating strap. b.

Irregular or sticking throttle cables could cause a loss of control. 1WARNING Be sure jiffy stand is fully retracted before riding. raising handlebars as necessary to clear fuel tank. it can contact the road surface causing loss of vehicle control. firm surface. Place a 2x4 in. See Figure 1-20. perform handlebar adjustment again (see ADJUSTING HANDLEBARS– ALL MODELS). If jiffy stand is not fully retracted. a. If contact between handlebars and fuel tank occurs and handlebars are properly centered. if turn signal contacts fuel tank. (00039a) 1WARNING The jiffy stand locks when placed in the full forward (down) position with vehicle weight on it. adjust turn signals and/or handlebar control housings according to appropriate Service Manual instructions. 7770 1WARNING Improperly aligned or adjusted handlebars can contact fuel tank when turned to left or right fork stops. Carefully roll vehicle off pallet. An unbalanced motorcycle can fall over which could result in death or serious injury. 4. 1WARNING Always park motorcycle on a level. the vehicle can fall over which could cause death or serious injury. (00006a) 1WARNING Throttle control must operate freely without binding. On models with turn signals mounted on handlebar control housings.6 mm) board between steel cross braces (see arrow) behind front tire to aid rolling motorcycle rearward off pallet. leading to an accident which could result in death or serious injury. If the jiffy stand is not in the full forward (down) position with vehicle weight on it.8x101. which could result in death or serious injury. Contact with fuel tank while riding can cause loss of vehicle control resulting in death or serious injury. Figure 1-20. (50. Also be sure cables and wiring are not pinched or stretched as handlebars are turned back and forth. Vehicle Pallet b. 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.2. 2005 PDI: All Models 1-11 . (00007a) 3.

0-5. ● 3 1. Beginning with the top screw.8-9. Clutch control housing clamp screw (2) Handlebar switch housing clamp screw (2) Figure 1-24. Remove plastic wrapping or protective foam from clutch hand lever and left handlebar grip. Clutch lever restraining foam Headlamp snap cap (XL 883 and XL 1200R only) 30-amp Maxi-Fuse Figure 1-22. 5 1 d. Location of Maxi-Fuse and Snap Cap on Clutch Hand Lever–All Sportster Models Except XL 883L b. Left Hand Controls (Typical) 1-12 2005 PDI: All Models . 1. 10616 4 2 1. 4. 2. All Dyna models have Maxi-Fuse wrapped in plastic wrapping around clutch hand lever and left handlebar grip.9 Nm). 10703 c. Rotate clutch control housing and handlebar switch housing as necessary for correct position and rider comfort. If handlebar controls need to be adjusted.CLUTCH HAND LEVER ● 10702 2 1 NOTE See Figure 1-21. Sportster model XL 883L also has righthand mirror fitted into protective foam. but do not remove. Loosen. All Sportster models have Maxi-Fuse and headlamp snap cap fitted into protective foam on clutch hand lever and left handlebar grip. clutch control housing clamp screws (1) and handlebar switch housing clamp screws (2). 2. See Figure 1-22. See Figure 1-23. 3.1 Nm). Location of Maxi-Fuse on Clutch Hand Lever–Dyna Models pd0217 2 1 2 1. 3. 2. perform the following procedure. 5. Clutch lever restraining foam Headlamp snap cap 30-amp Maxi-Fuse Mirror Package of mirror mounting hardware 3 Figure 1-23. tighten clutch control housing clamp screws.2-14. Location of Maxi-Fuse and Snap Cap on Clutch Hand Lever–Sportster XL 883L Figure 1-21. See Figure 1-24. All Sportster models: tighten to 108-132 in-lbs (12.0 Nm). Tighten handlebar switch housing clamp screws to 35-45 in-lbs (4. Save snap cap for installation after headlamp has been adjusted. 2. a. All other models: tighten to 60-80 in-lbs (6.

If swallowed. Avoid eye contact.O. 3. 4 brake fluid will damage painted and molded-in color surfaces it comes in contact with.T. pd0218 4 3 2 D. (00240a) CAUTION 4. Loosen. If it is necessary to top off the brake fluid in the reservoir.0-5. All other models: tighten to 60-80 in-lbs (6. 4 brake fluid spills off vehicle with water. Measurement must not exceed 1 meter in length. swelling. Use only D.T.FRONT BRAKE HAND LEVER If handlebar controls need to be adjusted. Front brake master cylinder clamp screw (2) Handlebar switch housing clamp screw (2) Reservoir sightglass (XL models) Reservoir sightglass (all models except XL) Figure 1-25.O. front brake master cylinder clamp screws (1) and handlebar switch housing clamp screws (2). Use only D.O.O. See Service Manual. Use in well ventilated area. Swallowing large amounts of D. View reservoir sightglass (3 or 4) and verify fluid presence. 5 brake fluid can cause digestive discomfort. Use in well ventilated area. Wash all residue of D. Rotate master cylinder housing and handlebar switch housing as necessary for correct position and rider comfort. (00144a) 2.0 Nm). Avoid eye contact. If swallowed.T. Sightglass should appear dark if fluid is present. tighten front brake master cylinder clamp screws. 2005 PDI: All Models 1-13 . 99902-77: 12 oz. 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. Right Hand Controls (Typical) IMPORTANT NOTE All Touring model motorcycles use D. VRSC and Sportster models. 2. 99901-77: 1 gal.T. Swallowing large amounts of D. obtain medical attention. KEEP OUT OF REACH OF CHILDREN.8-9. (00239a) CAUTION 1 2 1.). add brake fluid. Spilling brake fluid on handlebar switches may render them inoperative.2-14. 99953-99A). 4 HYDRAULIC BRAKE FLUID (Part No. All Dyna. In case of eye contact flush with large amounts of water and get medical attention. 99902-77: 12 oz.T. Softail. 1CAUTION Direct contact of D.1 Nm). 5 brake fluid with eyes can cause eye irritation.O.T. 4 brake fluid with eyes can cause irritation. 4 HYDRAULIC BRAKE FLUID (Part No. for all Dyna.).. 99901-77: 1 gal. If it does. make sure you add the correct type. and redness. 99953-99A) for all Touring models. 1CAUTION Direct contact of D. NOTE AUSTRALIAN MODELS ONLY: Measure from tip of clutch lever to tip of brake lever.O.O.9 Nm). but do not remove. In case of eye contact.O.T. All Sportster models: tighten to 108-132 in-lbs (12. 1. Softail.O. Beginning with the top screw. Cover handlebar switches with a shop towel before adding brake fluid to front master cylinder reservoir. 4. VRSC and Sportster models use D. If sightglass is not dark. Always use caution and protect surfaces from spills whenever brake work is performed.T. flush with large amounts of water and get medical attention. re-adjust accordingly. FRONT BRAKE MASTER CYLINDER RESERVOIR See Figure 1-25. Failure to comply can result in cosmetic damage. perform the following procedure. 4 brake fluid can cause digestive discomfort. Tighten handlebar switch housing clamp screws to 35-45 in-lbs (4. 3.T 5 SILICONE HYDRAULIC BRAKE FLUID (Part No.T.. obtain medical attention. KEEP OUT OF REACH OF CHILDREN. See Figure 1-25.O.

) Tighten straps to secure pallet bundles. This will allow stacking pallets for shipment. (00078b) CAUTION Avoid spraying water directly on handlebar switches. Wet handlebar switches may be inoperative. 7. 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). If you discover any condition requiring repair. Kent-Moore 28635 Mound Rd Warren. Remove and discard plastic motor shim (1). If vehicle is equipped with frame downtube reflectors. Call. To aid the dealer network in addressing quality concerns. Band pallets by threading hold-down straps through both end cross members of top and bottom pallets. Fax. 6. mufflers or air cleaner get wet when washing your motorcycle. at the following address. Additional cosmetic quality information is available in the Harley-Davidson Cosmetic Booklet (Part No. examine all painted parts for any damage or irregularities in the paint finish.h-dnet. See Figure 1-26. which enables us to exceed customer’s expectations. Start engine immediately after washing. engine. E-mail or use www. (1. available through Kent-Moore. 1. (736. 1-14 2005 PDI: All Models . RETURNING STEEL PALLETS NOTE International Dealers/Distributors should check with their H-D office to determine whether or not to return pallets. Wash entire motorcycle before beginning actual predelivery inspection. HD-39994). Place hold-down straps you are returning to factory in enclosed area (3) of pallets. which could result in death or serious injury. Stack seven pallets keeping all eye-bolts on same end.com to arrange pallet return to Harley-Davidson. Allowing these components to get too wet can adversely affect their performance. 4. (If necessary connect two straps together. 1.6 mm) width pallets with 43 in. 3.VEHICLE CLEANUP 1WARNING Do not let the brakes. use Paint Repair Kit (Part No. HD-99514-05) and on-line Cosmetic Training located on HDU On-line. Plastic motor shim Eye-bolts Enclosed area Figure 1-26. 7770 3 2 1 2 COSMETIC QUALITY Paint Finish Inspection and Repair Under good lighting conditions. Michigan 48092-3499 (phone) 1-800-345-2233 Instructions covering painted part repair are included with the Paint repair Kit.09 m) width pallets on the same 7-pallet stack. and make sure brakes and engine are operating properly before riding in traffic. 136. Remove protective shipping tape from motorcycle. Additional paint repair information is available from Harley-Davidson on the PHD training videotape No. Vehicle Pallet 2. 3. Mixing pallets of different width could result in an unstable bundle and pallet damage. NOTE On VRSC pallets place eye-bolt from rear in enclosed area (3) of pallet. 5. to correct the condition. CAUTION Do not mix 29 in. Harley-Davidson Motor Company has developed a zoning and criteria protocol. Turn eye-bolts (2) so they are parallel with sides of pallet. 2.

2. 6. Eyes f2180x3x 1 2 3 4 5 JA L FE 1 2 M A D E I N arge LICYt ch T POthou MEN wi or ST ed s JU ac erialte of pl at D AD re in m da date m Y AN l be fro m NT wi ctive s s fro r 6 e ll RA tte ry defe onthonth . The batteries are shipped pre-charged and ready to be put into service. Afte of th ry wi WAR ba be 12 m 6 m hase ths tte is to ba Th und ship se or purc monthe ged d on r .MAINTENANCE-FREE BATTERIES All models are equipped with maintenance-free batteries that are permanently sealed. 3. Call doctor immediately Flush with water. rubberized gloves and protective clothing when working with batteries. Warning Label Table 1-1. d mon -the-ed an rio the tim m t tra tors er pe r of no ov replacthe ice at mbe y is juvena e. ne SO20 pror nt ided rolyt rra 3 wa is vo elect VID5. the batteries are identified as “Type AGM” which is the acronym for Absorbed Glass Mat technology. lead/calcium and sulfuric acid electrolyte batteries. Wear a protective face shield. us be forlar pr e nu rra nt of re ab ly or on regu ver th wae use ect is gl N1 the atedy. I d an oper DA W. if forkman rchaunte the 12 se char ba se ha r wo cle pue-co thin rc hasershiprn pu e vehi er-thbut wite r purc ne retu of ra bl ov e s of ths. Contents are corrosive Wear safety glasses Contents are explosive 4. followed by milk of magnesia. Battery Warning Label 2005 PDI: All Models 1-15 . Perform Voltmeter Test to check if battery requires charging. im EY-EE U. Therefore. KEEP BATTERIES AWAY FROM CHILDREN.A pr . which could cause severe burns to eyes and skin. Battery Electrolyte Antidote PHYSICAL LOCATION External Internal PROCEDURE Flush with water Drink large quantities of milk or water. These batteries do not have a vent tube. get immediate medical attention. vegetable oil or beaten eggs. cound th of owe ofonth nsfe . f1730x8x DE U S A R UKE IN A HAWMAD IL M R PA T .S OC NO SE AU JY MA AP MY JU 3 4 5 6 7 8 9 0 6 1. NO 1WARNING Batteries contain sulfuric acid. Do not attempt to open these batteries for any reason. 5. valve-regulated. Keep flames away Read instructions Keep away from children Figure 1-28. Th by the. The electrolyte is immobilized in a glass fibre separator. (00063a) Figure 1-27.

Disconnect the red battery charger lead to the positive (+) terminal of the battery. Battery Warranty Tag/Date Code Sticker After the battery is fully charged. For example. punch out the month of August. 5. Connect the red battery charger lead to the positive terminal of the battery and the black charger lead to the negative terminal. which could result in death or serious injury. Disconnecting clamps with charger ON can cause a spark and battery explosion. 6.” To determine the correct number to punch out for the year. which is abbreviated on the tag as “AU. advance the date to the next month. Figure 1-29. Therefore. 1. 4. 2. Only remove battery if cable connection or marking the Warranty Tag requires it. 3. The battery date code sticker has a number and two letters. charge battery and recheck voltage after battery has sat 1-2 hours. Charge battery for time specified in Table 1-2. over 110˚F (44˚C) (warm to the touch). If the date is after the 15th day of the month. discontinue charging and let battery cool down.6 V. just reference the last digit of the current year. disconnect the black battery charger lead to the negative (–) terminal of the battery. Mark the date on the battery warranty tag by removing the applicable month and year.DATE OF MANUFACTURE CODE See Figure 1-29. Refer to Table 1-2. JA–January FE–February MA–March AP–April MY–May JU–June JY–July AU–August SE–September OC–October NO–November DE–December f1742x8x VOLTMETER TEST Refer to Table 1-2.6 V. 9 – 1999 0 – 2000 1 – 2001 2 – 2002 3 – 2003 4 – 2004 5 – 2005 The letters signify the month the battery was activated. Check the voltage of the battery to make sure it is 12. See Figure 1-29. (00067a) 1-16 2005 PDI: All Models . If battery gets hot. If the open circuit (disconnected) voltage reading is below 12. The voltmeter test provides a general indicator of battery condition. the number “5” is punched to signify the year 2005. The number signifies the year the battery was manufactured. if the battery is put in use July 22. 1WARNING Unplug or turn OFF battery charger before disconnecting charger cables from battery. Battery date of manufacture code CHARGING BATTERY NOTE The sealed AGM batteries do not need to be removed for charging.

3 12.0 11.5 hours 5 hours 7.6 V TOURING 28 12.25 hours 2. 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. never exceed 15 volts for more than 30 minutes. 20 minutes 30 minutes 1 hour 1. 20 minutes 4 hours. SOFTAIL 18 12.0 11. 30 minutes 1. use a slightly shorter charging time.5 hours 3 hours.25 hours 3 hours 20 AMP CHARGER 10 minutes 20 minutes 30 minutes 40 minutes 15 minutes 30 minutes 45 minutes 1 hour 25 minutes 50 minutes 70 minutes 1. do not exceed the charge times listed above and do not continue charging the battery if it gets hot. 40 minutes 2 hours.3 12. Battery Charging Rates/Times (Approximate) BATTERY AMP HOUR STATE OF CHARGE VOLTAGE 12.3 V 12.0 V 11. 14 minutes 50 minutes 1.5 hours 3.75 hours 3.8 12.75 hours 2. If warmer than room temperature.8 12.8 12.5 hours NOTE The figures listed above assume that the battery is charging at room temperature.5 hours 2. SPORTSTER 12 12. 20 minutes 1.8 V 12.5 hours 5 hours 6 hours. If colder. 20 minutes 3 hours.6 VRSC.75 hours 5 hours 10 AMP CHARGER 20 minutes 40 minutes 1 hour 1 hour.5 hours 10 hours 6 AMP CHARGER 34 minutes 70 minutes 1 hour. 2005 PDI: All Models 1-17 .8 V % OF CHARGE 100% 75% 50% 25% 0% 100% 75% 50% 25% 0% 100% 75% 50% 25% 0% 3 AMP CHARGER 70 minutes 2 hours. If a constant current charger is the only type available. 40 minutes 2.5 hours 2 hours 45 minutes 1. When charging.Table 1-2.6 DYNA.8 12.

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 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

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.

10683

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

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. 1.0 in (25.4 mm)
10684

Figure 1-33. Warning Label Placement– All VRSC Models (Typical)

Figure 1-31. Warning Label Placement– All Big Twin Carbureted (Typical) 1-18 2005 PDI: All Models

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

1.2
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.

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.

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Turn Signals (FLHRS Only) . . . . .1 Specifications . . . . . . . . . . . . . . . 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Maxi-Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idle Speed: Carbureted Only . . . . . . II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . Battery Testing And Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Windshield . . 2. . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . Indicator Lamps/Controls . . . . . . . . . . . . . Rear Suspension Air Pressure . . . .7 Brake System . . . . . . . . . . . . . . . . . . . . . . . Installing Tour-Pak . . . 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Sidecovers and Saddlebags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. . . . . . . . . . . . . . . . . . . . . . . . Engine Oil Level (Side Car Equipped Vehicles) . . . . . . . . 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2005 Touring Models Specifications . . . . . . . . . . 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Fuel Pump Fuse . . . . . . . . . . . . . . . . . . . . . .2 Initial Assembly . . . . . . . ABS System (Police Vehicles–Optional Equipment) . . . . . . . . . . . . . . . . Installing Data Link Connector . Directional Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-1 2-1 2-2 2-2 2-2 2-2 2-3 2-3 2-4 2-4 2-6 2-6 2-7 2-10 2-10 2-11 2-12 2-12 2-12 2-13 2-13 2-14 2-14 2-14 2-14 2-15 2-16 2-16 2-16 2-16 2-16 2-16 2-17 2-18 2-18 2-19 2-19 2-19 2-20 2-20 2-20 2-21 2-21 2-22 2-22 2-22 2. . . . . . . Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. . . . . . . . . . . . . . . . . . . . . . . . . .8 Dealer Road Test . Evaporative Emissions Control System–California Models Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Electrical System . . . . 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Vehicle PDI Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Quick Connect Fuel Line Fitting–Fuel Injected Models . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil Level . . . . . . . . . . Front and Rear Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seats And Passenger Strap . . . . . . . . . . . . . . . . . . . . . Throttle Control Cables . . . . . . . . . . . . Chaincase Lubricant Level and Clutch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . At Point of Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PREDELIVERY: TOURING MODELS SUBJECT PAGE NO. . . . . . . . . . . 2. . . . . . . . . . . . . . . Notice To Dealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Lubrication System . . . . . . . . . . Rear Speaker Harnesses . . . . . Torque Values . . . . . . Auxiliary Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mirrors . . . . . . . . Prior to Customer Delivery . . . . . . . . . . . . . . Radio Antenna Mast Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.

are shipped with All touring models except 20W50 Harley-Davidson 360 Motor oil.7-1.2 Nm 2.7 Nm 9. Use idle speed listed in the Touring Models Service Manual at Initial Maintenance check.3 Nm 1. NOTE The idle speed on electronic fuel injected models can only be set using a diagnostic tool such as DIGITAL TECHNICIAN (Part No.8 Nm 10.1 SPECIFICATIONS TORQUE VALUES The following torque values are included for fasteners that may be loosened and tightened during Predelivery and Setup.3 Nm 1.8-10.5-12.1-2.5 Nm 8. HD-44750). 2005 TOURING MODELS SPECIFICATIONS Table 2-2.7-2.5 Nm 6.1-2.1 Table 2-1.3 Nm NOTES Must be checked at set-up.1-12. 2005 PDI: Touring Models 2-1 .8-13.4 Nm 0.8-3. Torque Values ITEM Handlebar clamp screws (front and rear) Clutch inspection cover screws FLHT windshield screws FLTR windshield screws Saddlebag mounting bracket bolts Tour-Pak® FLHR/ FLHP mounting bolts Nacelle acorn nuts Handlebar clamp shroud screws Handlebar clamp shroud nut Nacelle trim nut TORQUE 12-16 ft-lbs 84-108 in-lbs 25-30 in-lbs 6-13 in-lbs 60-96 in-lbs 96-120 in-lbs 72-108 in-lbs 10-20 in-lbs 10-20 in-lbs 15-20 in-lbs 16. primary and transmission. Any fasteners that are not loosened/removed do not need to be checked during predelivery and setup. 2.3-21. The FLHTCSE2 model ships with Syn-3® lubricant in the engine. Engine idle speed may increase during engine break-in. 20-24 oz 32 oz FLHTCSE2 METRIC 3.2 Nm 1.79 liter 591-710 ml 946 ml Idle Speed: 950 RPM at Operating Temperature Use 950 RPM during Predelivery and Setup adjustments. Capacities Component Oil tank w/filter (Dry) Transmission (Wet) Primary Chaincase ENGLISH 4 qt.

perform steps 2 and 3 above. (00063a) 2. rubberized gloves and protective clothing when working with batteries.INITIAL ASSEMBLY BATTERY TESTING AND CHARGING 1WARNING Batteries contain sulfuric acid. and is to be installed under the left sidecover. Recheck battery voltage by repeating step 1 above. Check battery voltage at Maxi-Fuse plug. KEEP BATTERIES AWAY FROM CHILDREN. 3. For fuel-injected vehicles. 2-2 2005 PDI: Touring Models . 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. place red voltmeter probe on battery side (terminal A) of Maxi-Fuse plug. and black voltmeter probe on a suitable ground. in Section 1 and charge battery at rate and time specified. 2. Mark the date on the battery warranty tag by removing the applicable month and year. terminals and related accessories contain lead and lead components. 5. If voltage now is 12. See Service Manual. Failure to read and understand all precautions in warning could result in death or serious injury. See Section 1. the battery must be replaced. Cut the cable tie securing the Maxi-Fuse wire to the frame. Month and year punches may be removed with the point of a screwdriver without removing battery.2 INSTALLING MAXI-FUSE The 40 amp Maxi-Fuse provides battery power to the ignition switch and ECM. See Service Manual for Maxi-Fuse installation procedure. 1WARNING Never remove warning label attached to top of battery.6 VDC or greater. It is shipped in the saddlebag of the motorcycle. If the open circuit (disconnected) voltage reading is below 12.6 VDC or greater the battery is ready for use. If the open circuit (disconnected) voltage reading is still below 12.6 VDC. 6. refer to Table 1-2. 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. The 40 amp Maxi-Fuse is not installed at the factory.6 VDC. Wash hands after handling. 1. (00019a) NOTE It will be necessary to remove the left saddlebag and left sidecover to gain access to the Maxi-Fuse connector. chemicals known in the State of California to cause cancer and birth defects or other reproductive harm. Wear a protective face shield. If the open circuit (disconnected) voltage reading is 12. (00064a) 1WARNING Battery posts. 4. which could cause severe burns to eyes and skin. 28 amp-hour battery. With fuse removed.

remove seat. Data Link Connector 3. On Ultra models. repeat the procedure to release the CB antenna cable and connector. Remove map pouch and molded Tour-Pak liner from Tour-Pak prior to performing the following procedures. 1. pd0215 5029 1 2 Carbureted pd0216 Figure 2-2. Electrical bracket Data link connector [91] Figure 2-1. discard large shipping washers. If not already removed. see Figure 2-2. INSTALLING TOUR-PAK® NOTE The seat screw is not factory installed on models with TourPaks. remove the nuts and oversized shipping washers and then lift the Tour-Pak off the mounting bolts setting it on the blanket. 4. 53318-99. 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. Fuel injected 1. Retain nuts for use later. Cut the cable tie securing the data link connector harness to the frame and snap the connector into its clip on the electrical bracket. On Ultra models. Install both after work is completed.INSTALLING DATA LINK CONNECTOR See Figure 2-1. From inside Tour-Pak. Mount Tour-Pak in the rearward position (front four holes and rear center hole) so seat access screw can be reached. The seat screw is in the Parts Kit. Part No. Place a protective blanket across the frame tubes in the seat area. 2005 PDI: Touring Models 2-3 . disconnect the radio antenna cable and Tour-Pak lights connectors and feed wiring out through hole at front of Tour-Pak (after removing grommet). To avoid dropping or scratching the Tour-Pak. 1 2 2. The data link connector [91] (2) mounts in a clip on the electrical bracket (1) under the right side cover. 2.

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. 4. bolts.8 Nm) torque. On Ultra models. 1/4-20 x 2-1/4 in. Check that AM/FM/WB antenna (left side) cable is in its two clips on left side of TourPak floor. Locate Parts kit. Road Glide models must have the seat strap installed per the appropriate Service Manual. Part no. 8. See Figure 2-4. 7. and then tighten the bolts to 60-96 in-lbs (6.5. INSTALLING SIDECOVERS AND SADDLEBAGS Check that each saddlebag is firmly seated on its saddlebag bottom support rail. Tour-Pak Shipping Fasteners 2-4 2005 PDI: Touring Models .8-13. Check that adequate clearance exists between saddlebags and sidecovers. install right rear bolt (1) and washer (2) through bottom of Tour-Pak. 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. inside dia. 3. Remove and discard the pushnuts (5) from the mounting bolts (1). nuts and five washers used to mount Tour-Pak. see Figure 2-5. loosen the bolts which secure the saddlebag mounting brackets to the motorcycle. See Figure 2-3. washers. 2. hole in top support tube (3). Also check that CB antenna (right side) cable is in two clips on right side of Tour-Pak floor. The plastic bag contains three spacers. 10. (2) Washer 1/4 in. 11. Install washer (2) and locknut (6) on right rear bolt and tighten “finger-tight”. (2) (under bolt head) Top support tube Luggage rack spacer (2) Pushnuts (2) Figure 2-3. 6. SEATS AND PASSENGER STRAP Refer to Touring Models Owner’s Manual for seat and passenger strap removal and installation instructions. Also in parts kit is the seat retaining screw.8-10.5 Nm). 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). luggage rack spacer (4). (This fastener will keep Tour-Pak in position while remaining four bolts are installed. From inside Tour-Pak. Install antenna ground lead ring terminal under washer of rear mounting bolt and install rear bolt as shown in Figure 2-4. Bolt. Bolt head and washer must be inside Tour-Pak. 12. Tighten five nuts and bolts to 96-120 in-lbs (10.) 9. Move Tour-Pak to rear so five mounting holes align with five holes in top support tube. Press down and to the rear firmly on closed saddlebag. Verify that ground strap of AM/FM/WB antenna is securely fastened to base plate in Tour-Pak with rear mounting screw. If adjustment is necessary. 53318-99 in Tour-Pak or saddlebag. and hole in license plate bracket (5). Install remaining bolts. spacers and nuts as shown in Figure 2-4. NOTE Make certain bolts are installed with threaded end down. 5. pd0188 1 5 3 4 2 1.

Antenna Cable Clip (CB Antenna Cable Shown) 2005 PDI: Touring Models 2-5 . 2. 6. 1/4-20 (5) 3 5 5 f1467b2x Figure 2-5. inside dia. (7) Top support tube Luggage rack spacer (5) License plate bracket Locknut. 4. 5. 1/4-20 x 2-1/4 in. Figure 2-4. 2 4 4 3 6 2 2 6 1. (5) Washer 1/4 in. 3.pd0187e 1 Bottom view showing spacer (4) between license plate bracket (5) and top support tube (3). Nylon cap. Tour-Pak Mounting Bolt.

Thread the mast securely over the antenna mounting stud and tighten the set screw. Rear Speaker Harness Grommets (Seat removed for clarity) 2-6 2005 PDI: Touring Models . Reassemble mast to base and adjust distance between bottom of loading coil to top of base to 1 in. REAR SPEAKER HARNESSES 1. slide harness and connector into speaker box. 2. loosen upper setscrew in base. On Ultra models only. NOTE Standing Wave Ratio (SWR) will be checked later in these procedures. Press down on seat cushion. Thread each mast securely over its antenna mounting stud. 3. Right speaker harness Plastic grommet (shown partially installed) Figure 2-6. Locate plastic grommets packed in Tour-Pak.RADIO ANTENNA MAST INSTALLATION Open the Tour-Pak lid. Repeat for CB antenna. Repeat steps 2 and 3 for left side. FLHTC models are equipped with one antenna mast. slide mast from base and slide boot onto mast below loading coil. Install split plastic grommet on harness and push grommet into hole in speaker box. use soapy water as a lubricant to install a protective rubber boot (provided with vehicle) over tip of AM/FM antenna mast. FLHTCU models are equipped with two antenna masts — one with loading coil for CB radio for right side mounting. See Figure 2-6. slide boot down mast and over springloaded base. 2. the other for AM/FM radio for left side. but. the other for antenna mounting stud) located in the springloaded base of each antenna and one at top of loading coil. Cut cable straps securing rear speaker harnesses to passenger handrail (both right and left sides). 4. 6712 1 6711 2 1. Tighten the two (3 on CB) set screws (one for antenna mast.

FLHTCU. Make certain that the four outer screws are located at the upper end of the slots in the windshield.4 Nm). Tighten fasteners to 25-30 in-lbs (2. Place black plastic washers (4) on the five mounting screws (3). Windshield Installation: FLTR 1.8-3. 3. 5. 3.5 Nm). Windshield Installation–FLHT Models 1. See Figure 2-7. See Figure 2-8. 4. It is not necessary to remove the fasteners. Loosen the three fasteners along the top of the outer fairing. Push Wellnuts with rubber washers into holes in fairing. 2. Position rubber trim along bottom of windshield.INSTALLING WINDSHIELD FLHTC. Slide windshield down between the inner and outer fairing over the fasteners. Windshield Outer fairing Screw (5) Flat washer (plastic) (5) Wellnut (5) Flat washer (rubber) (5) Figure 2-8. 2. 2 2. Insert screws through windshield holes and thread loosely into five Wellnuts (5) with rubber washers (6). 6.7-1. Position on the raised boss on the inner fairing. pd0173x f2280x2x 5 1 6 4 3 2 Figure 2-7. tighten all screws to 6-13 in-lbs (0. 2005 PDI: Touring Models 2-7 . Beginning with the center screw and working outward toward the rear edges of windshield. FLHTCSE (Wind Deflector) and FLHTP (Fairing) 1. 3. Windshield Installation–FLTR Models CAUTION Overtightening windshield fasteners may crack windshield and/or fairing.

Remove eight fasteners (11) securing headlamp assembly (10). 2-8 2005 PDI: Touring Models . reposition handlebars. 4. 3. 1. 2. Nut Nacelle trim Screw Nut Flat washer Fork lock plate Screw (2) Nacelle Handlebar clamp shroud Headlamp assembly Screw (8) Chrome headlamp ring Screw Stud plate Acorn nut (2) Tachometer bracket Figure 2-10. 15. FLHP Headlamp Nacelle Figure 2-9. NOTE If windshield contacts clutch cable. 6. Slide the TOP bracket notches onto the top grommets. See Figure 2-10.Windshield Installation: FLHR/C and FLHP (Windshield) CAUTION Be sure you position the windshield bracket between the rubber grommets. 2. Remove screw (13) securing chrome ring (12) to headlamp nacelle (8). Incorrect mounting could result in damage to the windshield. 7. 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. pd0227 16 15 6 7 9 8 3 14 2 1 10 5 4 12 OMF53 11 13 1. The bracket relocates the tachometer to allow the addition of a radio speaker. Instrument Mounting Bracket Installation: FLHP The FLHP is provided with an instrument mounting bracket. and control panel. 5. 9. 13. 11. 12. See Figure 2-9. Remove headlamp assembly from vehicle. 10. FLHR/C and FLHP Windshield Installation Seat Adjustment: FLHTP Before applying load to the seat. 14. Squeeze two external tabs (if present) to remove wire connector at back of headlamp bulb. 16. 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. Remove chrome ring. 8.

17. Install two screws (7) to handlebar clamp shroud and tighten to 10-20 in-lbs (1. 1. Tighten to 15-20 in-lbs (1.3. 12. Install and secure headlamp assembly to nacelle with eight fasteners. FLHP Tachometer Mount 2005 PDI: Touring Models 2-9 . 15. Install nacelle trim (2).1-2. 13. Gently pry off fork lock plate (6) at rear of handlebar clamp shroud. Remove nut (1) (inside nacelle) securing nacelle trim (2). 4. NOTE Check for adequate clearance between windshield and clutch cable and handlebar position prior to completing assembly of vehicle. Remove nacelle trim. Tighten front handlebar clamp shroud nut (4) to 10-20 inlbs (1. A peel and stick foam tape holds the stud plate (4) in place inside the handlebar clamp shroud (3). Remove two acorn nuts (15) and flat washers securing Tachometer and bracket (16) to handlebar clamp shroud. Install nut (1) (inside nacelle) securing nacelle trim. 16. 5. 8. Remove two screws (7) beneath lock plate.3 Nm). Gently press fork lock plate (6) into place on handlebar clamp shroud. Reinstall handlebar clamp shroud. 6. 9. Loosen (but do not remove) front handlebar clamp shroud screw (3). Position instrument mounting bracket (2) on studs of stud plate and secure in position using hardware provided by radio manufacturer (1). See Figure 2-10. See Figure 2-11. Using screw (5) and nut (6) provided. 18.3 Nm). p0044x5x 1 2 6. Connect wire connector to socket on back of headlamp bulb. 7.1-12. 2. See Figure 2-12. Secure chrome ring (12) to headlamp nacelle with screw (13).7-2. 11.3 Nm). 5. Spread nacelle halves slightly and remove handlebar clamp shroud. Disconnect tachometer connector [108] inside headlamp nacelle. 4.1-2. secure front tab of instrument mounting bracket on handlebar clamp shroud. 3 5 4 Nut (2) Instrument mounting bracket Handlebar clamp shroud Stud plate Screw Nut Figure 2-11. Mount tachometer on bracket with acorn nuts and flat washers as shown.2 Nm). Connect tachometer lead [108]. nut (4) and washer (5). Loosen four acorn nuts securing nacelle halves to fork studs. FLHP Instrument Bracket 5530 Figure 2-12. 3. 14. Tighten acorn nuts securing nacelle halves to fork studs to 72-108 in-lbs (8. 6 10.

Adjust mirrors for proper rear view. THROTTLE CONTROL CABLES All Non-Ultra Models Check throttle cable adjustment in accordance with procedure given in Section 1 of Touring Models Service Manual. Verify that mirror fasteners are properly tightened. pdoo72b Ultra Models Check throttle cable adjustment in accordance with procedure given in Section 8 of Touring Models Service Manual.MIRRORS See Figure 2-13. Mirror Installation 2-10 2005 PDI: Touring Models . Figure 2-13.

REAR SUSPENSION AIR PRESSURE CAUTION Do not exceed maximum air pressure for rear suspension. Refer to Table 2-3.7 kg) Solo rider 200-250 lbs (90.4 kg) Rider and 150 lbs (68.48 kPa) to clear line and adjust for application. Rear Suspension Air Pressure Valve See Figure 2-14. use low air line pressure.0 kg) maximum Solo rider 150-200 lbs (68.4 kg) Rider and 150 lbs (68.0 kg) maximum Solo rider 160-200 lbs (73.7-113. add 3-5 psi (20.7-113. Failure to do so may result in possible damage to components. 8472 Figure 2-14.7 kg) Solo rider 200-250 lbs (90. above the left saddlebag.7 kg) passenger Gross vehicle weight rating (GVWR) 0 0-10 5-15 10-15 20-25 20-35 kPa 0 0-69 35-103 69-103 138-172 138-241 Table 2-4. Rear Suspension Air Pressure (FLHRS and FLHTCSE2 Only) Pressure Loading psi Solo rider -160 lbs (73. Table 2-3. These are recommended starting points. riding style and comfort desired. Check rear suspension air pressure at air valve located on the left side of the motorcycle below the frame cover. Less initial pressure does not necessarily result in a softer ride. Rear Suspension Air Pressure (All Models Except FLHRS) Pressure Loading psi Solo rider -150 lbs (68.68-34. Therefore. adjust to suit load conditions.0-90.0 kg) passenger Rider and Over 150 lbs (68 kg) passenger Gross vehicle weight rating (GVWR) 0-5 0-10 5-10 20-30 25-35 40-50 kPa 0-35 0-69 35-69 138-207 172-241 276-345 2005 PDI: Touring Models 2-11 . (00165a) IMPORTANT NOTE Maximum air pressure of rear suspension system is 50 psi (345 kPa).0-90.0 kg) passenger Rider and 200 lbs (90. Air components fill rapidly. Use a no-loss gauge.

If oil level is at or below the lower arrow. primary and transmission. See Figure 2-15. Remove the dipstick and note the level of the oil. check engine oil level with engine at normal operating temperature. Without sidecar attached. wipe it off and insert it back into the oil pan with the plug pushed completely into the fill spout. DO NOT use standard lubricants in the FLHTCSE2 model and do not mix lubricants as damage to the motorcycle can result. IMPORTANT NOTE Oil level cannot be accurately measured on a cold engine. Start engine and carefully check for oil leaks around drain plug and oil filter. To insure the correct oil level with sidecar attached perform the following: 1. the engine oil level reading must be adjusted in this case. 2. Do NOT add oil to bring the level to the FULL mark on a COLD engine. NOTE Once the predelivery inspection procedure is complete and the vehicle has been road-tested. Perform engine oil level COLD CHECK as follows: 1. 3. 3. allow engine to idle for 1-2 minutes. 2. add only enough oil to bring the level to the add arrow on the dipstick. For preride inspection with motorcycle leaning on jiffy stand on level ground. 4. 2. ENGINE OIL LEVEL (SIDE CAR EQUIPPED VEHICLES) NOTE Since a motorcycle equipped with a sidecar is fixed in an upright position. See HOT CHECK procedure above. COLD CHECK HOT CHECK f1254b3x Figure 2-15. Perform engine oil level HOT CHECK as follows: 1. 4. With the vehicle resting on the jiffy stand on level ground. Remove the dipstick. note engine oil level on dipstick. Scribe a line on dipstick at the oil level noted in step 4 above. ride until engine is at normal operating temperature. Engine Oil Dipstick 2-12 2005 PDI: Touring Models . With sidecar attached. Oil level should register on the dipstick. Add only enough oil to bring the level to the FULL mark on the dipstick. remove the dipstick. On a level surface. Turn engine off. 5. the actual FULL engine oil level will be about 1/2 inch above the original FULL mark on the oil tank dipstick. 2. Do not overfill. Verify oil level is at FULL mark on dipstick (add oil if needed). The scribed line is the FULL mark for sidecar operation.3 Remove the dipstick and note the level of the oil. With the vehicle resting on the jiffy stand on level ground. oil should register on dipstick between arrows when engine is cold. See Figure 2-15. wipe it off and insert it back into the oil pan with the plug pushed completely into the fill spout. the engine oil level should be checked again as described in the following procedure. If there is a need to top off lubricants.LUBRICATION SYSTEM ENGINE OIL LEVEL CAUTION The FLHTCSE2 model is shipped from the factory with SYN-3® lubricant exclusively in the engine.

3. Remove five screws. 2005 PDI: Touring Models 2-13 . 1. Also. Clutch lever should move freely and smoothly through its entire range of travel. the hydraulic clutch is not adjustable. and secure with five screws. Reinstall cover gasket and clutch inspection cover. 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. It is not necessary to check the primary chaincase lubricant level on this vehicle.2 Nm). 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 Check clutch action. Tighten to 84-108 in-lbs (9. 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).TRANSMISSION LUBRICANT NOTE Allow vehicle to stand upright for a moment before checking transmission lubricant level. This will allow lubricant level to normalize. See Figure 2-16. 2. pd0206 CHAINCASE LUBRICANT LEVEL AND CLUTCH OPERATION NOTE Do not remove the clutch cover on the FLHTCSE2.512. Figure 2-16. clutch inspection cover and cover gasket.

engine damage and/or equipment malfunction. always be sure the quick-connect fitting (under left side of fuel tank) is properly mated. Gasoline is extremely flammable and highly explosive. They are identified as “gasohol. Fuel Supply Valve 2-14 2005 PDI: Touring Models . Gasolines containing ETHANOL (ethyl alcohol or grain alcohol) can be used. Inspect fuel valve for leaks. Inspect fuel lines for leaks. (00150a). They are also formulated to evaporate less when you are filling your tank. Gasoline/ethanol blends are a mixture of 10% ethanol and 90% unleaded gasoline. 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. Using leaded fuel will damage the emission control system. If you experience these problems. Follow FUEL recommendations found in the Owner’s Manual. Inadequate safety precautions could result in death or serious injury. Verify function of fuel gauge as fuel tank is filling. CAUTION Do not use gasoline that contains methanol. After adding gasoline. Turn the ignition/light switch to the IGNITION position. Tug on fuel supply line (under left side of fuel tank) to be sure quick connect fitting is properly mated. then turn ignition/light switch OFF. o0046box Figure 2-17. The type and amount of alcohol or ether added to the fuel is important.FUEL SYSTEM GENERAL CAUTION Some fuel suppliers sell gasoline which has been blended with an alcohol or an ether.” or “contains ethanol. Doing so can result in fuel system component failure.” Gasolines containing METHYL TERTIARY BUTYL ETHER (MTBE) can also be used. ● Carbureted Models See Figure 2-17. (00148a) ● 2. drivability. Because of their different chemical properties (which affect fuel volatility and ignition characteristics). unleaded gasoline. A slight tug on the fuel line will verify this condition. 2. these blends may adversely affect the starting. leaving fewer “tailpipe” emissions. Gasoline/MTBE blends are a mixture of gasoline and as much as 15% MTBE. and fuel efficiency of the motorcycle. Reformulated gasolines use additives to “oxygenate” the gas. CAUTION Use only unleaded fuel in California model catalytic converter-equipped motorcycles. 1. push up on sleeve of quick-connect fitting and insert neck of fuel supply line fitting. Your motorcycle will run normally using this type of gas and Harley-Davidson recommends you use it when possible. HarleyDavidson recommends using straight. Fuel injected models: verify that Low Fuel lamp is lit. If fuel line comes free. Use unleaded gasoline. pull down on sleeve until it “clicks” into the locked position. as an aid to cleaner air in our environment ● FUEL TANK Make sure engine stop switch on the handlebar is switched to the OFF position.” “ethanol enhanced. Partially fill fuel tank with gasoline. While pushing up on bottom of fuel supply line fitting.4 CHECKING QUICK CONNECT FUEL LINE FITTING–FUEL INJECTED MODELS 1WARNING To avoid an uncontrolled discharge or spray of gasoline. check for smooth operation of the fuel valve. 91 octane or higher.

Vacuum tube 3. Clean air inlet tube from air cleaner backplate (carbureted models only) Purge tube to carburetor or induction module Fuel vapor vent tube from fuel tank Fuel vapor vent tube from vapor valve Figure 2-19. Filler neck fitting (Top of canopy on FLHR/C/S) 5. and fuel tank venting to canister (if equipped). Carburetor (induction module on fuel-injected models) 2. Fuel valve 4. Evaporative Emissions Control System Hose Routing 2005 PDI: Touring Models 2-15 . Charcoal canister 9. Purge tube 10. connections. Vapor valve 8. See Figure 2-19. Fuel vapor vent tube 7. 3. Verify correct evaporative emissions control system hose routing. 2. Clean air inlet tube (not used on fuel-injected models) 11. Fuel tank 6. 4. Evaporative Emissions Control System Hose Connections f1884x4x 1 3 4 2 1. 1. Air cleaner backplate 2 1 3 4 5 7 9 8 6 10 11 f1706x4x Figure 2-18.EVAPORATIVE EMISSIONS CONTROL SYSTEM–CALIFORNIA MODELS ONLY See Figure 2-18.

D A V I D S O N 7 4 6 4 FLHR Models 2 5 8 FLHT and FLTR Models pd0221 1. 4. 2. The instrument panel has a Low Fuel. (00030b) FRONT TURN SIGNALS (FLHRS ONLY) Adjust and tighten. 5. 3. ● The Low Fuel Warning lamp comes on when approximately 0. 8.ELECTRICAL SYSTEM HEADLAMP Check headlamp beam for proper height and lateral alignment in accordance with procedures given in Section 8 of the Touring Models Service Manual. ● f2185xax d0715x8x 1 8 2 3 1 40 30 20 10 0 50 60 70 MPH 80 90 100 110 120 30 20 10 0 HA 40 50 60 70 80 RPM x100 7 6 5 C H A E R TIFI E D R L E Y-D A V I D S O N R L E Y. INSTRUMENT PANEL See Figure 2-20. check lamp beam for proper height and lateral alignment in accordance with procedures given in the Touring Models Service Manual.5 DIRECTIONAL LAMPS Adjust front directional lamps so lenses are aimed directly forward. The Check Engine lamp illuminates briefly (4 seconds) at start-up and should then remain off unless an error code is present. Security (if equipped) Battery. 6. Check Engine.9 gallon (3. 9. 7. Verify that directional lamp fasteners are properly tightened. Instrument Panel Warning Lamps 2-16 2005 PDI: Touring Models . 10. Be sure headlamp is on at all times. 1WARNING The automatic-on headlamp feature provides increased visibility of the rider to other motorists. Cruise Control (if equipped) and ABS (if equipped) warning lamps.4 liter) of gasoline remains. AUXILIARY LAMPS On models equipped with auxiliary lamps. Poor visibility of rider to other motorists can result in death or serious injury. Ensure that directionals do not contact fuel tank. Speedometer Security system lamp Tachometer Cruise lamp Odometer/trip-odometer Low fuel warning lamp Engine check lamp Battery discharge lamp ABS lamp (optional police equipment) Pursuit lamp indicator (police) 30 20 10 0 HA 40 50 60 70 RPM x100 P 80 10 R L E Y-D A V I D S O N 9 FLHTP/FLHP Models Tachometer Figure 2-20. 2.

This time. 6. 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 Tail lamp–running lamp and brake lamp filaments Speedometer illumination lamp Tachometer illumination lamp (if equipped) License plate lamp (HDI only) Sound System Operation (if equipped) NOTES For any Systems problems. After engine has reached normal operating temperature. 4. The Check Engine lamp and if TSSM EQUIPPED. 9. Shift transmission to neutral position. 5. Ignition Switches 2005 PDI: Touring Models 2-17 . Check that oil pressure indicator lamp turns off when engine is running above 1000 RPM. NOTE On Police models. and check that Oil pressure indicator lamp turns on (before engine is started). 3.INDICATOR LAMPS/CONTROLS 1. Check operation of tachometer (if equipped). pd0192 3 1 2 1 1. Shift transmission to neutral position. and verify that neutral indicator lamp turns on. 7. turn engine off. See Figure 2-21. check operation of starter. 8. 2 Ignition switch unlocked Ignition switch locked “Key ON” Ignition position Figure 2-21. and verify that neutral indicator lamp turns on again. refer to the appropriate Electrical Diagnostic manual for your model. and verify that neutral indicator lamp turns off when transmission is shifted to any forward gear. Turn ignition/light switch to IGNITION position. Check horn operation. 10. Disengage clutch (depress clutch lever). 3. Start engine. the clutch lever must be depressed to operate the starter. 2. THE SECURITY LAMP will illuminate for approximately four seconds and then turn off. 2. fill oil tank to upper mark on filler cap/dipstick. Check engine oil level in manner previously specified.

Check for proper front and rear tire pressures when tires are cold. 2. (00027a). Tire Pressures Front Tires PSI Solo rider Rider & passenger 36 36 kPA 248 248 PSI 36 40 kPA 248 276 Rear 1WARNING Harley-Davidson front and rear tires are not the same. which could result in death or serious injury. (00026a) 1. Over inflated tires can blow out. Compare results against Table 2-5.TIRES FRONT AND REAR TIRES 1WARNING Do not inflate tire beyond maximum pressures specified on sidewall. which could result in death or serious injury. Interchanging front and rear tires can cause tire failure. 2-18 2005 PDI: Touring Models .6 Table 2-5.

If the ABS lamp turns on solid at ignition-ON.T. The lamp will then turn off.T. obtain medical attention.O. 4 brake fluid with eyes can cause irritation.T. and remains flashing until the motorcycle reaches 6 MPH (9. (00240a) CAUTION D.7 Figure 2-22. Use in well ventilated area. Wash all residue of D.O.T. Always use caution and protect surfaces from spills whenever brake work is performed. See Figure 2-22. 4 brake fluid can cause digestive discomfort. Spilling brake fluid on handlebar switches may render them inoperative. 2005 PDI: Touring Models 2-19 . Rear Brake Reservoir/Master Cylinder Sightglass (typical) ABS SYSTEM (POLICE VEHICLES– OPTIONAL EQUIPMENT) The ABS indicator lamp in the tachometer will flash when the ignition switch is turned on.7 KPH). (00239a) CAUTION Cover handlebar switches with a shop towel before adding brake fluid to front master cylinder reservoir. See Service Manual. Avoid eye contact. 4 brake fluid will damage painted and molded-in color surfaces it comes in contact with. it is an indication of a current fault condition in the ABS system. Sightglass should appear dark if fluid is present.BRAKE SYSTEM BRAKES 1CAUTION Direct contact of D. Swallowing large amounts of D. or does not turn off when vehicle exceeds 6 MPH (9. If sightglass is not dark. KEEP OUT OF REACH OF CHILDREN.O. In case of eye contact flush with large amounts of water and get medical attention.7 KPH). 99953-99A). add brake fluid.T. 4 brake fluid spills off vehicle with water. Use only D.O. 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. View reservoir sightglass and verify fluid presence. Failure to comply can result in cosmetic damage.O. 4 HYDRAULIC BRAKE FLUID (Part No. 6628 2. If swallowed.

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. 2-20 2005 PDI: Touring Models . ● ● Shift from first through fifth gear. Shift from first through third gear. 2 3 4 1 Carburetor stop plate Cable housing Spring Throttle cam stop Idle speed adjusting screw Figure 2-23. transmission. 2. HD-44750). 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. and transmission operation. Continuing to use the enrichener when the engine is at full operating temperature will cause fouled plugs.V. checking clutch operation. 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. 2. Set engine slow idle speed of 950 RPM with engine running at normal operating temperature and with enrichment control knob pushed in fully. check Cruise Control. After road test. Check for any abnormal vibrations. Turn carburetor idle speed adjusting screw (5) clockwise to increase speed. because there are variations in individual components. brakes. Check tire condition and pressure (adjust if necessary). indicators. 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. or counterclockwise to decrease speed. Check all electrical equipment and switches including stop lamp. etc. Check electrical lamps. Carburetor Adjustments ● 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. Check all systems and overall operation of motorcycle: engine. 3. Adjust mirrors to proper riding positions. 1. On Ultra models. throttle control. 6. handling. throttle control and transmission operation. Verify low-speed braking for front and rear brakes. return motorcycle to shop and thoroughly clean off any road dirt. 3. 4. Verify proper handling at highway speeds. 5. Check amount of gasoline in tank and add (if needed). See Figure 2-23. Check for any abnormal vibrations. Road Test of Vehicle: Low Speed 1. Handling under braking conditions. turn signals and horn for proper operation. f1381a2x 5 Road Test of Vehicle: Highway Speed 1. NOTE The C. Verify that vehicle does not pull to left or right. 5. Check and correct any problems you may have found during road test. 2. Low speed handling. Check controls to verify proper function. 2. Be aware that. Program Security System (if equipped) Engine Oil: Check and correct hot level. Before You Begin Check the following items before road test of vehicle: ● ● ● ● ● ● Lamps and indicators. clutch.DEALER ROAD TEST ROAD TEST After you complete motorcycle inspection. Refer to Touring Models Owner’s Manual to check for proper operation. rear speakers and rider/ passenger sound system controls. checking clutch operation.8 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. take motorcycle for a road test. 4. 3. Verify highway-speed braking operation of front and rear brakes. 4.

verify both key fobs operate properly. Make sure owner understands warranties. explain to customer that the Touring Models Owner’s Manual contains detailed operating instructions for the system. Also.CUSTOMER DELIVERY NOTICE TO DEALER Before delivering motorcycle to owner. Personal code should be written on the tear-out card in Touring Models Owner’s Manual and kept on the owner’s person. a video has been prepared to give the customer operating instructions for the Sound System. Review warranties with vehicle owner. Inform vehicle owner about changing TSM/TSSM to sidecar or solo configuration as appropriate. California dealers must give customer a copy of Emissions Control System Warranty. and involve Service Manager in delivery process. On Ultra models.9 IMPORTANT NOTE Make sure vehicle owner understands how to arm and disarm security system. and performing other basic maintenance functions. 10. 2. you may wish to schedule the Initial Scheduled Maintenance service appointment at this time. 9. In addition. Review the Initial Scheduled Maintenance requirement with owner. If motorcycle is equipped with a Sound System. tell customer helmet headset is shipped in saddlebag. 6. Whenever possible. 8. Supply owner with name(s) of dealer Service/ Parts Department personnel who should be contacted regarding vehicle service/parts questions. 5. Depending on owner’s anticipated frequency of operating motorcycle. Inform vehicle owner about checking engine oil level. 2005 PDI: Touring Models 2-21 . Give IMPORTANT sheet and other printed material in literature kit to vehicle owner. Complete and sign warranty registration form. 4. safety booklets and viewing Welcome To The Family video included with owner’s kit. Explain how to disarm security system with personal code if key fob is lost or not functioning. introduce dealer Service Manager to vehicle owner. Explain operation of vehicle controls to vehicle owner. Make sure vehicle owner receives. 2. Have vehicle owner sign it. Explain how turn signals and emergency flashers operate. checking tire pressure. 7. perform the following: 1. and is aware of importance of reading Owner’s Manual. 3.

Inspect fuel system for leaks. b. Fill. Position Tour-Pak and Install Seat and Seat Strap: If equipped Install Saddlebags and Side Covers: Verify adequate saddlebag/side cover clearance. b. 2. Verify handling under braking conditions. e. Program Security System. Primary Chaincase: Check and verify lubricant is present.VEHICLE PDI CHECKLIST PRIOR TO CUSTOMER DELIVERY NOTE Use this checklist for performing tasks related to this model motorcycle setup. b. throttle control and transmission operation. Jiffy Stand: Verify proper function. Note Any Additional Problems (including cosmetic quality): Perform Warranty repairs. connections and fuel tank venting to canister (if equipped). d. Install Antenna Mast(s): If equipped Position Rear Speaker Harness. Check electrical lamps. Create Vehicle Birth-Certificate Using Digital Technician (optional). f. Check for any abnormal vibrations. ❒ Road Test Vehicle: Highway Speed. Shift from first through fifth gear. ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ Uncrate: Check for damaged or missing parts. Install Data Link Connector. Battery: Perform required voltmeter test on Maxi Fuse (main fuse) and battery. Clean Vehicle. tighten clamps to proper torque. Check for any abnormal vibrations. a. Install Instrument Bracket (FLHP models). Verify proper handling at highway speeds. Mirrors: Inspect and adjust as necessary. throttle control and transmission operation. Install Windshield. Brake Systems (front and rear): a. Evaporative Control System: Inspect hose routings. Verify correct operation. c. if equipped). Correct fluid level (if necessary). Verify Proper Police Seat Air Bladder Pressure (Police models). Handlebars: Verify proper position. Gauges. Transmission Lubricant: Check and verify correct lubricant level. Verify low-speed handling. Verify low fuel light operation (if equipped). Install Fuel Pump Fuse (EFI vehicles only). Verify adequate directional-to-fuel tank clearance (FLHRS only). Shift Linkage Adjustment. 2-22 2005 PDI: Touring Models . Shift from first through third gear. ❒ ❒ Tires: Inspect condition and air pressure. Brake Hand Lever Adjustment. Verify proper ABS indicator function (Police models only. Lighting.10 ❒ ❒ ❒ Fuel Outlet (valve or quick connect fitting) and Hoses: Verify operation and connections. Verify highway speed braking operation of front and rear brakes. Review Vehicle Care and Maintenance Requirements. Rear Air Suspension: Inspect and adjust pressure as necessary. Verify low-speed braking for front and rear brakes. Fuel System: a. a. Verify that vehicle does not pull to left or right. verify sender operation. Clutch Operation: Verify proper adjustment. c. ❒ Road Test Vehicle: Low Speed. AT POINT OF CUSTOMER DELIVERY ❒ ❒ ❒ ❒ Suspension Adjustments. d. ❒ ❒ ❒ ❒ Engine Oil: Check and correct hot level. Electrical Systems: a. checking clutch operation. b. checking clutch operation. Throttle Control Cables: Inspect and adjust as necessary. Use DOT 4 fluid only for 2005 FL models. 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. c. Install Maxi Fuse (main fuse). Engine Oil: Verify oil is present (cold level). Lubrication System: Inspect condition of oil lines and fittings. b. indicators.

. . . . . . . . . . . . . . . . . . . . . . Seats And Passenger Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prior to Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shift Lever . . . . . . . . . . . . . 3. . . . . . . . . . . . . . . . . . . . . Front and Rear Tires . . . . . . . . . . 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Lubrication System . . . . . . . . . . . . . . . . . . .10 Vehicle PDI Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension Adjustment for FXDX Model . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . Battery Testing And Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Lubricant Level . . . . . . . . . . . . . . . . . . . . Mirrors and Directional Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Specifications . . . . . . . 3. . . . . . . . . . . . . 3. . . . . . . . . . . . . . . . . . . . .9 Customer Delivery . . . . . . . . . . . . . . . . . .8 Dealer Road Test . 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Quick Connect Fuel Line Fitting–Fuel Injected Models . . . . . . . . . . . . . . . . . . . . . . . . . Headlamp . . .PREDELIVERY: DYNA MODELS SUBJECT PAGE NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chaincase Lubricant Level and Clutch Operation . . . . . . Indicator Lamps/Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Fuel Pump Fuse . . Idle Speed: Carbureted Only . . . . . . . . . . . . . . . . . . . . . . At Point of Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes . . Road Test . . . . Notice To Dealer . . . . . . . . . . . . . III . . . . . . . . . . . . . . . . . . . . . . . .4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Initial Assembly . . . . . . . . . . . Throttle Cables . . . . . . . . . . . . .5 Electrical System . . . . . . . . . Installing Maxi-Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. . . . . . . . . . 3-1 3-1 3-1 3-2 3-2 3-2 3-2 3-2 3-3 3-4 3-4 3-4 3-5 3-5 3-5 3-5 3-6 3-6 3-6 3-6 3-7 3-7 3-7 3-8 3-9 3-9 3-10 3-10 3-11 3-11 3-12 3-12 3-13 3-13 3-13 3. . . . . . . . . . . . . . . . . . . .6 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2005 Dyna Models Specifications . . . . Fuel Tank . . . . . . . . . . . . . .

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7-0.9 Nm 16.1 SPECIFICATIONS TORQUE VALUES The following torque values are included for fasteners that may be loosened and tightened during Predelivery and Setup.3 Nm 9. Any fasteners that are not loosened/removed do not need to be checked during predelivery and setup. 20-24 oz 26 oz METRIC 2.84 liter 591-710 ml 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. 2005 PDI: Dyna Models 3-1 . Capacities Component Oil tank w/filter (Dry) Transmission (Wet) Primary Chaincase ENGLISH 3 qt. HD-44750).9 Nm 0. NOTE The idle speed on electronic fuel injected models can only be set using a diagnostic tool such as DIGITAL TECHNICIAN (Part No.2 Nm NOTES 2005 DYNA MODELS SPECIFICATIONS Table 3-2.3-24.8-10. 3.1 Table 3-1. Engine idle speed may increase during engine break-in.5-12.4 Nm 16. Torque Values ITEM Battery terminal screws Front brake master cylinder cover screws Handlebar clamp screws (front and rear) Mirror fasteners Clutch inspection cover screws TORQUE 60-96 in-lbs 6-8 in-lbs 12-18 ft-lbs 12 ft-lbs 84-108 in-lbs 6. Use idle speed listed in the Dyna Models Service Manual at Initial Maintenance check.

6 VDC. 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.2 INSTALLING MAXI-FUSE The 40 amp Maxi-Fuse provides battery power to the ignition switch and ECM. Be aware that. 2. 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. perform steps 2 and 3 above. (00064a) 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. 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. 6. See Section 1. It is shipped attached to the motorcycle. refer to Table 1-2. If voltage now is 12.6 VDC. Mark the date on the battery warranty tag by removing the applicable month and year. 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. in Section 1 and charge battery at rate and time specified. Recheck battery voltage by repeating step 1 above.INITIAL ASSEMBLY BATTERY TESTING AND CHARGING 1WARNING Batteries contain sulfuric acid. which could cause severe burns to eyes and skin. 1WARNING Battery posts. Place test probes of voltmeter on battery terminals and check the voltage of the battery to make sure it is at least 12. Set engine slow idle speed of 950 RPM with engine running at normal operating temperature and with enrichment control knob pushed in fully. Failure to read and understand all precautions in warning could result in death or serious injury. If the open circuit (disconnected) voltage reading is below 12. (00063a) 3. because there are variations in individual components. 12 amp-hour battery. 4. The 40 amp Maxi-Fuse is not installed at the factory. If the open circuit (disconnected) voltage reading is 12.6 VDC or greater the battery is ready for use. chemicals known in the State of California to cause cancer and birth defects or other reproductive harm. HD-44750). Turn carburetor idle speed adjusting screw (5) clockwise to increase speed.6 VDC or greater. terminals and related accessories contain lead and lead components. If the open circuit (disconnected) voltage reading is still below 12. Month and year punches may be removed with the point of a screwdriver without removing battery. Wear a protective face shield. (00019a) NOTE It will be necessary to remove the battery sidecover to gain access to the battery. INSTALLING FUEL PUMP FUSE For non-carbureted vehicles. 1WARNING Never remove warning label attached to top of battery. the battery must be replaced. KEEP BATTERIES AWAY FROM CHILDREN. 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. 3-2 2005 PDI: Dyna Models . Wash hands after handling. or counterclockwise to decrease speed. rubberized gloves and protective clothing when working with batteries. 1. Continuing to use the enrichener when the engine is at full operating temperature will cause fouled plugs. See Figure 3-1.6 VDC. NOTE The C. 5. See Service Manual. 3.V.

See Figure 3-2. Recheck engine slow idle speed. Recheck operation of throttle control (Step 7). Interference with steering could cause loss of vehicle control which could result in death or serious injury. 9. Twist throttle control grip to fully open position. Tighten jam nut (5) on idle control cable (3) adjuster (4). 2. Carburetor Adjustments 6. 4. If this is not the case. THROTTLE CABLES Twist and release throttle control grip a few times to verify proper operation of throttle control system. With throttle friction screw (1) loosened. 8. 5. 3. 4. Check throttle cable adjustment. 5. Carburetor stop plate Cable housing Spring Throttle cam stop Idle speed adjusting screw Figure 3-1. 3. 2005 PDI: Dyna Models 3-3 . 7. Turn adjuster on throttle control cable until throttle cam stop (4) touches carburetor stop plate (1). Turn handlebars fully to right. Steering must be smooth and free with no binding or interference. 5 4 Throttle friction screw Throttle control cable Idle control cable Adjuster Jam nut 3 Figure 3-2. Slide rubber boot (if applicable) over each cable adjuster (4). With throttle friction screw loosened. Carburetor throttle must return to idle position each time throttle grip is released. 10. adjust throttle cables as follows: 1. hold in position. 1WARNING Throttle cables must not pull tight when handlebars are turned fully to left or right fork stops. carburetor throttle must return to idle position each time throttle control grip is released. If engine speed changes during this maneuver. See Figure 3-2. 4. twist and release throttle control grip a few times. Turn adjuster on idle control cable until end of cable housing (2) just touches spring (3) within carburetor cable guide. Loosen jam nut (5) on each adjuster (4). turn handlebars through full range of travel.f1381a2x 5428 5 1 2 2 3 4 1 1. With engine running. Throttle Cable Adjustment 5. 2. See Figure 3-2. Slide rubber boot (if applicable) off each cable adjuster. turn adjuster (4) on idle control cable (3) (shortening cable housing) until throttle control functions properly. 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. 1. Point front wheel straight ahead. Tighten jam nut (5) on throttle control cable (2) adjuster (4). 2. Turn adjusters in direction which will shorten cable housings to minimum length. 3. See Figure 3-1. See Figure 3-1. adjust if required. release throttle control grip.

rider’s foot must be able to fit easily under shift lever. Adjust shift lever if required. Check shift lever adjustment.SUSPENSION ADJUSTMENT FOR FXDX MODEL Refer to the Dyna Models Owner’s Manual for suspension adjustment instructions for FXDX model. 3-4 2005 PDI: Dyna Models . SHIFT LEVER Inspect shift linkage for free movement. SEATS AND PASSENGER STRAP Refer to the Dyna Models Owner’s Manual for seat and passenger strap removal and installation instructions.

pd0206 NOTE Do not fill oil tank to full (upper) mark on filler cap/dipstick at this time. If oil level in pan is below lower mark on dipstick. you would fill a Dyna oil pan (with warm engine) to this level. Tighten to 84-108 in-lbs (9. Remove filler cap with attached dipstick. See Figure 3-4. and secure with five screws. clutch inspection cover and cover gasket. add enough Harley-Davidson oil to bring level up between lower mark (1) and cold check level (2) on dipstick.512. See Figure 3-3. 1. 4. TRANSMISSION LUBRICANT LEVEL NOTE Allow vehicle to stand upright for a moment before checking transmission lubricant level. d0386x1x 1 2 3 NOTE For cold check level do not exceed this point when filling with oil. Refer to the Dyna Models Service Manual for recommended viscosity. Engine Oil Dipstick 3. The primary chaincase lubricant level is acceptable when lubricant is visible in bottom of chaincase with motorcycle standing upright (not resting on jiffy stand). Clutch lever should move freely and smoothly through its entire range of travel. 3. 3.LUBRICATION SYSTEM ENGINE OIL LEVEL Check engine oil level with engine turned off and motorcycle resting on jiffy stand on level surface. Check clutch action. NOTE The clutch inspection cover gasket may be reused ONLY when checking chaincase lubricant level and reinstalling clutch inspection cover at PDI. 2005 PDI: Dyna Models 3-5 . Install filler cap. Figure 3-4. and check oil level on dipstick.2 Nm). 2. Remove filler cap. 5. This will allow lubricant level to normalize. 3. Lower arrow (add oil) Cold check level Upper arrow (hot check level) Figure 3-3.3 CHAINCASE LUBRICANT LEVEL AND CLUTCH OPERATION 1. Remove five screws. after engine has reached normal operating temperature. Final check of oil level must be made with engine off. if any oil has flowed from oil pan to crankcase during shipping. Make sure cap is fully seated in oil pan filler neck. Reinstall cover gasket and clutch inspection cover. filling oil pan to full mark might result in overfilling of oil pan when engine is started. Ordinarily. 2. Wipe dipstick clean. In this situation. Check clutch adjustment according to the procedures given in the Dyna Models Service Manual. Check the transmission lubricant level with the motorcycle standing upright in accordance with the procedure given in the Dyna Models Service Manual. 2. however. Chaincase Lubricant Level 1.

” or “contains ethanol. 2. 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. these blends may adversely affect the starting. ● Carbureted Models See Figure 3-5. Because of their different chemical properties (which affect fuel volatility and ignition characteristics). Tug on fuel supply line (under left side of fuel tank) to be sure quick connect fitting is properly mated. Gasoline/ethanol blends are a mixture of 10% ethanol and 90% unleaded gasoline. (00148a) ● 3.4 CHECKING QUICK CONNECT FUEL LINE FITTING–FUEL INJECTED MODELS 1WARNING To avoid an uncontrolled discharge or spray of gasoline. Gasoline is extremely flammable and highly explosive. Follow FUEL recommendations found in the Owner’s Manual. Fuel Supply Valve 3-6 2005 PDI: Dyna Models . If you experience these problems. Reformulated gasolines use additives to “oxygenate” the gas. Using leaded fuel will damage the emission control system. Partially fill fuel tank with gasoline. Fuel injected models: verify that Low Fuel lamp is lit. Gasolines containing ETHANOL (ethyl alcohol or grain alcohol) can be used. check for smooth operation of the fuel valve. Use unleaded gasoline. Doing so can result in fuel system component failure. Verify function of fuel gauge as fuel tank is filling. They are also formulated to evaporate less when you are filling your tank.FUEL SYSTEM GENERAL CAUTION Some fuel suppliers sell gasoline which has been blended with an alcohol or an ether. (00150a). They are identified as “gasohol. always be sure the quick-connect fitting (under left side of fuel tank) is properly mated. engine damage and/or equipment malfunction. unleaded gasoline. Inadequate safety precautions could result in death or serious injury. o0046b Figure 3-5.” “ethanol enhanced.” Gasolines containing METHYL TERTIARY BUTYL ETHER (MTBE) can also be used. push up on sleeve of quick-connect fitting and insert neck of fuel supply line fitting. Inspect fuel valve for leaks. CAUTION Do not use gasoline that contains methanol. After adding gasoline. 91 octane or higher. Your motorcycle will run normally using this type of gas and Harley-Davidson recommends you use it when possible. Inspect fuel lines for leaks. If fuel line comes free. The type and amount of alcohol or ether added to the fuel is important. A slight tug on the fuel line will verify this condition. and fuel efficiency of the motorcycle. Gasoline/MTBE blends are a mixture of gasoline and as much as 15% MTBE. HarleyDavidson recommends using straight. Turn the ignition/light switch to the IGNITION position. then turn ignition/light switch OFF. CAUTION Use only unleaded fuel in California model catalytic converter-equipped motorcycles. as an aid to cleaner air in our environment ● FUEL TANK Make sure engine stop switch on the handlebar is switched to the OFF position. While pushing up on bottom of fuel supply line fitting. drivability. leaving fewer “tailpipe” emissions. pull down on sleeve until it “clicks” into the locked position. 1.

check that oil pressure indicator lamp turns on (before engine is started) and check engine lamp illuminates for about four seconds and goes off. 8. 2. (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. Instruments & Indicator Lamps FXDX (typical) 7. Check operation of tachometer. Check engine oil level in manner previously specified. and verify that neutral indicator lamp turns off when transmission is shifted to any forward gear. 9. Poor visibility of rider to other motorists can result in death or serious injury. Figure 3-6. 9. Install snap cap after headlamp has been adjusted.5 9 8 1 1WARNING The automatic-on headlamp feature provides increased visibility of the rider to other motorists. 2005 PDI: Dyna Models 3-7 . 4. turn engine off. indicators in headlamp bracket. This time. 2 3 4 5 6 7 INDICATOR LAMPS/CONTROLS NOTE See Figure 3-6. 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 ● ● ● ● ● ● ● ● ● 2. 1. Instruments and indicators on remaining Dyna models are located as follows: ● ● 1. 5. 10. 6. 5. check operation of starter. Be sure headlamp is on at all times. 4. tachometer illumination lamp After engine has reached normal operating temperature. Turn ignition switch to “IGNITION” position. 3. Shift transmission to neutral position. Check that oil pressure indicator lamp turns off when engine is running above 1000 RPM. Start engine.ELECTRICAL SYSTEM HEADLAMP Check headlamp beam for proper height and lateral alignment in accordance with procedures given in the Dyna Models Service Manual 10648 3. Check horn operation. if equipped. Shift transmission to neutral position. Check operation of all remaining lamps: ● ● FXDL Speedometer and tachometer in console on gas tank. fill oil tank to upper mark on filler cap/dipstick. Speedometer Odometer and trip odometer Left directional (turn signal) indicator lamp High beam indicator lamp Neutral indicator lamp Oil pressure indicator lamp Right directional (turn signal) indicator lamp Tachometer Check engine lamp FXD Speedometer and indicators in handlebar bracket. 7. and verify that neutral indicator lamp turns on. FXDWG Speedometer and indicators in panel on gas tank. This figure shows instruments and indicators on FXDX models. 8. 3. and verify that neutral indicator lamp turns on again. 6. Disengage clutch (depress clutch lever). All other models are shipped in position.

Adjust front directional lamps so lenses are aimed directly forward.3 Nm). pd0104c 1. 2. 3. Tighten mirror fasteners to 12 ft-lbs (16. Mirror and Directional Lamp Mounting 3-8 2005 PDI: Dyna Models . Verify that mirror and directional lamp fasteners are properly tightened. adjust rear directional lamps so lenses are aimed directly rearward. 4. Adjust mirrors for proper rear view.MIRRORS AND DIRECTIONAL LAMPS See Figure 3-7. Mirror Star washer Acorn nut Front directional lamp Figure 3-7.

Over inflated tires can blow out. (00026a) 1. (00027a) Front Rear TIRES PSI 30 36 kPA 207 248 3. Compare results against Table 3-3. Interchanging front and rear tires can cause tire failure. which could result in death or serious injury. 2005 PDI: Dyna Models 3-9 .TIRES FRONT AND REAR TIRES 1WARNING Do not inflate tire beyond maximum pressure as specified on sidewall.6 Table 3-3. which could result in death or serious injury. Tire Pressures SOLO RIDER RIDER & ONE PASSENGER PSI 30 40 kPA 207 276 1WARNING Harley-Davidson front and rear tires are not the same. Check for proper front and rear tire pressures when tires are cold.

O. obtain medical attention. swelling. If swallowed.O.T. 5 brake fluid can cause digestive discomfort. Avid eye contact. See Service Manual. If sightglass is not dark. Swallowing large amounts of D.7 Figure 3-8. add brake fluid. 5 brake fluid can cause eye irritation. 5 SILICONE HYDRAULIC BRAKE FLUID. Use only D. Sightglass should appear dark if fluid is present. Rear Master Cylinder Shown 3-10 2005 PDI: Dyna Models . Use in well ventilated area. View reservoir sightglass and verify fluid presence. 4934 3. and redness.T.O.BRAKE SYSTEM BRAKES 1CAUTION Direct contact with D. In case of eye contact flush with large amounts of water and get medical attention. (00144a) See Figure 3-8. KEEP OUT OF REACH OF CHILDREN.T.

5. and transmission operation. 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. and thoroughly clean off any road dirt. Verify low speed braking for front and rear brakes. indicators. throttle control. Before You Begin Check the following items before road test of vehicle: ● ● ● ● ● ● Lamps and indicators. Check for any abnormal vibrations. Low speed handling. Adjust mirrors to proper riding positions. Check controls to verify proper function. Check all electrical equipment and switches including stop lamp. Road Test of Vehicle: Highway Speed 1. Check and correct any problems you may have found during road test. Check for any abnormal vibrations. brakes. checking clutch operation.8 Road Test of Vehicle: Low Speed 1. Check electrical lamps.DEALER ROAD TEST ROAD TEST After you complete motorcycle inspection. 2. 3. Verify that vehicle does not pull to left or right. Verify highway speed braking operation of front and rear brakes. Check tire condition and pressure (adjust if necessary). Shift from first through third gear. turn signals and horn for proper operation. return motorcycle to shop. 2005 PDI: Dyna Models 3-11 . Verify proper handling at highway speeds. 6. take motorcycle for a road test. etc. 4. transmission. and transmission operation. Check all systems and overall operation of motorcycle: engine. 3. 2. throttle control. 3. handling. ● ● Shift from first through fifth gear. checking clutch operation. 4. clutch. Check amount of gasoline in tank and add (if needed). After road test. Handling under braking conditions.

CUSTOMER DELIVERY
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. Review warranties with vehicle owner. Make sure owner understands warranties. California dealers must give customer a copy of Emissions Control System Warranty. Give IMPORTANT sheet and other printed material in literature kit to vehicle owner. Complete and sign warranty registration form. Have vehicle owner sign it. Explain operation of vehicle controls to vehicle owner. Explain how turn signals and emergency flashers operate. 8.

3.9
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. Inform vehicle owner about checking engine oil level, checking tire pressure, and performing other basic maintenance functions. Review the Initial Scheduled Maintenance 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.

2.

3. 4. 5. 6.

3-12

2005 PDI: Dyna Models

VEHICLE PDI CHECKLIST
PRIOR TO CUSTOMER DELIVERY
NOTE Use this checklist for performing tasks related to this model motorcycle setup.

3.10
❒ ❒
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 operation. Verify low-speed braking for front and rear brakes. Verify handling under braking conditions. Verify low-speed handling. Verify that vehicle does not pull to left or right. Check for any abnormal vibrations. Check electrical lamps, indicators. Shift from first through fifth gear, checking clutch operation, throttle control, and transmission operation. Verify highway speed braking operation of front and rear brakes. Verify proper handling at highway speeds. Check for any abnormal vibrations.

❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒

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

Road Test Vehicle: Highway Speed a.

❒ ❒ ❒

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.

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.

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. . . . . . . . . . . . . . . . Mirrors and Directional Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Customer Delivery . . . . . . . Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chaincase Lubricant Level and Clutch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Fuel Pump Fuse . . . . . . . . . . . . Road Test . . . . . . . . . . . . . . .PREDELIVERY: SOFTAIL MODELS SUBJECT PAGE NO. . . . . . . .3 Lubrication System . . . . . . . . . . . . . . .1 Specifications . . Brakes . . . . . . . . . . . . . . . . . . . . . . 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 4-1 4-1 4-1 4-2 4-2 4-2 4-2 4-3 4-3 4-4 4-5 4-5 4-5 4-5 4-6 4-6 4-6 4-6 4-7 4-7 4-7 4-7 4-8 4-8 4-9 4-9 4-10 4-10 4-11 4-11 4-12 4-12 4-12 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. . . . . . . . . . . . . Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. . . . . . . . .10 Vehicle PDI Checklist . . . . . . . . . . . . . . . . . . . . . 4. . . . 2005 Softail Models Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prior to Customer Delivery . .8 Dealer Road Test . . . . . . . . . . . . . . . . . .2 Initial Assembly . . . . . . . . . . . Idle Speed: Carbureted Only . . . . . Transmission Lubricant Level . . . . Notice To Dealer . . . . . . .5 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. . . . . . Front and Rear Tires . . . . . . . . . . . . . . . . . . . . . . . . . Seats And Passenger Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Lamps . . . Battery Testing And Charging . . . . . . . . . Ignition Timing . . . . . . . . . . . . . . . Checking Quick Connect Fuel Line Fitting–Fuel Injected Models . . . IV . . . . . . . . . 4. . . . . . . . . At Point of Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Values . . . . . . . . . . . . . . . . . .7 Brake System . . . . . . . . . . . . Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.

1 SPECIFICATIONS TORQUE VALUES The following torque values are included for fasteners that may be loosened and tightened during Predelivery and Setup.2 Nm NOTES 2005 SOFTAIL MODELS SPECIFICATIONS Table 4-2. Any fasteners that are not loosened/removed do not need to be checked during predelivery and setup. 4.1 Table 4-1.7-0. 2005 PDI: Softail Models 4-1 .5 qt.8-10. Idle Speed: 950 RPM at Operating Temperature Use 950 RPM during Predelivery and Setup adjustments. Engine idle speed may increase during engine break-in.31 liter 591-710 ml 769 ml All Softail models except FLSTFSE are shipped with 20W50 Harley-Davidson 360 Motor oil.3 Nm 0. Torque Values ITEM Handlebar clamp screws (front and rear) Brake master cylinder cover screws (front and rear) Battery terminal screws Mirror fasteners Clutch inspection cover screws TORQUE 12-15 ft-lbs 6-8 in-lbs 60-96 in-lbs 60-96 in-lbs 84-108 in-lbs 16. Use idle speed listed in the Softail Models Service Manual at Initial Maintenance check.3-20. Capacities Component Oil tank w/filter (Dry) Transmission (Wet) Primary Chaincase ENGLISH 3.5-12.8-10-9 Nm 9. The FLSTFSE model ships with Syn-3® lubricant in the engine.9 Nm 6. NOTE The idle speed on electronic fuel injected models can only be set using a diagnostic tool such as DIGITAL TECHNICIAN (Part No. 20-24 oz 26 oz METRIC 3.9 Nm 6. primary and transmission. HD-44750).

6 VDC. 2.3 LUBRICATION SYSTEM and perform initial engine oil level check prior to starting engine.2 Connecting Battery NOTE One battery terminal bolt is attached to red plastic terminal cover covering positive battery terminal. Wash hands after handling.INITIAL ASSEMBLY BATTERY TESTING AND CHARGING 1WARNING Batteries contain sulfuric acid. Recheck battery voltage by repeating step 1 above. and verify that neutral indicator lamp turns on. Start engine. Check that oil pressure indicator lamp turns off when engine is running above 1000 RPM. 5.8-10. 4-2 2005 PDI: Softail Models . Refer to the Softail Models Service Manual for service instructions. (00063a) 4. If the open circuit (disconnected) voltage reading is below 12. Attach positive battery cable first. Month and year punches may be removed with the point of a screwdriver without removing battery. Speedometer needle will “vibrate” and speedometer amber backlight will be visible. Mark the date on the battery warranty tag by removing the applicable month and year. and verify that neutral indicator lamp turns on again. refer to Table 1-2.. If voltage now is 12 VDC or greater. If the open circuit (disconnected) voltage reading is 12. If vehicle is equipped with optional Security System (TSSM). Shift transmission to neutral position. Check horn operation. it will also be necessary to install the fuel pump fuse that is located in the spare fuse slot of the fuse-block. 3.9 Nm). please refer to the appropriate Electrical Diagnostic manual for your model. 1. INDICATOR LAMPS NOTE All Softail models have an electronic speedometer with selfdiagnostic capabilities.8-10. 1WARNING Never remove warning label attached to top of battery. 12 amp-hour battery.9 Nm). 3. chemicals known in the State of California to cause cancer and birth defects or other reproductive harm. 1WARNING Battery posts. Disengage clutch and verify that neutral indicator lamp turns off when transmission is shifted to any forward gear. in Section 1 and charge battery at rate and time specified. 4. See Service Manual. the battery must be replaced. Place test probes of voltmeter on battery terminals and check the voltage of the battery to make sure it is at least 12. KEEP BATTERIES AWAY FROM CHILDREN. Remove seat according to procedure in appropriate Service Manual. and check that oil pressure indicator lamp turns on (before engine is started). 4. The Check Engine indicator will illuminate for about four seconds and then go off. NOTE For any systems problems. The second battery terminal bolt is in negative battery terminal. perform steps 2 and 3 above. 6. (00064a) INSTALLING FUEL PUMP FUSE For non-carbureted vehicles. If the open circuit (disconnected) voltage reading is still below 12. rubberized gloves and protective clothing when working with batteries. 2. Shift transmission to neutral position. Orient terminal so cable is oriented away from oil tank and tighten terminal bolt to 60-96 in-lbs (6. which could cause severe burns to eyes and skin. Turn ignition switch to “IGNITION” position. Attach negative battery cable and tighten terminal bolt to 60-96 in-lbs (6. a key icon (9) (security lamp) will illuminate for about four seconds and then go off. 1. See Figure 4-1. 2. check operation of starter. Failure to read and understand all precautions in warning could result in death or serious injury.6 VDC.6 VDC or greater the battery is ready for use. Battery Testing and Charging 1. (00019a) NOTE It will be necessary to remove the seat to perform required battery tests. terminals and related accessories contain lead and lead components.6 VDC. NOTE See 4. 6. 5. Wear a protective face shield. See Section 1.

3. 2. 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.7. Be aware that. Carburetor stop plate Cable housing Spring Throttle cam stop Idle speed adjusting screw Figure 4-2. pd0189 7 8 40 30 20 10 0 50 60 70 1 MPH E F 80 90 100 110 120 H AR E R T I F I E D C LE Y -D A V I D S O N f1381a2x 9 5 2 1. 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. 5. fill oil tank to upper mark on filler cap/dipstick. 2. Carburetor Adjustments 2005 PDI: Softail Models 4-3 . 5. 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. 4. This time.V. Check engine oil level per instructions in 4. 8. HD-44750). NOTE The C. Check operation of all remaining lamps: ● ● ● ● ● ● ● ● ● 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. After engine has reached normal operating temperature. 7. 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. or counterclockwise to decrease speed. 9. 6. 3. 4. 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. 9. 1. Continuing to use the enrichener circuit when the engine is at normal operating temperature will cause fouled plugs. Speedometer Left turn signal High beam Neutral Oil pressure Right turn signal Check engine lamp Fuel gauge Security lamp 3 4 5 6 2 3 4 1 Figure 4-1. Indicator Lamps IGNITION TIMING Ignition timing is not adjustable on The Twin Cam 88B™ engine. it is possible for a properly warmed-up engine to idle at 2000 RPM with the enrichener knob pulled out partially.3 LUBRICATION SYSTEM. See Figure 4-2. because there are variations in individual components. turn engine off.

SEATS AND PASSENGER STRAP Refer to the Softail Models Owner’s Manual for seat and passenger strap removal and installation instructions.Windshield Installation: FLSTC CAUTION Be sure you position the windshield bracket notches in the grooves in the mounting bushings. See Figure 4-3. gently push the top of the windshield toward the rear until the upper notches fully engage the upper bushings. Incorrect mounting could result in damage to the windshield. Windshield Mounting 4-4 2005 PDI: Softail Models . Standing at the front of the vehicle. 1. Figure 4-3. o0138xox 2. 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.

and check oil level on dipstick. Make sure cap is fully seated on tank. and secure with five screws. add 3/4 quart (0. 4. after engine has reached normal operating temperature. 2005 PDI: Softail Models 4-5 . 1. This will allow lubricant level to normalize. In this situation. Remove filler cap (with attached dipstick) from oil tank. Also. It is not necessary to check the primary chaincase lubricant level on this vehicle. Wipe dipstick clean. primary and transmission. TRANSMISSION LUBRICANT LEVEL NOTE Allow vehicle to stand upright for a moment before checking transmission lubricant level. Remove filler cap. See Figure 4-5. Tighten to 84-108 in-lbs (9. 2. Remove five screws. filling oil tank to full mark might result in overfilling of oil tank when engine is started. DO NOT use standard lubricants in the FLSTFSE model and do not mix lubricants as damage to the motorcycle can result.2 Nm). The primary chaincase lubricant level is acceptable when lubricant is visible in bottom of chaincase with motorcycle standing upright (not resting on jiffy stand). 3. Ordinarily. 1. if any oil has flowed from tank to crankcase during shipping. Clutch lever should move freely and smoothly through its entire range of travel. Chaincase Lubricant Level Add 1 quart mark Figure 4-4. See Figure 4-4. Reinstall cover gasket and clutch inspection cover. Install filler cap onto oil tank. NOTE Do not fill oil tank to full (upper) mark on filler cap/dipstick at this time. Final check of oil level must be made with engine off.LUBRICATION SYSTEM ENGINE OIL LEVEL CAUTION The FLSTFSE model is shipped from the factory with SYN-3® lubricant exclusively in the engine. Check clutch action. Full mark with engine at normal operating temperature pd0219 Figure 4-5. Check engine oil level with engine turned off and motorcycle resting on side stand on level surface. 5.512. Refer to the Softail Models Service Manual for recommended viscosity. the hydraulic clutch is not adjustable.7 liter) of Harley-Davidson oil to tank. If there is a need to top off lubricants. clutch inspection cover and cover gasket. Check clutch adjustment according to the procedures given in the Softail Models Service Manual. Engine Oil Dipstick 3. 2. however.3 CHAINCASE LUBRICANT LEVEL AND CLUTCH OPERATION NOTE Do not remove the clutch cover on the FLSTFSE. NOTE The clutch inspection cover gasket may be reused ONLY when checking chaincase lubricant level and reinstalling clutch inspection cover at PDI. you would fill a Softail oil tank (with warm engine) to this level. Check the transmission lubricant level with the motorcycle standing upright in accordance with the procedure given in the Softail Models Service Manual. If oil level in tank is below lower mark on dipstick. pd0206 4.

o0046box Figure 4-6. Inspect fuel lines for leaks.” “ethanol enhanced. 2. Use unleaded gasoline. After adding gasoline. A slight tug on the fuel line will verify this condition. Inadequate safety precautions could result in death or serious injury. pull down on sleeve until it “clicks” into the locked position. If fuel line comes free. Partially fill fuel tank with gasoline. Gasoline/MTBE blends are a mixture of gasoline and as much as 15% MTBE. They are also formulated to evaporate less when you are filling your tank. Gasoline is extremely flammable and highly explosive. Fuel Supply Valve 4-6 2005 PDI: Softail Models . CAUTION Do not use gasoline that contains methanol.” Gasolines containing METHYL TERTIARY BUTYL ETHER (MTBE) can also be used.” or “contains ethanol. as an aid to cleaner air in our environment ● FUEL TANK Make sure engine stop switch on the handlebar is switched to the OFF position. HarleyDavidson recommends using straight. (00148a) ● 4. 91 octane or higher. Verify function of fuel gauge as fuel tank is filling. Follow FUEL recommendations found in the Owner’s Manual. then turn ignition/light switch OFF. unleaded gasoline. (00150a).4 CHECKING QUICK CONNECT FUEL LINE FITTING–FUEL INJECTED MODELS 1WARNING To avoid an uncontrolled discharge or spray of gasoline. Doing so can result in fuel system component failure. 1. They are identified as “gasohol. 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. Turn the ignition/light switch to the IGNITION position. Gasolines containing ETHANOL (ethyl alcohol or grain alcohol) can be used. engine damage and/or equipment malfunction. The type and amount of alcohol or ether added to the fuel is important. push up on sleeve of quick-connect fitting and insert neck of fuel supply line fitting. Fuel injected models: verify that Low Fuel lamp is lit. Your motorcycle will run normally using this type of gas and Harley-Davidson recommends you use it when possible. and fuel efficiency of the motorcycle. Gasoline/ethanol blends are a mixture of 10% ethanol and 90% unleaded gasoline. Tug on fuel supply line (under left side of fuel tank) to be sure quick connect fitting is properly mated. If you experience these problems. check for smooth operation of the fuel valve. Because of their different chemical properties (which affect fuel volatility and ignition characteristics). ● Carbureted Models See Figure 4-6. leaving fewer “tailpipe” emissions. drivability.FUEL SYSTEM GENERAL CAUTION Some fuel suppliers sell gasoline which has been blended with an alcohol or an ether. Reformulated gasolines use additives to “oxygenate” the gas. Using leaded fuel will damage the emission control system. Inspect fuel valve for leaks. always be sure the quick-connect fitting (under left side of fuel tank) is properly mated. CAUTION Use only unleaded fuel in California model catalytic converter-equipped motorcycles. While pushing up on bottom of fuel supply line fitting. these blends may adversely affect the starting.

1. Adjust front directional lamps so lenses are aimed directly forward.ELECTRICAL SYSTEM HEADLAMP Check headlamp beam for proper height and lateral alignment in accordance with procedures given in the Softail Models Service Manual. check lamp beam for proper height and lateral alignment in accordance with procedures given in the Softail Models Service Manual.5 1WARNING The automatic-on headlamp feature provides increased visibility of the rider to other motorists. 3. Poor visibility of rider to other motorists can result in death or serious injury. (00030b) AUXILIARY LAMPS On models equipped with auxiliary lamps. Be sure headlamp is on at all times. Mirror Star washer Acorn nut Front directional lamp Figure 4-7. Adjust mirrors for proper rear view. MIRRORS AND DIRECTIONAL LAMPS See Figure 4-7. pd0104c 4. Verify that mirror and directional lamp fasteners are properly tightened. 4. Mirrors And Turn Signals 2005 PDI: Softail Models 4-7 . 2. adjust rear directional lamps so lenses are aimed directly rearward.

which could result in death or serious injury. This may cause loss of control. Interchanging front and rear tires can cause tire failure. which could result in death or serious injury.TIRES FRONT AND REAR TIRES 1WARNING Do not alter or modify front suspension/fender/tire type on FXSTS models. (00027a) 1WARNING Harley-Davidson front and rear tires are not the same. which could result in death or serious injury. The motorcycle handling characteristics and front end structural integrity might be adversely affected.6 Table 4-3. Check for proper front and rear tire pressures when tires are cold. MODEL FLSTC/F/N/SC FXST/D/S/B All models 4. (00026a) 1. Compare results against Table 4-3. 4-8 2005 PDI: Softail Models . Tire Pressures TIRES TIRE Front Front Rear SOLO RIDER PSI 36 30 36 kPA 248 207 248 RIDER AND PASSENGER PSI 36 30 40 kPA 248 207 276 1WARNING Do not inflate tire beyond maximum pressure as specified on sidewall. Over inflated tires can blow out.

In case of eye contact flush with large amounts of water and get medical attention. 4. 99902-77: 12 oz. Use in well ventilated area. 5 brake fluid can cause eye irritation. If sightglass is not dark.BRAKE SYSTEM BRAKES 1CAUTION Direct contact with D. KEEP OUT OF REACH OF CHILDREN. Sightglass should appear dark if fluid is present.O. swelling. 99901-77: 1 gal.). Swallowing large amounts of D.7 2005 PDI: Softail Models 4-9 .. obtain medical attention. 5 SILICONE HYDRAULIC BRAKE FLUID (Part No.O.T. add brake fluid. 5 brake fluid can cause digestive discomfort.T. Use only D. If swallowed. Avid eye contact. See Softail Models Service Manual. (00144a) View reservoir sightglass and verify fluid presence. and redness.O.T.

2. After road test. and transmission operation. Road Test of Vehicle: Highway Speed 1. Check all electrical equipment and switches including stop lamp. 4.DEALER ROAD TEST ROAD TEST After you complete motorcycle inspection. return motorcycle to shop. Check tire condition and pressure (adjust if necessary). 4. turn signals and horn for proper operation. Program Security System (if equipped) Engine Oil: Check and correct hot level. 3. Shift from first through third gear. transmission. Verify proper handling at highway speeds. Low speed handling. brakes. throttle control. etc. checking clutch operation. Check electrical lamps. indicators. 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. and transmission operation. Check controls to verify proper function. and thoroughly clean off any road dirt. Verify that vehicle does not pull to left or right. Verify highway speed braking operation of front and rear brakes.8 Road Test of Vehicle: Low Speed 1. 4. take motorcycle for a road test. Adjust mirrors to proper riding positions. ● ● Shift from first through fifth gear. Check amount of gasoline in tank and add (if needed). 3. 6. clutch. 4-10 2005 PDI: Softail Models . Check for any abnormal vibrations. 2. handling. Check for any abnormal vibrations. Handling under braking conditions. Check all systems and overall operation of motorcycle: engine. checking clutch operation. Check and correct any problems you may have found during road test. throttle control. Verify low speed braking for front and rear brakes. Before You Begin Check the following items before road test of vehicle: ● ● ● ● ● ● Lamps and indicators.

Review the Initial Scheduled Maintenance* requirement with owner. 6. Also. you may wish to schedule the Initial Scheduled Maintenance* service appointment at this time. 5. and performing other basic maintenance functions. safety booklets and viewing Welcome To The Family video included with owner’s kit. Depending on owner’s anticipated frequency of operating motorcycle. Explain how turn signals and emergency flashers operate. (1600 km) FLSTSC and FXSTS @ 500 mi. Review warranties with vehicle owner. 8.9 IMPORTANT NOTE Make sure vehicle owner understands how to arm and disarm security system. 4.CUSTOMER DELIVERY NOTICE TO DEALER Before delivering motorcycle to owner. and involve Service Manager in delivery process. Initial Scheduled Maintenance is required as follows: All Softails. introduce dealer Service Manager to vehicle owner. Explain how to disarm security system with personal code if key fob is lost or not functioning. Make sure vehicle owner receives. Inform vehicle owner about checking engine oil level. Personal code should be written on the tear-out card in the Softail Models Owner’s Manual and kept on the owner’s person. Complete and sign warranty registration form. ● ● 2. checking tire pressure. Explain operation of vehicle controls to vehicle owner. Give IMPORTANT sheet and other printed material in literature kit to vehicle owner. perform the following: 1. and is aware of importance of reading Owner’s Manual. California dealers must give customer a copy of Emissions Control System Warranty. verify both key fobs operate properly. Have vehicle owner sign it. 7. except FLSTSC and FXSTS @ 1000 mi. Make sure owner understands warranties. 3. Supply owner with name(s) of dealer Service/ Parts Department personnel who should be contacted regarding vehicle service/parts questions. 4. (800 km) 2005 PDI: Softail Models 4-11 . Whenever possible.

Shift from first through fifth gear. Tires: Inspect condition and air pressure. Headlamps: Inspect and adjust as necessary. ❒ ❒ ❒ ❒ ❒ ❒ Evaporative Control System: Inspect hose routings. Verify low-speed braking for front and rear brakes. Verify handling under braking conditions. verify sender operation. c. checking clutch operation. ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ Uncrate: Check for damaged or missing parts. d. Review Vehicle Care and Maintenance Requirements. and transmission operation. Gauges. indicators.10 ❒ ❒ Fuel Outlet (valve or quick connect fitting) and Hoses: Verify operation and connections. throttle control. Verify low-speed handling. throttle control. Check electrical lamps. Verify low fuel light operation (if equipped). b. AT POINT OF CUSTOMER DELIVERY ❒ ❒ ❒ ❒ ❒ Suspension Adjustments. Brake Hand Lever Adjustment. Lighting. and transmission operation. checking clutch operation. Verify proper handling at highway speeds. Clean Vehicle. ❒ ❒ ❒ Engine Oil: Check and correct hot level. Note Any Additional Problems (including cosmetic quality): Perform Warranty repairs.VEHICLE PDI CHECKLIST PRIOR TO CUSTOMER DELIVERY NOTE Use this checklist for performing tasks related to this model motorcycle setup. Primary Chaincase: Check and verify lubricant is present. Battery: Perform required voltmeter test on battery. Fuel System: a. Lubrication System: Inspect condition of oil lines. Verify that vehicle does not pull to left or right. c. Road Test Vehicle: Low Speed a. Mirrors: Inspect and adjust as necessary. Connect negative battery cable to battery. 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. Verify highway speed braking operation of front and rear brakes. d. ❒ Road Test Vehicle: Highway Speed a. connections and fuel tank venting to canister (if equipped). Check for any abnormal vibrations. Fill. Check for any abnormal vibrations. Brake Pedal Height Adjustment. Brake Systems (front and rear): Correct fluid level (if necessary). Electrical Systems: Verify correct operation. Engine Oil: Verify oil is present (cold level). 4-12 2005 PDI: Softail Models . b. Shift from first through third gear. b. e. f. Jiffy Stand: Verify proper function. 4. Create Vehicle Birth-Certificate Using Digital Technician (optional). Shift Linkage Adjustment. Inspect fuel system for leaks. c.

. . . . . . . . . . . . . Road Test . . . . . . . . . . . . Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General .5 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Operation and Primary Chaincase . Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2005 Sportster Models Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V . . . . . . .6 Tires . . . . 5-1 5-1 5-1 5-2 5-2 5-3 5-3 5-4 5-4 5-4 5-4 5-4 5-5 5-5 5-5 5-6 5-6 5-6 5-7 5-7 5-7 5-8 5-8 5-9 5-9 5-10 5-10 5-11 5-11 5-12 5-12 5-12 5. . . . . . . . . . . . . . . . . . . . . . . . . . 5. . . . . . Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. . . . . . Battery Testing And Charging . Seats And Passenger Strap . . . . . . . . . . . . . . . . . . . . . . . .7 Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Vehicle PDI Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prior to Customer Delivery . . At Point of Customer Delivery . . . . . . . . . . . . . . . . . Notice To Dealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Fuel System . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. . . . . . . . . Indicator Lamps/Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Dealer Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Maxi-Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front and Rear Tires . . . . Rear Brake . . . . . . . . . . . . . Headlamp Alignment . . . . . . . Directional Lamps . . . . . . . . . . . . . . . . Throttle Control Cables . . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Values . . . . . . . . . .3 Lubrication System . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Specifications . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Initial Assembly . . . . . . . . . . . . . . . . . . . . . . . . .PREDELIVERY: SPORTSTER MODELS SUBJECT PAGE NO. . .

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3 Nm 4. Capacities Component Oil tank w/filter (Dry) Transmission/Primary Chaincase ENGLISH 3.3-24.0-2.7 Nm NOTES 2005 SPORTSTER MODELS SPECIFICATIONS Table 5-2. Engine idle speed may increase during engine break-in. Torque Values ITEM Handlebar clamp screws (front and rear) Front brake master cylinder cover screws Mirror fasteners Battery terminal screw (positive and negative) TORQUE 12-18 ft-lbs 9-17 in-lbs 96-144 in-lbs 40-50 in-lbs 16. 2005 PDI: Sportster Models 5-1 . Any fasteners that are not loosened/removed do not need to be checked during predelivery and setup.4 liters 946 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.4 Nm 1.1 Table 5-1. 5. 32 oz METRIC 3.0 Nm 10.5-5.1 SPECIFICATIONS TORQUE VALUES The following torque values are included for fasteners that may be loosened and tightened during Predelivery and Setup. Use idle speed listed in the Sportster Models Service Manual at Initial Maintenance check.6 qt.9-16.

2 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. Failure to read and understand all precautions in warning could result in death or serious injury. If the open circuit (disconnected) voltage reading is still below 12. in Section 1 and charge battery at rate and time specified. 5.6 VDC. Month and year punches may be removed with the point of a screwdriver without removing battery. Mounting slots (top) Mounting grommet (bottom) Figure 5-1.INITIAL ASSEMBLY BATTERY TESTING AND CHARGING 1WARNING Batteries contain sulfuric acid. Wear a protective face shield. Left Side Cover 5-2 2005 PDI: Sportster Models . Mark the date on the battery warranty tag by removing the applicable month and year. Line up top of side cover with mounting clips aligning with front clip first. 10. the battery must be replaced. which could cause severe burns to eyes and skin. If the open circuit (disconnected) voltage reading is 12. perform steps 2 and 3 above. Grasp left side cover at upper corners and gently pull away from plastic mounting clips on frame. 8. If voltage now is 12 VDC or greater. Place bottom of side cover with grommet onto mounting tab on battery tray. Lift cover up slightly so mounting grommet clears mounting tab on battery tray. KEEP BATTERIES AWAY FROM CHILDREN. x0628x1x 1 2 1. See Section 1. Recheck battery voltage by repeating step 2 above. (00064a) 7. refer to Table 1-2. 4. 9. 6. (00019a) 1. terminals and related accessories contain lead and lead components. Wash hands after handling. 5.6 VDC or greater the battery is ready for use. If the open circuit (disconnected) voltage reading is below 12. 12 amp-hour battery. Remove cover. rubberized gloves and protective clothing when working with batteries. chemicals known in the State of California to cause cancer and birth defects or other reproductive harm. 2. 1WARNING Never remove warning label attached to top of battery. (00063a) 3. 1WARNING Battery posts. 2.6 VDC. Press top of side cover into clips until snug.

INSTALLING MAXI-FUSE The 30 amp Maxi-Fuse provides battery power to the ignition switch and ICM. The Maxi-Fuse is not installed at the factory.V. because there are variations in individual components. or counterclockwise to decrease speed. Carburetor adjustments 2005 PDI: Sportster Models 5-3 . 4. Installing Maxi-Fuse 4 1. 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. See Figure 5-2. 2. Turn carburetor idle speed adjusting screw (5) clockwise to increase speed. 8946 8948a x0505a1x 5 1 2 3 Figure 5-2. Continuing to use the enrichener when the engine is at full operating temperature will cause fouled plugs. 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. Throttle cam stop Cable housing Spring Throttle cam Idle speed adjusting screw Figure 5-3. The Maxi-Fuse holder is located under the left side cover. NOTE The C. Set engine slow idle speed of 950 RPM with engine running at normal operating temperature and with enrichment control knob pushed in fully. See the Sportster Models Service Manual for the proper installation procedure. 5. 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. 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. attached to the battery strap. It is mounted in protective foam attached to the left handlebar grip of the motorcycle in the crate. IDLE SPEED See Figure 5-3. Be aware that.

Check that spring preload is set the same on both rear shock absorbers. 5-4 2005 PDI: Sportster Models . adjust spring preload to softest setting using SPANNER TOOL (Part No.9-16. Install lock washer (3) and lock nut (4). Steering must be smooth and free with no binding or interference. b. Adjusting Spring Preload DIRECTIONAL LAMPS 1. 3 4 Figure 5-4. 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. 2. Installing Righthand Mirror on XL 883L 2. HD-94820-75A) for all models. Tighten to 96-144 in-lbs (10. Righthand mirror Front brake master cylinder assembly Lock washer Lock nut Adjust rear directional lamps so lenses are aimed directly rearward. REAR SUSPENSION See Figure 5-5.3 Nm). Interference with steering could cause loss of vehicle control which could result in death or serious injury. 4. Verify that directional lamp fasteners are properly tightened. NOTE A 4 mm allen wrench will be needed to perform the front directional adjustments. 10628 pd0225 1 2 Figure 5-5.MIRRORS NOTE XL 883L model: righthand mirror is shipped in protective foam on left hand grip and must be installed. Insert mirror (1) stem into hole in master cylinder assembly (2). SEATS AND PASSENGER STRAP Refer to Sportster Models Owner’s Manual for seat and passenger strap removal and installation instructions. Verify that mirror and directional lamp fasteners are properly tightened. 3. 1. See Figure 5-4. Adjust front directional lamps so lenses are aimed directly forward. THROTTLE CONTROL CABLES 1WARNING Throttle cables must not pull tight when handlebars are turned fully to left or right fork stops. For a solo rider of average weight. 4. Adjust mirrors for proper rear view. XL 883L models: a. Check throttle cable adjustment in accordance with procedure given in Section 1 of Sportster Models Service Manual. 3.

LUBRICATION SYSTEM ENGINE OIL LEVEL Check engine oil level in oil tank at least once every 500 miles (800 km). add one quart (0. Insert dipstick into tank. 2. 2. Check clutch action. it is fully seated. Oil Level Marks 5.) (3. a. Remove filler cap again and check warm oil level on dipstick. If you added oil in step 5.946 liter) of Harley-Davidson oil to tank.6 quarts (U. Press down on filler cap until it clicks in place. 4. Run engine until engine oil is at normal operating temperature. 3. Turn engine off. Note that dipstick has a wide slot and a narrow slot and can only be inserted in oil tank one way. Press straight down on filler cap and release. Press down on filler cap while turning clockwise one-quarter turn as if screwing filler cap into tank. NOTE See Figure 5-6. When filler cap “snaps” slightly. Filler Cap/Dipstick Slots Wipe attached dipstick clean. Do not fill oil tank to the level above upper mark on dipstick. remove filler cap and verify correct engine oil level in oil tank. Clutch lever should move freely and smoothly through its entire range of travel. NOTE It will be necessary to check engine oil with motorcycle leaning on jiffy stand. Figure 5-7. Cap will pop up. See Figure 5-7. Refer to Owner’s Manual for recommended engine oil viscosity.3 Figure 5-6. Check level more frequently if engine uses more oil than normal or if vehicle is operated under harsh conditions. 7. 8. Pull up on filler cap while turning counterclockwise one-quarter turn as if unscrewing filler cap. If oil level in tank is at or below lower mark. Dipstick has two marks. 2005 PDI: Sportster Models 5-5 . 6. b.S. 10099 10100 5. Remove filler cap from oil tank on right side of vehicle. Repeat step 4 to replace filler cap. Repeat step 4 to replace filler cap. 1.4 liters). Oil tank capacity is 3. CLUTCH OPERATION AND PRIMARY CHAINCASE 1. Check clutch adjustment and primary chaincase lubricant level according to the procedures in Chapter 1 of the Sportster Models Service Manual.

If you experience these problems. They are also formulated to evaporate less when you are filling your tank. 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. Doing so can result in fuel system component failure.” Gasolines containing METHYL TERTIARY BUTYL ETHER (MTBE) can also be used. check for smooth operation of the fuel valve. Fuel Supply Valve Because of their different chemical properties (which affect fuel volatility and ignition characteristics). and fuel efficiency of the motorcycle. engine damage and/or equipment malfunction. The type and amount of alcohol or ether added to the fuel is important. CAUTION Use only unleaded fuel in California model catalytic converter-equipped motorcycles. unleaded gasoline. (00148a) ● 5.” “ethanol enhanced. these blends may adversely affect the starting. and 87 octane or higher on 883 Standard and Custom models. HarleyDavidson recommends using straight. After adding gasoline. Using leaded fuel will damage the emission control system. Inspect fuel valve and fuel lines for leaks. They are identified as “gasohol. Follow FUEL recommendations found in the Owner’s Manual. Use unleaded gasoline. Gasoline/ethanol blends are a mixture of 10% ethanol and 90% unleaded gasoline.4 FUEL TANK Partially fill fuel tank with gasoline. drivability. leaving fewer “tailpipe” emissions. 5-6 2005 PDI: Sportster Models .” or “contains ethanol. o0046box Gasolines containing ETHANOL (ethyl alcohol or grain alcohol) can be used. See Figure 5-8. CAUTION Do not use gasoline that contains methanol. Your motorcycle will run normally using this type of gas and Harley-Davidson recommends you use it when possible. Reformulated gasolines use additives to “oxygenate” the gas. Gasoline/MTBE blends are a mixture of gasoline and as much as 15% MTBE. (00150a). 91 octane or higher on all 1200 Roadster and Custom models. as an aid to cleaner air in our environment ● ● Figure 5-8.FUEL SYSTEM GENERAL CAUTION Some fuel suppliers sell gasoline which has been blended with an alcohol or an ether.

8. 7. 2. and verify that neutral indicator lamp turns on again. 2. 3. Shift transmission to neutral position. Instruments (Typical) 10. and check that oil pressure indicator lamp (6) turns on (before engine is started). (00030b) 2 INDICATOR LAMPS/CONTROLS 1. Check operation of all remaining lamps: ● ● ● ● ● ● ● ● ● ● ● 3 4 5 6 7 1200 Roadster shown. 6.ELECTRICAL SYSTEM 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. 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 Tail lamp–running lamp and brake lamp filaments Speedometer (1) illumination lamp Tachometer (8) illumination lamp (1200 Roadster only) 2005 PDI: Sportster Models 5-7 . After engine has reached normal operating temperature. 3. 4. See Figure 5-9. Check operation of tachometer (8) (1200 Roadster only). Poor visibility of rider to other motorists can result in death or serious injury. 9. Be sure headlamp is on at all times. 1. other Sportster models not originally equipped with tachometer. Disengage clutch (depress clutch lever). This time. Start engine. Shift transmission to neutral position. 11.5 1 8 1WARNING The automatic-on headlamp feature provides increased visibility of the rider to other motorists. Check that oil pressure indicator lamp (6) turns off when engine is running above 1000 RPM. turn engine off. and verify that neutral indicator lamp (5) turns on. 8. and verify that neutral indicator lamp (5) turns off when transmission is shifted to any forward gear. 4. 5. 5. Check horn operation. 7. 4911 5. 6. fill oil tank to upper mark on filler cap/dipstick. Turn ignition switch to IGNITION position. check operation of starter. Check engine oil level in manner previously specified. Speedometer Odometer and trip odometer Left directional (turn signal) indicator lamp High beam indicator lamp Neutral indicator lamp Oil pressure indicator lamp Right directional (turn signal) indicator lamp Tachometer (1200 Roadster only) Figure 5-9.

6 Table 5-3. (00026a) 1.TIRES FRONT AND REAR TIRES 1WARNING Do not inflate tire beyond maximum pressure as specified on sidewall. (00027a) 5. 5-8 2005 PDI: Sportster Models . Check for proper front and rear tire pressures when tires are cold. which could result in death or serious injury. Tire Pressures TIRES MODEL All models All models TIRE Front Rear SOLO RIDER PSI 30 36 kPA 207 248 RIDER & PASSENGER PSI 30 40 kPA 207 276 1WARNING Harley-Davidson front and rear tires are not the same. Compare results against Table 5-3. Interchanging front and rear tires can cause tire failure. which could result in death or serious injury. Over inflated tires can blow out.

7 Figure 5-10. check that fluid level is between the upper and lower marks on reservoir. and redness. In case of eye contact flush with large amounts of water and get medical attention. Avid eye contact.O.T.T. (00144a) 1.. 99902-77: 12 oz. With vehicle upright (not on sidestand).O. obtain medical attention. 8967 5. If brake fluid level is low. Use in well ventilated area.O. 5 brake fluid can cause eye irritation. 5 brake fluid can cause digestive discomfort. add brake fluid. swelling. Use only D. See Sportster Models Service Manual. If swallowed.T. 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. KEEP OUT OF REACH OF CHILDREN. Swallowing large amounts of D.BRAKE SYSTEM REAR BRAKE 1CAUTION Direct contact with D. Rear Brake Master Cylinder Remote Reservoir 2005 PDI: Sportster Models 5-9 .). 99901-77: 1 gal.

Verify highway speed braking operation of front and rear brakes. Before You Begin Check the following items before road test of vehicle: ● ● ● ● ● ● Lamps and indicators. Verify proper handling at highway speeds. Check tire condition and pressure (adjust if necessary). take motorcycle for a road test. 5-10 2005 PDI: Sportster Models . clutch. brakes. Check and correct any problems you may have found during road test.8 Road Test of Vehicle: Low Speed 1. Check all systems and overall operation of motorcycle: engine. Check controls to verify proper function. 4. Low speed handling. Road Test of Vehicle: Highway Speed 1.DEALER ROAD TEST ROAD TEST After you complete motorcycle inspection. checking clutch operation. throttle control. transmission. Check for any abnormal vibrations. return motorcycle to shop. Program Security System (if equipped) Engine Oil: Check and correct hot level. Adjust mirrors to proper riding positions. After road test. Handling under braking conditions. turn signals and horn for proper operation. 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. checking clutch operation. Check all electrical equipment and switches including stop lamp. 6. indicators. and transmission operation. Check for any abnormal vibrations. 2. etc. 3. 5. and transmission operation. 5. ● ● Shift from first through fifth gear. Shift from first through third gear. and thoroughly clean off any road dirt. throttle control. Verify low speed braking for front and rear brakes. Check electrical lamps. Check amount of gasoline in tank and add (if needed). 2. 4. Verify that vehicle does not pull to left or right. 3. handling.

California dealers must give customer a copy of Emissions Control System Warranty. 5. 5. checking tire pressure. Depending on owner’s anticipated frequency of operating motorcycle. Explain operation of vehicle controls to vehicle owner. Make sure vehicle owner receives. Supply owner with name(s) of dealer Service/ Parts Department personnel who should be contacted regarding vehicle service/parts questions. Make sure owner understands warranties. and is aware of importance of reading Owner’s Manual. Whenever possible. 3. Personal code should be written on the tear-out card in the Sportster Models Owner’s Manual and kept on the owner’s person. safety booklets and viewing Welcome To The Family video included with owner’s kit. 8.CUSTOMER DELIVERY NOTICE TO DEALER Before delivering motorcycle to owner. Explain how to disarm security system with personal code if key fob is lost or not functioning. and performing other basic maintenance functions. 2. introduce dealer Service Manager to vehicle owner. 7. Review the Initial Scheduled Maintenance requirement with owner. Inform vehicle owner about checking engine oil level. 4. Have vehicle owner sign it. perform the following: 1. Explain how turn signals and emergency flashers operate. 2005 PDI: Sportster Models 5-11 . you may wish to schedule the Initial Scheduled Maintenance service appointment at this time. Complete and sign warranty registration form. verify both key fobs operate properly. Also. Review warranties with vehicle owner. and involve Service Manager in delivery process. 6. Give IMPORTANT sheet and other printed material in literature kit to vehicle owner.9 IMPORTANT NOTE Make sure vehicle owner understands how to arm and disarm security system.

Tires: Inspect condition and air pressure. indicators. Jiffy Stand: Verify proper function. Evaporative Control System: Inspect hose routings. Check for any abnormal vibrations. Review Vehicle Care and Maintenance Requirements. ❒ Road Test Vehicle: Highway Speed a. e. b. Verify low-speed handling. d. Clean Vehicle. c. Mirrors: Inspect and adjust as necessary. Lubrication System: Inspect condition of oil lines.VEHICLE PDI CHECKLIST PRIOR TO CUSTOMER DELIVERY NOTE Use this checklist for performing tasks related to this model motorcycle setup. connections and fuel tank venting to canister (if equipped). and transmission operation. Verify that vehicle does not pull to left or right. Lighting. d. checking clutch operation. 5. ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ Uncrate: Check for damaged or missing parts. Create Vehicle Birth-Certificate Using Digital Technician (optional). Install Maxi Fuse (main fuse). 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. Verify low-speed braking for front and rear brakes. Check for any abnormal vibrations. Road Test Vehicle: Low Speed a. throttle control. Verify handling under braking conditions. Shift from first through fifth gear. ❒ ❒ ❒ Engine Oil: Check and correct hot level. b. Check electrical lamps. Engine Oil: Verify oil is present (cold level). Brake Hand Lever Adjustment. Electrical Systems: Verify correct operation. Note Any Additional Problems (including cosmetic quality): Perform Warranty repairs. Shift from first through third gear. and transmission operation. c. AT POINT OF CUSTOMER DELIVERY ❒ ❒ ❒ ❒ Suspension Adjustments. Verify proper handling at highway speeds. f.10 ❒ ❒ Fuel Outlet valve and Hoses: Verify operation and connections. Primary Chaincase: Check and verify lubricant is present. 5-12 2005 PDI: Sportster Models . throttle control. Brake Systems (front and rear): Correct fluid level (if necessary). Install righthand mirror (XL 883L only). Battery: Perform required voltmeter test on Maxi-Fuse (main fuse) and battery. Fuel System: Inspect fuel system for leaks. Gauges. checking clutch operation. Headlamps: Inspect and adjust as necessary. Verify highway speed braking operation of front and rear brakes. Shift Linkage Adjustment.

. 6. . . . . . . .6 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PREDELIVERY: VRSC MODELS SUBJECT PAGE NO. . . . . . . . . . . . . . . . . . . . . . .1 Specifications . . . . . . . . . . . . . . . . . . Front and Rear Tires . . . . . . . . . . . . . . . . . . . . . . . . .4 Fuel System . . . . . . . . . . . . . . . . . . . . Rear Brake Master Cylinder . . . . . . . 6. . . . . . . . . . . . . . . . . . . . . . . . . . . Prior to Customer Delivery . . . . Battery Testing And Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. . . . . 6. . . . . . 6. . . . . . . . . . . . . . 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Values . .3 Lubrication System . . . . . . . . . . . . . . 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Maxi-Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seats And Passenger Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . At Point of Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indicator Lamps/Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Electrical System . . . .7 Brake System . . . . . . . .2 Initial Assembly . . . . . . . . . Road Test . . . . . . . . . . . . Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notice To Dealer . . . . . . . . . . . . . . . . . . . . . . . . VI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1 6-1 6-2 6-2 6-3 6-3 6-4 6-4 6-6 6-7 6-7 6-8 6-8 6-9 6-10 6-10 6-11 6-11 6-12 6-12 6-13 6-13 6-14 6-14 6-14 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2005 VRSC Models Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Dealer Road Test . . . . .9 Customer Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. .10 Vehicle PDI Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Capacities Component Fuel tank total Oil sump Coolant Metric 14.3 liters 2. 6.4 liters English 3.54 qt.5 qt.1 SPECIFICATIONS TORQUE VALUES The following torque values are included for fasteners that may be loosened and tightened during Predelivery and Setup. 2005 PDI: VRSC Models 6-1 .0 liters 4.7-0.8-10. 4.7 gal.36 Nm 0.90 Nm 6. 2.9 Nm 9-11 Nm – Hand-tighten 2005 VRSC MODELS SPECIFICATIONS Table 6-1. Any fasteners that are not loosened/removed do not need to be checked during Predelivery and Setup.1 ITEM Front axle nut Rear axle nut All master cylinder cover screws Battery terminal screws Coolant air bleed plug Radiator drain plug 68-75 Nm TORQUE 50-55 ft-lbs 95-105 ft-lbs 6-8 in-lbs 60-96 in-lbs 80-97 in-lbs – NOTES 129-142.

It will be necessary to remove the airbox cover to gain access to the battery. 2. KEEP BATTERIES AWAY FROM CHILDREN. 6. See appropriate Service Manual for procedure. perform steps 2 and 3 above.6 VDC. Recheck battery voltage by repeating step 1 above. If voltage now is 12 VDC or greater. (00064a) 6. 5. 1WARNING Battery posts. the battery must be replaced. Mark the date on the battery warranty tag by removing the applicable month and year. rubberized gloves and protective clothing when working with batteries. If the open circuit (disconnected) voltage reading is still below 12. NOTES The engine is equipped with a compression release.6 VDC or greater the battery is ready for use. Wash hands after handling. Failure to read and understand all precautions in warning could result in death or serious injury.INITIAL ASSEMBLY BATTERY TESTING AND CHARGING 1WARNING Batteries contain sulfuric acid. so a smaller (12 amp hour) battery provides adequate starting current. 4. 1WARNING Never remove warning label attached to top of battery.6 VDC. Wear a protective face shield. (00019a) ● IMPORTANT NOTE Only remove air cleaner and air cleaner bottom if battery could not be charged to 12. which could cause severe burns to eyes and skin. (00063a) 3. refer to Table 1-2. Month and year punches may be removed with the point of a screwdriver without removing battery. 6-2 2005 PDI: VRSC Models . If the open circuit (disconnected) voltage reading is 12.6 VDC. in Section 1 and charge battery at rate and time specified. air cleaner and air cleaner bottom must be removed. 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 and battery must be removed and replaced. ● 1. chemicals known in the State of California to cause cancer and birth defects or other reproductive harm. 12 amp-hour battery. To remove battery. If the open circuit (disconnected) voltage reading is below 12. terminals and related accessories contain lead and lead components.2 See Section 1.

See Figure 6-1.INSTALLING MAXI-FUSE ● 2. See Service Manual. 9010 Figure 6-2. NOTES The 40 amp Maxi-Fuse provides battery power to the ignition switch and ECM. It will also be necessary to install the fuel pump fuse that is located in a spare fuse location. Reinstall sidecover and secure with screw. ● 9020 1. Removing Sidecover Refer to VRSC Models Owner’s Manual for seat and passenger strap removal and installation instructions.1-6. 3.8 Nm (30-60 in-lbs). It is shipped in the fuse holder boot next to the socket. Remove fastener at upper corner of louvered cover and remove cover. Tighten to 4. See Figure 6-2. 2005 PDI: VRSC Models 6-3 . Inserting Maxi-Fuse SEATS AND PASSENGER STRAP Figure 6-1. See Figure 6-1. The Maxi-Fuse is not installed at the factory. The fuse holder and boot is located just forward of the coolant reservoir. Fold back the flap on the fuse holder boot and insert the fuse into the fuse holder socket.

This design allows engine oil in the sump to be used to lubricate the engine. transmission and primary drive. Screw filler cap into engine. See Figure 6-3. add enough Harley-Davidson oil to bring level up to the FULL mark. 4. Make sure cap is fully seated on crankcase. Observe “CAUTIONS” stated above. Remove filler cap and check oil level on dipstick. Screw filler cap into engine. Engine damage will result. See Figure 6-4. Stop engine and allow oil to drain into sump for about three minutes. add enough Harley-Davidson oil to bring level up to the midpoint shown in Figure 6-4. Engine Oil Dipstick 3. 5. Unscrew filler cap (with attached dipstick) by turning filler cap counterclockwise. 5. Figure 6-4. wait approximately three minutes after adding oil before checking the oil level with the dipstick. If oil level is below FULL mark on dipstick. Make sure cap is fully seated on crankcase. 3. See Figure 6-3. An over-filled sump can cause engine damage. Stand motorcycle upright (not leaning on side stand) on a level surface. Remove filler cap and dipstick and wipe dipstick clean. Hot Engine Oil Level Check Check engine oil level with engine at normal operating temperature as follows: 1. Unscrew oil filler cap (with attached dipstick) by turning filler cap counterclockwise. 9015 6. If oil level is below midpoint on cross-hatched area on dipstick. 4. Stand motorcycle upright (not leaning on side stand) on a level surface. 6-4 2005 PDI: VRSC Models . 2. 6. gear driven primary drive and wet clutch.3 Figure 6-3. (00188a) NOTE This engine has a wet sump. Remove filler cap and check oil level on dipstick. (00187a) CAUTION To avoid over-filling the oil sump. 2. Remove filler cap and dipstick and wipe dipstick clean. Oil Filler Cap (Left Side Of Engine) o0239aox Midpoint Cold Engine Oil Level Check Check engine oil level with engine COLD as follows: 1. See Figure 6-4.LUBRICATION SYSTEM ENGINE OIL LEVEL CAUTION Do NOT operate the engine when the oil level is below the add mark on the dipstick at operating temperature. an integral transmission. The clutch and primary drive housing is on the right side of the engine.

2005 PDI: VRSC Models 6-5 . Add enough premixed HARLEY-DAVIDSON EXTENDED LIFE ANTIFREEZE & COOLANT (Part No.Pressure Cap Location ● 9032 NOTES See Figure 6-5. NOTE The engine ends of the radiator hoses are secured with a plastic “shrink” clamp and do not require checking. remove the air bleed plug and then fill through filler neck at pressure cap. See Figure 6-5. 2. Coolant should rise in filler neck. The pressure cap is located beneath seat behind the air box. See Figure 6-6. Check the four hose clamps (two each on hoses) for tightness. Coolant Hoses (Engine right side) Check Hose Clamps For Tightness 1. remove air bleed plug shown in Figure 6-6. To verify that the coolant system has been filled perform the check following these notes. If the coolant system is drained. 2. Tighten air bleed plug to 9-11 Nm (80-97 in-lbs). Coolant level can be checked at the expansion tank located on right side behind steering head. 9098 3. 2. Replace air bleed plug and pressure cap. Hose Hose (To thermostat housing) Hose clamps (4) (2 on each hose) Figure 6-7. 2 3 9030 1 1. 99822-02) so coolant is visible in filler neck. Coolant can be added at the expansion tank if level is low. Remove pressure cap. Gently squeeze center of hose (1) while looking into coolant filler neck. 4. See Figure 6-7. Pressure Cap See Figure 6-7. Coolant System Air Bleed Plug ● Verifying Coolant System Is Filled 1. Normally the pressure cap does not need to be removed. With a long bladed screwdriver check two hose clamps one at top left and one at top right of radiator. 3. If coolant is not visible in filler neck. Figure 6-6. Figure 6-5.

In case of eye contact flush with large amounts of water and get medical attention.O.T. CLUTCH MASTER CYLINDER 1. See Figure 6-9. Avoid eye contact.O. 5 silicone hydraulic brake fluid is used in the hydraulic clutch.Checking Coolant Level In Expansion Tank 1. 99902-77) in clutch master cylinder reservoir. and redness. swelling. 5 brake fluid can cause digestive discomfort. 99902-77).T. As clutch friction discs wear.O.O. 99822-02) until fluid level reaches “COLD FULL” line. If sightglass is not dark. (00204a) 9019 Figure 6-9. Cold Full Line On Expansion Tank NOTE Do not reinstall louvered cover now. Direct contact of D. See Figure 6-8.T. 6-6 2005 PDI: VRSC Models . View reservoir sightglass and verify fluid presence.T. add D. KEEP OUT OF REACH OF CHILDREN. The 40 amp fuse will be installed later in the fuse holder located just forward of the expansion tank. (00144a) CAUTION D. Remove fastener at upper corner of louvered cover and remove cover. 5 brake fluid with eyes can cause eye irritation. See Service Manual. Do not use other types of fluids as they are not compatible and could cause equipment damage.T. If swallowed. obtain medical attention. Do not overfill clutch master cylinder reservoir. If level is below “COLD FULL” line on tank. the piston in the clutch cylinder will force fluid back into the reservoir and this could cause fluid overflow. NOTES Use only D. Swallowing large amounts of D. 9010 ● ● 1CAUTION Figure 6-8.O. Removing Cover to Check Coolant Level 2. 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. Sightglass should appear dark if fluid is present. Use in well ventilated area. Check coolant level in expansion tank with coolant cold and vehicle resting on jiffy stand. remove cap from tank and add premixed HARLEY-DAVIDSON EXTENDED LIFE ANTIFREEZE & COOLANT (Part No.

engine damage and/or equipment malfunction.” “ethanol enhanced.” Gasolines containing METHYL TERTIARY BUTYL ETHER (MTBE) can also be used. HarleyDavidson recommends using straight. (00148a) ● 6. unleaded gasoline 2005 PDI: VRSC Models 6-7 . and fuel efficiency of the motorcycle. Use unleaded gasoline.4 CAUTION Use only unleaded fuel in California model catalytic converter-equipped motorcycles. Reformulated gasolines use additives to “oxygenate” the gas. CAUTION Do not use gasoline that contains methanol. Partially fill fuel tank with gasoline. 91 octane or higher on all VRSC models. Using leaded fuel will damage the emission control system. Gasoline/ethanol blends are a mixture of 10% ethanol and 90% unleaded gasoline. 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.” or “contains ethanol. Gasoline/MTBE blends are a mixture of gasoline and as much as 15% MTBE. leaving fewer “tailpipe” emissions. Inspect fuel system for leaks. Doing so can result in fuel system component failure. Gasolines containing ETHANOL (ethyl alcohol or grain alcohol) can be used. drivability. They are identified as “gasohol. If you experience these problems. They are also formulated to evaporate less when you are filling your tank. these blends may adversely affect the starting. The type and amount of alcohol or ether added to the fuel is important. Your motorcycle will run normally using this type of gas and Harley-Davidson recommends you use it when possible.FUEL SYSTEM GENERAL CAUTION Some fuel suppliers sell gasoline which has been blended with an alcohol or an ether. as an aid to cleaner air in our environment ● ● Because of their different chemical properties (which affect fuel volatility and ignition characteristics). (00150a).

Loosen headlamp adjustment screws. one on each side of headlamp Tilt headlamp up or down to properly aim it in relation to the horizontal line. equal area of light above and below line). Turn ignition/light switch to “IGNITION” position. Center of headlamp to floor 7. Once the headlamp is properly adjusted. 2. NOTE The lateral headlamp alignment on VRSCA models is established by the headlamp mounting and does not require adjustment. Verify correct front and rear tire inflation pressure.) Figure 6-10. Checking Headlamp Alignment Adjustment VRSCA models: 1. Stand motorcycle upright with both tires resting on floor and with front wheel held in straight alignment (directly forward). Proceed as follows: 1. at same height above floor. Check light beam for proper height alignment. (00030b) b0008c7x 6. Set handlebar switch to high beam position. Be sure headlamp is on at all times. directly below front axle). 2. whose weight is roughly the same as that of the principal rider. on screen or wall. sit on motorcycle seat. Point front of motorcycle toward a screen or wall which is 25 ft. flat pattern of light) should be centered on horizontal line of screen or wall (i. 6. 3. Check headlamp beam for proper height and lateral alignment. 5. (7.62 M (25 ft.e. See Figure 6-11.e. 9026 Figure 6-11. Measure the vertical distance from center of headlamp to floor and draw a horizontal line. Poor visibility of rider to other motorists can result in death or serious injury. 4.5-7.62 m) away from front tire contact patch on floor (i. Headlamp Adjustment–VRSCA Model 6-8 2005 PDI: VRSC Models . Weight of rider will compress vehicle suspension slightly. 8. Have a person. Main beam of light (broad. tighten both headlamp adjustment screws to 4. 3.5 Nm (40-66 inlbs).5 Inspection See Figure 6-10. Place motorcycle on level floor (or pavement) in an area with minimum light. 7.ELECTRICAL SYSTEM HEADLAMP 1WARNING The automatic-on headlamp feature provides increased visibility of the rider to other motorists.

1 VRSCSE MODEL. Tilt headlamp (6) up or down to properly aim it in relation to the horizontal line. Headlamp clamp nut Lock washer Washer Headlamp bracket plug Headlamp bracket Headlamp assembly Figure 6-12. (00188a) INDICATOR LAMPS/CONTROLS ● NOTES All VRSC models have an Instrument Module with selfdiagnostic capabilities. The Battery icon will illuminate to indicate low voltage. Fuel gauge should also indicate fuel tank level. Engine Coolant temperature icon will illuminate to verify bulb filament and then go off. Check engine oil level in manner previously specified. at the same time. See Figure 6-12. Check that tachometer is functioning. Start engine. wait approximately three minutes after adding oil before checking the oil level with the dipstick. The Check Engine indicator lamp will illuminate for about four seconds and then go off. VRSCSE models are equipped with a separate speedometer. 4. Headlamp Adjustment–VRSCB Model ● ● ● 9. 2. tachometer and instrument console. Shift transmission to neutral position. Shift transmission to neutral position. check operation of starter. NOTE For any systems problems. View instrument cluster and turn ignition switch to “IGNITION” position. a key icon (Security lamp) will illuminate for about four seconds and then go off. and verify that neutral indicator lamp turns on. turn engine off. Disengage clutch (depress clutch lever). Check that oil pressure indicator lamp turns off when engine is running above 1200 RPM. Check operation of all remaining lamps: ● ● 3. Engine Coolant temperature icon must not illuminate. packaged in traveler included with motorcycle in crate. 4. 10. An over-filled sump can cause engine damage. ● 1. please refer to the appropriate Electrical Diagnostic manual for your model. and. and verify that neutral indicator lamp turns on again. This time. 2005 PDI: VRSC Models 6-9 . and verify that neutral indicator lamp turns off when transmission is shifted to any forward gear. 2. Tighten headlamp clamp nut to 13. If cycle is equipped with optional Security System (TSSM). Check that battery icon turns off.VRSCB models: 1. Locate headlamp bracket plug (4). 3. CAUTION To avoid over-filling the oil sump. 3. See BATTERY TESTING AND CHARGING under 7. pd0223 1 2 3 4 7. Check that the oil pressure indicator lamp turns on (before engine is started). 6. 4. 8. fill sump to upper mark on filler cap/dipstick. tail lamp–running lamp and brake lamp filaments After engine has reached normal operating temperature. turn it right or left to direct light beam straight ahead. 6.3 Nm (120-180 in-lbs) after headlamp is properly positioned. Check horn operation. 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 5 6 ● ● ● ● 1. Refer to VRSC Model Electrical Diagnostic Manual for service instructions. 5. Snap plug into place in headlamp bracket (5). 5. Loosen headlamp clamp nut (1). 2.6-20.

6 Table 6-2.TIRES FRONT AND REAR TIRES 1WARNING Do not inflate tire beyond maximum pressure as specified on sidewall. Compare results against Table 6-2. which could result in death or serious injury. Over inflated tires can blow out. 6-10 2005 PDI: VRSC Models . (00027a) 6. which could result in death or serious injury. (00026a) 1. Check for proper front and rear tire pressures when tires are cold. Interchanging front and rear tires can cause tire failure. Tire Pressures TIRES MODEL VRSC TIRE Front Rear SOLO RIDER kPA 248 262 PSI 36 38 RIDER & PASSENGER kPA 248 276 PSI 36 40 1WARNING Harley-Davidson front and rear tires are not the same.

2.890 in. item (1). swelling. 3.T. and add only D.90 Nm (6-8 inlbs). (00144a) 1.BRAKE SYSTEM REAR BRAKE MASTER CYLINDER 1CAUTION Direct contact of D. 99901-77: 1 gal. Check push rod length (3). 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. loosen and reposition exhaust to obtain the 1/4 in. 6. clearance.25 in. 3. remove cover screws and cover. and redness.7 mm) below reservoir top. Verify that fluid level in rear brake master cylinder reservoir is 1/2 in. Rear Brake Master Cylinder (Radiator Cover Removed for Photo Clarity) 2.O. KEEP OUT OF REACH OF CHILDREN.) Figure 6-14.O.690-0. If master cylinder or reservoir hose does not have 1/4 in. Use a flashlight to view rear brake master cylinder located behind radiator cover.O. If swallowed.T.7 1WARNING See Figure 6-14.. 9022 6. Refer to VRSC Model Service Manual for exhaust system instructions. (12. Use in well ventilated area. If level is low.) clearance Reservoir Push rod length: 18-22 mm (0. 3 Figure 6-13.). Swallowing large amounts of D. Contact with the hot exhaust pipe could cause fluid leakage and reduced braking which could result in loss of vehicle control and death or serious injury. 5 brake fluid with eyes can cause eye irritation. Tighten cover screws to 0. 5 brake fluid can cause digestive discomfort. See Figure 6-14. Replace cover. Loosen jam nut and turn push rod with a wrench placed on push rod wrench flats if adjustment is required. 9022 2 1 1. In case of eye contact flush with large amounts of water and get medical attention. obtain medical attention. Avoid eye contact. See Figure 6-13. clearance.T. from exhaust pipe. 99902-77: 12 oz. Rear Brake Pedal Adjustments 2005 PDI: VRSC Models 6-11 .68-0.4 mm (0.

turn signals and horn for proper operation. Adjust mirrors to proper riding positions. Verify that vehicle does not pull to left or right. indicators. Before You Begin Check the following items before road test of vehicle: ● ● ● ● ● ● Lamps and indicators. Shift from first through third gear. checking clutch operation. Check amount of gasoline in tank and add (if needed). take motorcycle for a road test. After road test. Check controls to verify proper function. 2.8 Road Test of Vehicle: Low Speed 1. Check electrical lamps. Verify highway speed braking operation of front and rear brakes. Low speed handling. throttle control. 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. and thoroughly clean off any road dirt. 3. Road Test of Vehicle: Highway Speed 1. handling. Check for any abnormal vibrations.DEALER ROAD TEST ROAD TEST After you complete motorcycle inspection. Verify proper handling at highway speeds. ● ● Shift from first through fifth gear. 3. return motorcycle to shop. 6-12 2005 PDI: VRSC Models . clutch. Verify low speed braking for front and rear brakes. Check tire condition and pressure (adjust if necessary). Handling under braking conditions. 6. Program Security System (if equipped) Engine Oil: Check and correct hot level. 5. 2. and transmission operation. and transmission operation. 4. Check all systems and overall operation of motorcycle: engine. 6. Check all electrical equipment and switches including stop lamp. 4. checking clutch operation. throttle control. etc. Check and correct any problems you may have found during road test. brakes. transmission. Check for any abnormal vibrations.

perform the following: 1. Explain how to disarm security system with personal code if key fob is lost or not functioning. If a personal code is not assigned and key fob is lost or damaged while vehicle is armed. verify both key fobs operate properly. An Instruction Sheet covering care of this motorcycle has been added to the Owner’s Kit. Whenever possible. Give IMPORTANT sheet and other printed material in literature kit to vehicle owner. Personal code should be written on the tearout card in VRSC Models Owner’s Manual and kept on the owner’s person. Make sure vehicle owner understands how to arm and disarm security system. 7. 6. 4. 8. The painted finish on frame. Explain how turn signals and emergency flashers operate. rear fork (swingarm) and all components painted with a special Silver paint require special care. Review this Instruction Sheet with the Customer and answer any questions he or she may have. If motorcycle is equipped with a TSSM. and performing other basic maintenance functions. Also. 2005 PDI: VRSC Models 6-13 . ● ● 6. air box cover and fenders on the VRSCSE model requires special care. Complete and sign warranty registration form. you may wish to schedule the Initial Scheduled Maintenance service appointment at this time. Inform vehicle owner about checking engine oil level. checking tire pressure. Make sure owner understands warranties. and is aware of importance of reading Owner’s Manual. 5. introduce dealer Service Manager to vehicle owner. make sure key fob (remote control) and personal code have been assigned to control the Harley-Davidson Factory Security System. safety booklets and viewing Welcome To The Family video included with owner’s kit. California dealers must give customer a copy of Emissions Control System Warranty. TSSM must be replaced. Review warranties with vehicle owner.CUSTOMER DELIVERY NOTICE TO DEALER Before delivering motorcycle to owner. 3. and involve Service Manager in delivery process. Also the wheels. Have vehicle owner sign it. Review the Initial Scheduled Maintenance requirement with owner. Explain operation of vehicle controls to vehicle owner. 2. Make sure vehicle owner receives. Supply owner with name(s) of dealer Service/ Parts Department personnel who should be contacted regarding vehicle service/parts questions. Depending on owner’s anticipated frequency of operating motorcycle.9 IMPORTANT NOTES The bright anodized finish on air box cover and fenders requires special care.

❒ ❒ ❒ ❒ ❒ ❒ Cooling System: a. AT POINT OF CUSTOMER DELIVERY ❒ ❒ ❒ ❒ ❒ Suspension Adjustments. Controls and Seat Strap: Adjust and tighten (if necessary). and transmission operation. Verify low-speed handling. Brake Hand Lever Adjustment. throttle control. Battery: Perform required voltmeter test on Maxi-Fuse (main fuse) and battery. Primary Chaincase: Check and verify lubricant is present. b. Verify low fuel light operation. Check for any abnormal vibrations. Shift from first through fifth gear. Gauges. d. Verify low-speed braking for front and rear brakes. Clean Vehicle. e. Check and correct fluid level (if necessary). checking clutch operation. ❒ ❒ ❒ Engine Oil: Check and correct hot level. Road Test Vehicle: Low Speed a. b. Check electrical lamps. Check radiator hose clamps for tightness. Verify highway speed braking operation of front and rear brakes. Verify proper handling at highway speeds. 6-14 2005 PDI: VRSC Models . checking clutch operation. Note Any Additional Problems (including cosmetic quality): Perform Warranty repairs. c. Evaporative Control System: Inspect hose routings. Headlamps: Inspect and adjust as necessary. Handlebars. Electrical Systems: Verify correct operation. Inspect fuel system for leaks. Fill. 6. Shift from first through third gear. Lighting. ❒ Road Test Vehicle: Highway Speed a. Fuel System: a. verify sender operation. Mirrors: Inspect and adjust as necessary. c. 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. throttle control. Brake Pedal Height Adjustment. Tires: Inspect condition and air pressure. and transmission operation. b. Check for any abnormal vibrations. Jiffy Stand: Verify proper function. Install Fuel Pump Fuse. c. indicators. Verify that vehicle does not pull to left or right.VEHICLE PDI CHECKLIST PRIOR TO CUSTOMER DELIVERY NOTE Use this checklist for performing tasks related to this model motorcycle setup. Lubrication System: Inspect condition of oil lines. Verify handling under braking conditions. Create Vehicle Birth-Certificate Using Digital Technician (optional).10 ❒ ❒ ❒ ❒ ❒ Throttle Cable Adjustment (if necessary). Engine Oil: Verify oil is present (cold level). d. ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ ❒ Uncrate: Check for damaged or missing parts. Clutch Fluid: Correct fluid level (if necessary). Review Vehicle Care and Maintenance Requirements. connections and fuel tank venting to canister (if equipped). Brake Systems (front and rear): Correct fluid level (if necessary). Install Maxi-Fuse (main fuse). b. f. Shift Linkage Adjustment.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Clutch Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mirrors And Turn Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 FLSTFSE Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Uncrating . . . . . . . . . . . . Checking Clutch Fluid . . . . . . . . . . . . . . . . . . . . 7-1 7-1 7-1 7-1 7-2 7-3 7-3 7-5 7-6 7-6 7-7 7-7 7-8 7-8 7-8 7-8 7-9 7-9 7-10 7-10 7-10 7-14 7-14 7-15 7-16 7-16 7-17 7-17 7-17 7-17 7-18 7-19 7-19 7-20 7-20 7-20 7. . . . . . . . . . . . . Leather Dressing Application . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . Adjusting Handlebar Controls . . . . . . . . . . . Checking Clutch Fluid . . . . . . . . . . Footrest Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank Console Extension . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Handlebars . . . . . . . . . . . . . . . . . VII . . . . . . . . . . . . . . . . . . . . . . . . . Wind Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Uncrating . . . . . . . . . . . Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radio Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Testing And Charging .2 FLHTCSE2 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mirrors And Turn Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Handlebars . . Adjusting Handlebar Controls . . . . . . . 7. . . . . . . . . . . . . . . . . . . . . . . . . Seats And Passenger Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Uncrating . . . . . .1 VRSCSE Model . . . . . . . . . . . . . . Removable Tour-Pak® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Predelivery Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Handlebar Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Predelivery Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removable Passenger Backrest . . . . . . . . . . Removable Rider Backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delivering Vehicle With Removable Passenger Backrest Installed . . . . . . . . . . . . . Final Predelivery Inspections . . Indicator Lamps and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PREDELIVERY: CVO MODELS SUBJECT PAGE NO. . . . . . . . . . . . . . . . . . . . .

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Wash hands after handling. 3. Remove foam block from left handlebar grip. Failure to read and understand all precautions in warning could result in death or serious injury. Wear a protective face shield. 7. 4. This motorcycle is equipped with the Harley-Davidson Factory Security System and siren. Console Connector 2005 PDI: CVO Models 7-1 . NOTES The engine is equipped with a compression release. KEEP BATTERIES AWAY FROM CHILDREN. so a smaller (12 amp hour) battery provides adequate starting current. terminals and related accessories contain lead and lead components. See Figure 7-1. Provide your Dealer name. part number of missing item. Unlatch and lift rear of airbox cover a few inches. Discard foam block and plastic end caps.1 BATTERY TESTING AND CHARGING 1WARNING Batteries contain sulfuric acid. (00064a) Check Contents of Crate Check that the following items are in a box in the crate: ● ● ● ● 1WARNING Battery posts. ● Removing Airbox Cover 1. (00063a) UNCRATING The VRSCSE is shipped in a “turn-wheel” crate which allows the handlebar to be shipped in position on the handlebar risers. 10769 Figure 7-1. Carefully slide airbox cover back to disengage locating pins at front of cover from mounting tabs on frame. rubberized gloves and protective clothing when working with batteries. Remove cover. person to contact. chemicals known in the State of California to cause cancer and birth defects or other reproductive harm.1 VRSCSE MODEL GENERAL Follow the instructions in section I (All Models) and Section VI (VRSC Models) and the following instructions to perform the predelivery setup procedure on the VRSCSE model. number. Remove plastic end caps from both handlebar grips. 2. and Motorcycle VIN. Disconnect console connector. 1WARNING Never remove warning label attached to top of battery. (00019a) ● Motorcycle cover inside a storage bag Owner’s kit Two mirror kits CVO ignition key NOTE If any parts are missing. Unlock and open seat. call 1-800-695-2925 or Fax 1-717852-6717. which could cause severe burns to eyes and skin. It will be necessary to remove the airbox cover to gain access to the battery.

6 VDC or greater the battery is ready for use. View indicator lamps and displays and turn ignition switch to “IGNITION” position. Place test probes of voltmeter on battery terminals and check the voltage of the battery to make sure it is at least 12. the battery must be replaced. Installing Airbox Cover 1. 13. See Figure 7-1. See Section 1.Testing and Charging Battery 1. 3 2 4 IMPORTANT NOTE Only remove air cleaner and air cleaner bottom if battery could not be charged to 12. INDICATOR LAMPS AND DISPLAYS 1. console or speedometer. 9. 3. please refer to the appropriate Electrical Diagnostic manual for your model. 10771 6.6 VDC. Month and year punches may be removed with the point of a screwdriver without removing battery. Mark the date on the battery warranty tag by removing the applicable month and year. Connect console connector halves together.6 VDC and battery must be removed and replaced. Recheck battery voltage by repeating step 1 above. 5. 4. See appropriate Service Manual for procedure. If the open circuit (disconnected) voltage reading is below 12. VRSCSE Indicator Lamps and Displays 7-2 2005 PDI: CVO Models . If the open circuit (disconnected) voltage reading is 12. 10. air cleaner and air cleaner bottom must be removed. 8 1. in Section 1 and charge battery at rate and time specified. 3. 3. If the open circuit (disconnected) voltage reading is still below 12. To remove battery. Close and lock seat. Check that the oil pressure indicator lamp (12) turns on (before engine is started). refer to Table 1-2.6 VDC. 12. NOTE For any systems problems. Lower rear of airbox cover onto frame and latch in place. The security lamp (5) will illuminate for about four seconds and then go off. 5. 7. The Check Engine indicator lamp (2) will illuminate for about four seconds and then go off.6 VDC. 4. perform steps 2 and 3 above. Fuel gauge (7) should also indicate fuel tank level. 11. 4. 2. Engine Coolant temperature lamp (1) will illuminate to verify bulb filament and then go off. 9 10 11 12 13 Engine coolant temperature Check engine Low fuel Alternator Security system Odometer/trip odometer Fuel gauge Left turn signal High beam Clock Neutral Oil Right turn signal Figure 7-2. 2. Carefully install airbox cover over airbox. Be careful not to scratch or damage airbox cover. 6. 8. 12 amp-hour battery. The Battery icon (4) will illuminate to indicate low voltage. 1 7 6 5 2. See Figure 7-2. Engage locating pins on front of airbox cover with tabs on frame. If voltage now is 12 VDC or greater.

Start engine. proceed as follows: 1. 5. Loosen (but do not remove) brake and clutch lever assembly clamp screws (1) and handlebar switch housing screws (2). Handlebar Lever and Control Mounting Screws (Right Side Shown) 2. Check that tachometer is functioning. Handlebar surface contains range marks to properly locate brake and clutch master cylinder and control assemblies. See Figure 7-4.3 Nm (12-15 ft-lbs). ADJUSTING HANDLEBARS The VRSCSE is shipped with the handlebars adjusted to a standard riding position. headlamp–low and high beams headlamp high beam indicator lamp (9) left directional (turn signal) lamps–front and rear Ieft directional (turn signal) indicator lamp (8) right directional (turn signal) lamps–front and rear right directional (turn signal) indicator lamp (13) Ieft front running lamp right front running lamp d0419x1x 2 9. Shift transmission to neutral position. check operation of starter. CAUTION Do not rotate front brake lever assembly too far. Loosen.3-20. they may be rotated slightly for more comfortable riding position. Check operation of all remaining lamps: ● ● ● ● ● ● ● ● ● ADJUSTING HANDLEBAR CONTROLS If handlebar controls and clutch and brake lever assemblies are incorrectly positioned. This time. 1 Front brake lever assembly clamp screw (2) Handlebar switch housing screw (2) Figure 7-3. 10. If handlebars need to be adjusted for more comfortable rider position. but do not remove.3-20. 8. Check that battery icon (4) turns off. Check horn operation. Tighten two front handlebar clamp screws until top and bottom risers meet (no gap in front). Make sure control assembly is positioned so that clamp mating surface (3) is located in area between range marks. These assemblies MUST be located within that range. Check engine oil level in manner previously specified. fill sump to upper mark on filler cap/dipstick. master cylinder can be damaged when clamp screws are tightened. DO NOT tighten screws to more than 20. Rotate right control and brake master cylinder assembly (2) slightly for most comfortable position. and verify that neutral indicator lamp (11) turns off when transmission is shifted to any forward gear. Raise or lower handlebars to desired position. Engine Coolant temperature icon (1) must not illuminate.3 Nm (15 ft-lbs). If not properly located in the machined relief. Shift transmission to neutral position. 4. 4. CAUTION To avoid over-filling the oil sump. An over-filled sump can cause engine damage. 6. 2. Range marks (4) are located on bottom of handlebar adjacent to brake lever clamp assembly. 3. 5. Tighten rear handlebar clamp screws to 16. 7. Check that oil pressure indicator lamp (12) turns off when engine is running above 1200 RPM. 3. wait approximately three minutes after adding oil before checking the oil level with the dipstick. and verify that neutral indicator lamp turns on again. Brake master cylinder fits into a machined relief in handlebar. Disengage clutch (squeeze clutch lever). 2. and verify that neutral indicator lamp turns on. (00188a) 1. turn engine off.3 Nm (12-15 ft-lbs). See Figure 7-3. tail lamp–running lamp and brake lamp filaments After engine has reached normal operating temperature. To adjust handlebar controls. 2005 PDI: CVO Models 7-3 . proceed as follows: 1.2. all four handlebar riser clamp screws. Final tighten front handlebar clamp screws to 16. Make certain handlebars are centered side-to-side in risers.

6. CAUTION Control wiring is routed inside handlebar and may be pinched or cut if controls are rotated too far. tighten left handlebar switch housing screws to 4. tighten left lever assembly clamp screws to 6. tighten right lever assembly clamp screws to 6. Right Handlebar Control Assembly (Bottom View) 5. Beginning with top screw. Handlebar Right control and brake lever assembly Control assembly clamp mating surface Range marks Figure 7-4. Coolant Hose Cover (Engine right side) 7-4 2005 PDI: CVO Models . 2. Check the four hose clamps (two each on hoses) for tightness. 2.0 Nm (60-80 in-lbs). 7.1 Nm (35-45 in-lbs).0 Nm (60-80 in-lbs). 1. 3. 4.4 Nm (10-12 in-lbs). Beginning with top screw. If removed.8-9. 4. pd0214a 1 3 2 NOTE The engine ends of the radiator hoses are secured with a plastic “shrink” clamp and do not require checking.8-9. 3. Screw (4) Decorative hose cover Figure 7-5. 8. Orient the left handlebar control assembly to match the position of the right handlebar control assembly. 1.Check Hose Clamps For Tightness CAUTION Control wiring is routed inside handlebar and may be pinched or cut if controls are rotated too far. remove four screws (1) and decorative cover (2) from water pump hose. Beginning with lower screw.0-5. 4. See Figure 7-5.1 Nm (35-45 in-lbs).0-5. 3. 10770 1 4 2 1. Beginning with lower screw. tighten right handlebar switch housing screws to 4. Test handlebar switches to make sure they are functioning properly and wiring has not become pinched or otherwise damaged.1-1. With a long bladed screwdriver check two hose clamps one at top left and one at top right of radiator. Tighten screws to 1. If necessary. install decorative cover with four screws. 2.

Turn the handlebars to the right if necessary.T. Use only D. Sightglass should appear dark if fluid is present. 1. If swallowed. (00204a) CAUTION Do NOT allow foreign matter to enter the clutch master cylinder reservoir. In case of eye contact flush with large amounts of water and get medical attention. 2. 5 brake fluid can cause digestive discomfort. Swallowing large amounts of D. (00144a) The clutch is hydraulically actuated.O. View reservoir sightglass on reservoir cover and verify fluid presence. 99902-77: 12 oz. Figure 7-6.O. 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. dirt or debris in the reservoir may cause improper operation of the clutch and equipment damage. If sightglass is not dark. KEEP OUT OF REACH OF CHILDREN. Clutch Master Cylinder Reservoir Stand the motorcycle upright (not leaning on the jiffy stand) on a level surface.O. and redness.T. See Figure 7-6. 5 silicone hydraulic brake fluid is used in the hydraulic clutch. obtain medical attention.). 9990177: 1 gal. 5 brake fluid with eyes can cause eye irritation. 2005 PDI: CVO Models 7-5 . Avoid eye contact. See Service Manual. add brake fluid.CHECKING CLUTCH FLUID CAUTION D. 8834 1CAUTION Direct contact of D. so the top of the clutch master cylinder reservoir is level.T.T.. swelling. Do not use other types of fluids as they are not compatible and could cause equipment damage.O. Use in well ventilated area. The clutch master cylinder fluid reservoir is located on the left handlebar.

nor desirable. NOTE It is not necessary.MIRRORS AND TURN SIGNALS The mirrors are enclosed in a box in the crate. Position front turn signal housings (1. install left side mirror assembly. Nylon lock pellet on set screw maintains locking ability after many loosening/tightening cycles. 3. 11. 12. 9. pd0208 10 11 13 6 9 10 12 3 5 7 1 9 8 3 1. 8. In the same fashion. adjust turn signal and re-tighten set screw. 13 2 2. 7. This helps establish the relative distance of vehicles to the rear of the motorcycle. If set screw is completely removed. Loosen set screws (9) approximately 1/8 turn. slide mirror stem down through hole in front brake master cylinder assembly and right turn signal bracket (5). Right turn signal housing Left turn signal housing Jam nut (2) Ball stud (2) Right turn signal bracket Left turn signal bracket Acorn nut (2) Lockwasher (2) Set screw (2) Spacer (2) Clutch control housing Brake control housing Mirror stem (2) Figure 7-7. c. Turn Signals 7-6 2005 PDI: CVO Models . 4.8 Nm (50-60 inlbs).0 Nm (60-96 in-lbs). b. 6. See Figure 7-7. 5. to completely remove set screw to re-adjust turn signal housing. Tighten each set screw to 5. Install mirrors and adjust for proper rear view as follows: 1. To adjust turn signals: a. Tighten acorn nuts to 6. 2. 3. 5.8-9. 8 4 7 SEATS AND PASSENGER STRAP Refer to VRSC Models Owner’s Manual for seat and passenger strap removal and installation instructions. It is only necessary to loosen set screw 1/8 turn. 13. it should be replaced. 4 4. Place spacer (10) onto right side mirror stem. 10. 2) evenly with lenses pointing straight ahead. Install lockwasher (8) and screw on acorn nut (7) finger tight.7-6. Adjust mirrors so a small portion of the rider’s shoulder is visible in each mirror.

Removing Footrest Rubber Insert 10773 Figure 7-9. Footrest assembly Screw Rubber insert Figure 7-8. Footrest Adjustment Screw 2005 PDI: CVO Models 7-7 . DO NOT REPEAT INSPECTIONS THAT WERE PERFORMED IN THIS SECTION. 2. Reinstall rubber insert (3) into footrest assembly (1) and secure with screw (2). Loosen footrest adjustment screw. 2. Tighten screw to 25. FINAL PREDELIVERY INSPECTIONS CAUTION Do not use sharp objects to peel protective film from console insert and clutch release cover in the next two steps. 3. 2 1. Carefully peel the film away from the console insert. See Figure 7-9. Remove screw (2) and footrest rubber insert (3) from footrest assembly (1). 3.0 Nm (35-53 in-lbs).FOOTREST ADJUSTMENT If it is necessary to rotate rider or passenger footrests for customer comfort. See Figure 7-8. The clutch release cover (righthand side of engine) is protected during shipment by a clear plastic film.8 Nm (19 ft-lbs).06. Sharp objects can scratch and damage finished surfaces. 1. proceed as follows: 1. 10772 3 1 NOTE Perform all the remaining Predelivery Inspections given in Section I (All Models) and Section VI (VRSC Models) that apply to the VRSCA. See Figure 7-8. Rotate footrest assembly to desired angle. Carefully peel the film away from the clutch release cover. Tighten to 4. The airbox console insert is protected during shipment by a clear plastic film. 2.

NOTE FLHTCSE2 models sold in the Australian market are not equipped with a siren. Handlebar Lever and Control Mounting Screws (Right Side Shown) 2. If there is a need to top off lubricants. master cylinder can be damaged when clamp screws are tightened. Provide your Dealer name. CAUTION Do not rotate front brake or clutch master cylinder assemblies too far. These assemblies MUST be located within that range. CAUTION 7. number. and Motorcycle VIN. This motorcycle is equipped with the Harley-Davidson Factory Security System and siren. See Figure 7-10. DO NOT use standard lubricants and do not mix lubricants as damage to the motorcycle can result. part number of missing item.FLHTCSE2 MODEL GENERAL CAUTION The FLHTCSE2 model is shipped from the factory with SYN-3® lubricant exclusively in the engine. f1993x8x 2 Check Contents of Crate Verify that the following items have been included: NOTE Keep garage door opener receiver with vehicle for delivery to customer. Loosen (but do not remove) front brake lever assembly clamp screws (1) and handlebar switch housing screws (2). primary and transmission. 1. ● Antenna (shipped by right floorboard) ● Key fobs ● Leather care ● Saddlebag liners ● Tour-Pak liner ● Passenger backrest (detachable sissy bar) A rider backrest is mounted on the vehicle. ● ● 1 1. The following items are shipped in the Tour-Pak® and saddlebags: Tour-Pak mounting hardware kit Tour-Pak support tube ● Garage door opener receiver ● Wind deflector ● Tool pouch ● Maxi-Fuse and cover ● Data link plug ● Keys (including CVO key) ● Motorcycle cover ● Owner’s kit (including owner’s manual cover for vehicles sold in domestic markets only). Follow the instructions in section I (All Models) and Section II (Touring Models) and the following instructions to perform the predelivery setup procedure on the FLHTCSE2 model. If not properly located. adjust handlebar controls as follows: 1. If necessary. NOTE If any parts are missing. 2. call 1-800-695-2925 or Fax 1-717852-6717. Handlebar surface contains range marks to properly locate brake and clutch master cylinder and control assemblies. UNCRATING CAUTION Roll motorcycle rearward off pallet slowly to avoid striking the oil cooler on the skid and causing damage to the motorcycle. Front brake lever assembly clamp screw (2) Handlebar switch housing screw (2) Figure 7-10. 7-8 2005 PDI: CVO Models . person to contact.2 ADJUSTING HANDLEBAR CONTROLS Control wiring is routed inside handlebar and may be pinched or cut if controls are rotated too far.

4 brake fluid can cause digestive discomfort. The clutch master cylinder fluid reservoir is located on the left handlebar. re-install in correct orientation and adjust for proper rear view. If swallowed. CHECKING CLUTCH FLUID CAUTION D. Failure to comply can result in cosmetic damage. Handlebar Control Assembly (Bottom View. Right Side Shown) 8834 MIRRORS Mirrors are installed on motorcycle and are rotated upside down for shipping.2. Beginning with top screw. 1. Make sure control assembly is positioned so that clamp mating surface (3) is located in area between range marks. 5.O.T. pd0224 1 3 2 D. Remove mirrors. Range marks (4) are located on bottom of handlebar adjacent to front brake lever clamp assembly. CAUTION 3. See Touring Models Service Manual for mirror installation procedure. Rotate switch housing and front brake master cylinder assembly (2) slightly for most comfortable position. Clutch Master Cylinder Reservoir 2005 PDI: CVO Models 7-9 . Swallowing large amounts of D. In case of eye contact flush with large amounts of water and get medical attention. See Figure 7-12. 2. 4. obtain medical attention. 4 brake fluid will damage painted and molded-in color surfaces it comes in contact with.O. (00239a) 1CAUTION 4 Direct contact of D. tighten assembly clamp screws to 60-80 in-lbs (6.T.T. tighten handlebar switch housing screws to 35-45 in-lbs (4-5 Nm). (00240a) The clutch is hydraulically actuated.0 Nm). 4 brake fluid with eyes can cause irritation. CAUTION Do NOT allow foreign matter to enter the clutch master cylinder reservoir. 3. Always use caution and protect surfaces from spills whenever brake work is performed. dirt or debris in the reservoir may cause improper operation of the clutch and equipment damage. Avoid eye contact. Do not use other types of fluid as they are not compatible and could cause equipment damage. Test handlebar switches to make sure they are functioning properly and wiring has not become pinched or otherwise damaged. Use in well ventilated area.O.T.8-9. 4 hydraulic brake fluid is the only type of fluid that should be used in the hydraulic clutch. Handlebar Right control and brake lever assembly Control assembly clamp mating surface Range marks Figure 7-11. 4. See Figure 7-11.O. Beginning with lower screw. Figure 7-12. 6. Repeat steps 1-4 above for clutch master cylinder and switch housing assemblies on left handlebar. KEEP OUT OF REACH OF CHILDREN.

1 Tour-Pak bracket mounts Passenger backrest mounts Figure 7-13. so the top of the clutch master cylinder reservoir is level. Wash all residue of D. 4 HYDRAULIC BRAKE FLUID (Part No. CAUTION When assembling Tour-Pak and mounting bracket. The Tour-Pak assembly mounts on the two rear mounting points (1) on each side of the vehicle. Sightglass should appear dark if fluid is present. washers. washers and nuts that secure Tour-Pak to removable mounting bracket. Open Tour-Pak lid and remove three long screws. 99953-99A). Removable mounting bracket has two sets of holes for mounting Tour-Pak. Tour-Pak Mounting Assembly as Shipped 7-10 2005 PDI: CVO Models . Place Tour-Pak on its front surface on a clean. 10692 2 1 2. Remove and discard long screws. 2. The FLHTCSE2 is shipped with the Tour-Pak (1) mounted forward of its normal mounting position. 3 Tour-Pak Removable mounting bracket Cardboard shipping spacer NOTE See Figure 7-15. If sightglass is not dark. NOTE Assembly of the Tour-Pak to its mounting bracket is facilitated with the help of an assistant. View reservoir sightglass on reservoir cover and verify fluid presence. 3. Unpack and mount on vehicle following the INSTALLING WINDSHIELD Section of the Touring section. 1. 1.O. 4 brake fluid spills off vehicle with water. 2.O. removable mounting bracket (5) and support tube (3). 3. five locknuts (6). 1. Stand the motorcycle upright (not leaning on the jiffy stand) on a level surface. 10681 2 REMOVABLE RIDER BACKREST Rider backrest is installed on seat at factory. 2. Turn the handlebars to the right if necessary. soft cloth or mat. The rear set of holes will be used to mount the Tour-Pak. See Figure 7-17. 4. add brake fluid. This temporary mounting allows motorcycle to fit in shipping crate. Locate five screws (1). five saddle spacers (4). See Figure 7-16.T. Use only D. ten washers (2). WIND DEFLECTOR The wind deflector is shipped in the saddlebag. be careful to avoid damaging painted surfaces. on the removable mounting bracket (2) with a cardboard shipping spacer (3) in between Tour-Pak and mounting bracket. Figure 7-14.T. See Service Manual. Refer to FLHTCSE2 Owner’s Manual for backrest and seat removal/ installation instructions. being careful not to damage painted surfaces. nuts and cardboard shipping spacer. Passenger Backrest and Tour-Pak Docking Locations REMOVABLE TOUR-PAK See Figure 7-13.1. See Figure 7-14.

5. 4. 6. Removable Mounting Bracket 3 10704 4 5 6 Figure 7-16. (5) Washer 1/4 in. Tour-Pak Mounting 2005 PDI: CVO Models 7-11 . 2. Positioning Tour-Pak for Assembly 1. inside dia. 1/4-20 x 2-1/4 in. 3. (10) Support tube Saddle spacer (5) Removable mounting bracket Locknut.10767 pd0222 Mount Tour-Pak in rear holes 1 2 Figure 7-15. Screw. 1/4-20 (5) Figure 7-17. Nylon cap.

See Figure 7-19. Locate Tour-Pak power connector between seat and fender strut cover on left side of motorcycle. Install washers and locknuts (2. Install one saddle spacer onto screw with curved surface of spacer facing support tube. Install washer and locknut.5 Nm).5. Tighten all five screws and locknuts to 96-120 in-lbs (10. Removable mounting bracket Screw and locknut (4) Washer (4) Saddle spacer (4) Tour-Pak (front surface facing down) Figure 7-19. See Figure 7-20. Install saddle spacers on screws with curved surface of each spacer facing support tube. Support tube Saddle spacer Screw and locknut Washer Tour-Pak (front surface facing down) Figure 7-18. Mounting Support Tube Figure 7-20. 1 5 10705 4 1 1.8-13. See Figure 7-18. 3. 4. 10. Finger-tighten locknut only. 2. 3. Install Tour-Pak on Tour-Pak bracket mounts (1) and lock latches in place. through Tour-Pak and support tube. Slide support tube onto screw. 5. 2 7. See Figure 7-13. 3). Insert one screw with washer through rear-most hole in Tour-Pak. 4. 2. Install screws and washers in other four locations. 10768 6. Slide removable mounting bracket (1) onto screws with bracket latches facing rear of Tour-Pak. 9. 5. Tour-Pak Power Connector 7-12 2005 PDI: CVO Models . Removable Mounting Bracket 10688 2 3 5 1. 3 4 8. 11.

Finger-tighten securely. See Figure 7-21. Connecting Antenna Cable (Tour-Pak Installed) 10679 2005 PDI: CVO Models 7-13 . pd0220 10689 Figure 7-22. Coaxial Adapter 10690 10678 1 2 Figure 7-21. allowing for a small amount of slack in cable. With the radio antenna mast mounted on the Tour-Pak antenna mount. Make certain that coaxial adapter (2) is securely finger-tightened into the antenna chassis mount (3). 1. 15. Coaxial connector Coaxial adapter Antenna chassis mount Figure 7-23. Pull enough coaxial cable from Tour-Pak to reach coaxial adapter on antenna chassis mount. 14. Screw coaxial cable connector (1) into coaxial adapter on antenna chassis mount. the coaxial adapter shown in the figure allows connecting the antenna cable to the chassis antenna mount. the adapter may be removed and antenna mast threaded directly onto the chassis antenna mount. 2. With Tour-Pak removed. Connecting Tour-Pak Power Cable 3 NOTE See Figure 7-22. 13.12. See Figure 7-23. 3. Plug Tour-Pak harness into power connector and tuck cable assembly between seat and fender strut cover.

RADIO ANTENNA
See Figure 7-24. Screw antenna (1) into antenna mount (2) on Tour-Pak and tighten set screw with allen wrench (3).

10681

1

10680

2 1
1. 2. Passenger backrest mounts Tour-Pak bracket mount Figure 7-25. Passenger Backrest and Tour-Pak Docking Locations

2 3

10707

1. 2. 3.

Antenna Antenna Tour-Pak mount Allen wrench Figure 7-24. Installing Antenna on Tour-Pak

1

REMOVABLE PASSENGER BACKREST
See Figure 7-25. The passenger backrest assembly mounts on the two forward mounting points (1) on each side of the vehicle when the Tour-Pak is not installed. Since the vehicle will ordinarily be delivered to the customer with the Tour-Pak installed, store the removable passenger backrest inside the Tour-Pak and deliver to customer with vehicle. NOTE Retain protective cardboard packaging for passenger backrest. Secure backrest in Tour-Pak to prevent damage to backrest assembly and interior of Tour-Pak. 1. 2. Rear latch (2) “C” bracket guides (2)

2

Figure 7-26. Passenger Backrest

7-14

2005 PDI: CVO Models

DELIVERING VEHICLE WITH REMOVABLE PASSENGER BACKREST INSTALLED
If the customer wishes the vehicle to be delivered with the removable passenger backrest (see Figure 7-26.) installed on the vehicle instead of the Tour-Pak, follow the instructions below.

10675

1

Passenger Backrest
NOTE If the Tour-Pak is installed on the vehicle, it must be removed. See Figure 7-25. Mount the passenger backrest assembly on the two forward mounting points (1) on each side of the vehicle.
10676

Radio Antenna
NOTE See Figure 7-27. With the antenna mast mounted on the Tour-Pak antenna mount, the coaxial adapter shown in the figure allows connecting the antenna cable to the chassis antenna mount. With Tour-Pak removed, the adapter may be removed and antenna mast threaded directly onto the chassis antenna mount.

2

pd0220

10677

Figure 7-27. Coaxial Adapter 1. See Figure 7-28. Unscrew coaxial adapter (1) from antenna chassis mount. Place coaxial adapter in TourPak and deliver to customer with vehicle. Screw antenna (3) onto chassis mount and tighten set screw with allen wrench (4). 1. 2. 3. 4. Coaxial adapter Antenna chassis mount Antenna Allen wrench

3 4

2.

Figure 7-28. Installing Antenna (Tour-Pak Removed)

2005 PDI: CVO Models

7-15

LEATHER DRESSING APPLICATION
Apply Harley-Davidson Leather Dressing, Part No. 9826191V to the following:
● ● ● ●

FINAL PREDELIVERY INSPECTIONS
Perform all the remaining Predelivery Inspections given in Section I (All Models) and Section II (Touring Models) that apply to the ELECTRA GLIDE (FLHT). NOTE Do not remove the clutch cover. It is not necessary to check the primary chaincase lubricant level on the FLHTCSE2. Also, the hydraulic clutch is not adjustable. DO NOT REPEAT INSPECTIONS THAT WERE PERFORMED IN THIS SECTION.

Seat. Rider backrest pad. Passenger backrest pad (mounted on Tour-Pak). Detachable passenger backrest pad.

7-16

2005 PDI: CVO Models

number. Final tighten front handlebar clamp screws to 12-15 ft-lbs (16. If there is a need to top off lubricants. Check Contents of Crate Check that the following items are in a box in the crate: ● ● ● ● Seat Motorcycle cover Owner’s kit Right mirror Figure 7-29. part number of missing item.FLSTFSE MODEL GENERAL CAUTION The FLSTFSE model is shipped from the factory with SYN-3® lubricant exclusively in the engine. 7. 10762 UNCRATING See Figure 7-29.3 Nm). 3. Provide your Dealer name. FLSTFSE Shipped in Turn-Wheel Crate ● NOTES If any parts are missing.3 Tighten two front handlebar clamp screws until top and bottom risers meet (no gap in front). 4.3 Nm). Raise or lower handlebars to desired position. all four handlebar riser clamp screws. After crating straps have been removed. Make certain handlebars are centered side-to-side in risers.3-20.3 Nm). This motorcycle is equipped with the Harley-Davidson Factory Security System and siren. If handlebars need to be adjusted for more comfortable rider position. and Motorcycle VIN. Follow the instructions in section I (All Models) and Section IV (Softail Models) and the following instructions to perform the predelivery setup procedure on the FLSTFSE model. The FLSTFSE is shipped in a “turn-wheel” crate which allows the handlebar to be shipped in position on the handlebar risers. call 1-800-695-2925 or Fax 1717-852-6717. Figure 7-30. Plastic Crating Strap Bracket 2005 PDI: CVO Models 7-17 . primary and transmission. but do not remove.3-20. Tighten rear handlebar clamp screws to 12-15 ft-lbs (16. 2. Loosen. make sure to remove the plastic crating strap bracket from the vehicle. DO NOT tighten screws to more than 15 ft-lbs (20. See Figure 7-30. 5. person to contact. 10763 ● ADJUSTING HANDLEBARS The FLSTFSE is shipped with the handlebars adjusted to a standard riding position. proceed as follows: 1. DO NOT use standard lubricants and do not mix lubricants as damage to the motorcycle can result.

Orient the left handlebar control assembly to match the position of the right handlebar control assembly. they may be rotated slightly for more comfortable riding position. To adjust handlebar controls. master cylinder can be damaged when clamp screws are tightened. Handlebar surface contains range marks to properly locate brake and clutch master cylinders and control assemblies. 4.8-9. Right Handlebar Control Assembly (Bottom View) 7-18 2005 PDI: CVO Models . Range marks (4) are located on bottom of handlebar adjacent to brake lever clamp assembly.ADJUSTING HANDLEBAR CONTROLS If handlebar controls and clutch and brake lever assemblies are incorrectly positioned. Handlebar Right control and brake lever assembly Control assembly clamp mating surface Range marks Figure 7-32. Brake master cylinder fits into a machined relief in handlebar. CAUTION Do not rotate front brake lever assembly too far. If not properly located in the machined relief. 5. CAUTION Control wiring is routed inside handlebar and may be pinched or cut if controls are rotated too far. 2. 3. Beginning with top screw. tighten left handlebar switch housing screws to 35-45 in-lbs (4-5 Nm).0 Nm). Make sure control assembly is positioned so that clamp mating surface (3) is located in area between range marks. 8. Beginning with top screw. tighten right lever assembly clamp screws to 60-80 in-lbs (6.8-9. These assemblies MUST be located within that range. 6. proceed as follows: 1. CAUTION Control wiring is routed inside handlebar and may be pinched or cut if controls are rotated too far. 2. 3. Front brake lever assembly clamp screw (2) Handlebar switch housing screw (2) Figure 7-31. Beginning with lower screw. Test handlebar switches to make sure they are functioning properly and wiring has not become pinched or otherwise damaged.0 Nm). tighten left lever assembly clamp screws to 60-80 in-lbs (6. See Figure 7-32. tighten right handlebar switch housing screws to 35-45 in-lbs (4-5 Nm). 4 1. Handlebar Lever and Control Mounting Screws (Right Side Shown) pd0214a 1 3 2 2. Loosen (but do not remove) brake and clutch lever assembly clamp screws (1) and handlebar switch housing screws (2). 4. 7. See Figure 7-31. Beginning with lower screw. Rotate right control and brake master cylinder assembly (2) slightly for most comfortable position. d0419x1x 2 1 1.

0 Nm) Lockwasher (2) Set screw (2) @ 50-60 in-lbs (5.7-6.O. See Figure 7-34. Clutch Master Cylinder Reservoir 1. 3. 5 brake fluid with eyes can cause eye irritation. 7 4 7 Figure 7-33. 9990177: 1 gal. 99902-77: 12 oz. 1CAUTION Direct contact of D. 5 brake fluid can cause digestive discomfort. KEEP OUT OF REACH OF CHILDREN. so the top of the clutch master cylinder reservoir is level. dirt or debris in the reservoir may cause improper operation of the clutch and equipment damage. This helps establish the relative distance of vehicles to the rear of the motorcycle. pd0213 10 11 4 10 12 3 5 8 9 6 2 8834 1 9 8 3 1. MIRRORS AND TURN SIGNALS The right mirror is enclosed in a box in the crate.). The clutch master cylinder fluid reservoir (1) is located on the left handlebar.T.0 Nm). 2005 PDI: CVO Models 7-19 . Use in well ventilated area.T. Adjust both mirrors so a small portion of the rider’s shoulder is visible in each mirror. obtain medical attention. See Figure 7-33.O. 10. (00204a) CAUTION Do NOT allow foreign matter to enter the clutch master cylinder reservoir. 2. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. 4. View reservoir sightglass on reservoir cover and verify fluid presence.CHECKING CLUTCH FLUID CAUTION D. Sightglass should appear dark if fluid is present. 6. (00144a) The clutch is hydraulically actuated. slide mirror stem down through hole in front brake master cylinder assembly and right turn signal bracket (5).O. Use only D.T. add brake fluid.8 Nm) Spacer (2) Clutch control housing Brake control housing Figure 7-34. Tighten acorn nuts to 60-96 in-lbs (6. Place spacer (10) onto right side mirror stem. Do not use other types of fluids as they are not compatible and could cause equipment damage.. 3. 9. 2. Stand the motorcycle upright (not leaning on the jiffy stand) on a level surface. Swallowing large amounts of D. 5 silicone hydraulic brake fluid is used in the hydraulic clutch.8-9. 12. If sightglass is not dark. Turn Signals 2. 11. swelling.O. 4. 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. 7.8-9. If swallowed. Turn the handlebars to the right if necessary.T. 5. Install mirror and adjust for proper rear view as follows: 1. Right turn signal housing Left turn signal housing Jam nut (2) Ball stud (2) Right turn signal bracket Left turn signal bracket Acorn nut (2) @ 60-96 in-lbs (6. To adjust turn signals: a. Loosen set screws (9) approximately 1/8 turn. 8. See Service Manual. and redness. Install lockwasher (8) and screw on acorn nut (7) finger tight.

the hydraulic clutch is not adjustable. If setscrew is completely removed. adjust turn signal and re-tighten setscrew. 1. to completely remove setscrew to re-adjust turn signal housing. c. Also. Secure with mounting screw into rear fender. b. 3. Tighten each set screw to 50-60 in-lbs (5. FINAL PREDELIVERY INSPECTIONS Perform all the remaining Predelivery Inspections given in Section I (All Models) and Section IV (Softail Models) that apply to the FLSTF model. 7-20 2005 PDI: CVO Models . It is not necessary to check the primary chaincase lubricant level on the FLSTFSE. 2) evenly with lenses pointing straight ahead. Tighten securely. Insert screw through hole in rear end of fuel tank console extension (1) and screw into fuel tank mounting tab.7-6. Nylon lock pellet on setscrew maintains locking ability after many loosening/tightening cycles. nor desirable. See Figure 735.8 Nm). Place tang on front underside of seat into channel in frame (3). DO NOT REPEAT INSPECTIONS THAT WERE PERFORMED IN THIS SECTION. it should be replaced. Fuel Tank Console Extension SEAT Remove seat and mounting screw from carton.NOTE It is not necessary. Slide seat forward into place. NOTE Do not remove the clutch cover. Position front turn signal housings (1. It is only necessary to loosen setscrew 1/8 turn. Remove screw (2) from fuel tank mounting tab. 2. 10766 1 2 FUEL TANK CONSOLE EXTENSION See Figure 7-35. 3 Fuel tank console extension Mounting screw Seat mounting channel Figure 7-35.

2005 General Touring Models Dyna Models Softail Models Sportster Models VRSC Models CVO Models .