Harley Davidson Softail (2005) Bruksanvisning

Harley Davidson Motor Softail (2005)

Läs nedan 📖 manual på svenska för Harley Davidson Softail (2005) (135 sidor) i kategorin Motor. Denna guide var användbar för 7 personer och betygsatt med 4.5 stjärnor i genomsnitt av 2 användare

Ladda ner PDF

Sida 1/135

DYNA III

TOURING II

GENERAL I

SOFTAIL IV

SPORTSTER V

VRSC VI

CVO VII

2005

HARLEY-DAVIDSON

MOTORCYCLE

PREDELIVERY

AND SETUP

MANUAL

The information in this Manual

applies to all 2005 motorcycle

models manufactured by

Harley-Davidson Motor Company.

Printed in the U.S.A.

VISIT THE HARLEY-DAVIDSON WEB SITE

http://www.harley-davidson.com

Binder 99946-88

Contents 99947-05

CMI-4.0M-06/04

iii

FOREWORD

INTRODUCTION

This PREDELIVERY AND SETUP MANUAL has been pre-

pared 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 cus-

tomer.

NOTE

Harley-Davidson Motor Company considers the predelivery

inspections and procedures in this manual necessary to

assure customer safety and satisfaction. None of these

inspections or procedures should ever be left out, and only

qualiﬁed technicians should perform them.

HOW TO USE YOUR PREDELIVERY

AND SETUP MANUAL

Your Predelivery and Setup Manual is divided into seven sec-

tions:

●Section I–General Information: All Models

●Section ll–Predelivery Inspections: Touring Models

●Section lll–Predelivery Inspections: Dyna Models

●Section IV–Predelivery Inspections: Softail Models

●Section V–Predelivery Inspections: Sportster Models

●Section VI–Predelivery Inspections: VRSC Models

●Section VII–Predelivery Inspections: CVO Models

Refer to Section I ﬁrst for general setup instructions pertain-

ing to all current model motorcycles. Then, proceed to the

one Section (either II, III, IV, V, VI or VII) which covers the

inspection procedures for your speciﬁc model vehicle.

WARNINGS AND CAUTIONS

1WARNING1WARNING

WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious

injury. (00119a)

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.

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 fol-

lowing 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.

CONTENTS

All photographs, illustrations and procedures may not neces-

sarily 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, Harley-

Davidson reserves the right to change speciﬁcations, equip-

ment or designs at any time without notice and without incur-

ring obligation.

ORDERING INFORMATION

Additional binders or contents may be ordered from Parts &

Accessories. The binder and the contents must be ordered

separately.

●Binder: Part No. 99946-88

●Contents: Part No. 99947-05

TABLE OF CONTENTS

SECTION SUBJECT PAGE NUMBER

I General Information: All Models 1-1

II Predelivery Inspections: Touring Models 2-1

III Predelivery Inspections: Dyna Models 3-1

IV Predelivery Inspections: Softail Models 4-1

V Predelivery Inspections: Sportster Models 5-1

VI Predelivery Inspections: VRSC Models 6-1

VII Predelivery Inspections: CVO* Models 7-1

*Custom Vehicle Operations

SUBJECT PAGE NO.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

PREDELIVERY: ALL MODELS

2005 PDI: All Models 1-1

UNCRATING AND GENERAL SETUP: ALL MODELS 1.1

VEHICLE CRATE INSPECTION

Inspect each crate for external damage while it is still on

delivery truck. Open crate and inspect motorcycle for damage

before truck leaves your dealership. Refer to HARLEY-

DAVIDSON/BUELL WARRANTY MANUAL, “SHIPPING

DAMAGE PROCEDURE” for complete information on ﬁling

claims for damaged and over/short freight.

UNCRATING VEHICLE

CAUTION

Use caution when removing cardboard carton from pal-

let. DO NOT remove uprights before removing carton.

Failure to do so can cause damage to motorcycle.

NOTE

All Harley-Davidson motorcycles are shipped in crates using

returnable steel pallets. The steel pallets have fork openings

2x7 in. (5.1x17.8 cm) at the front and sides. Crates have

widths of 29 in. (73.7 cm) and 43 in. (109.2 cm) and all are 50

in. (127 cm) high. The VRSC, SPORTSTER, DYNA and some

SOFTAIL models are shipped with the front wheel turned to

the left or right in a “turn-wheel” crate. Removing the shipping

crate is similar on all models so the procedure given below is

typical for all models. Call your SPOC representative if you

have questions regarding steel pallet return.

REMOVING CARDBOARD CARTON

1. See Figure 1-1. Use a T-20 bit and an electric or air pow-

dered drill/driver to remove all fasteners from cardboard

carton. Open top carton ﬂaps.

2. See Figure 1-2. Using a box cutter, cut one end of the

cardboard carton. Slide carton away from pallet as

shown. Set carton aside for recycling.

3. See Figure 1-3. Remove both uprights (VRSC, FLST and

FLSTC crates have three uprights) by lifting upward. Set

uprights aside for recycling.

4. Open plastic bag enclosing motorcycle and push it down

off motorcycle. Remove protective tape and elastic pro-

tective netting, if present, from chrome and painted parts

of motorcycle.

Figure 1-1. Removing Screws

8796

Figure 1-2. Remove Cardboard Carton from Pallet.

Figure 1-3. Remove Uprights from Pallet

10426

8798

1-2 2005 PDI: All Models

NOTE

Always install/adjust handlebars before removing motorcycle

from pallet. See HANDLEBAR INSTALLATION–FLSTSC,

FLSTN AND FXDWG MODELS ADJUSTING HANDLE- and

BARS– ALL MODELS.

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

separate items by comparing with parts list in shipping

crate.

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

the factory, submit warranty claim form. Accurately

describe damage and cause. (e.g.–“Found nail in tire;

caused tire to go ﬂat.”) Supply proper failure code(s).

1WARNING1WARNING

Do not alter or disable any device or system to circum-

vent local, state, or federal regulations. All safety and

environmental devices or systems must be left intact as

designed and built at the factory. Tampering with safety

and environmental devices or systems could result in

death or serious injury.

1WARNING1WARNING

The automatic-on headlamp feature provides increased

visibility for riders. Be sure headlamp is on at all times.

Low visibility of rider can result in death or serious

injury. (00030a).

1WARNING1WARNING

Some motorcycles are shipped with the hand brake lever

wrapped tight against the hand grip. Remove plastic

wrap and warning label (see ) and pump brakeFigure 1-4.

lever 3-4 times before moving motorcycle from pallet.

Failure to pump brake lever could result in an inoperable

front brake which could result in death or serious injury.

HANDLEBAR INSTALLATION–

FLSTSC, FLSTN AND FXDWG

MODELS

FLSTSC

After removing carton and protective plastic wrap:

1. See Figure 1-5. While holding handlebars, remove the

riser bolts (2) securing handlebar shipping cradle (1) to

risers. Retain the four bolts, discard washers.

2. While holding the handlebar shipping cradle, cut cable

straps (3). Discard cradle and cable straps. Remove and

discard protective block (4) from left handlebar grip.

3. Route handlebar switch conduits between and behind

risers.

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

caps and riser bolts.

5. See and ADJUSTING HANDLEBARS– ALL MODELS

Figure 1-10. Following the Dyna Glide, Softail, XL 883,

XL 883L and XL 1200R Models procedure, adjust the

handlebars and tighten the riser bolts to 12-15 ft-lbs

(16.3-20.3 Nm) in the sequence given.

6. Push the four plastic wire retainers on the handlebar

switch conduits into the holes in the handlebars. Replace

any broken wire retainers.

7. Attach hand control and directional wire harnesses to

handlebar risers with cable straps (Part No. 10039).

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

frame downtube.

Figure 1-4. Warning Label

WARNING:

PUMP BRAKE LEVER

3-4 TIMES BEFORE

USING BRAKES

pd0171

Figure 1-5. FLSTSC

1. Handlebar shipping cradle

2. Riser bolt (4)

3. Cable strap (4)

4. Protective block

5. Protective pad

10612

2005 PDI: All Models 1-3

FLSTN

After removing carton and protective plastic wrap:

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

ing handlebar.

2. Remove the riser bolts (2) and shipping clamp (1) from

handlebar risers. Retain the bolts. Remove and discard

protective block (4) from right handlebar grip.

3. Route handlebar switch conduits between and behind

risers.

4. Position handlebar on top of the risers and secure with

riser caps, and bolts removed in step 2.

5. See and ADJUSTING HANDLEBARS– ALL MODELS

Figure 1-10. Following the Dyna Glide, Softail, XL 883,

XL 883L and XL 1200R Models procedure, adjust the

handlebars and tighten the riser bolts to 12-15 ft-lbs

(16.3-20.3 Nm) in the sequence given.

6. Push the four plastic wire retainers on the handlebar

switch conduits into the holes in the handlebars. Replace

any broken wire retainers.

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

frame downtube.

8. See Figure 1-7. Install front brake line (1) in clamps (2),

inboard of screws (3) and attach to fork stem cover (4).

Tighten screws to 30-50 in-lbs (3.4-5.7 Nm).

9. Install brake line in clamp (5) in underside of lower fork

clamp. Tighten screw (6) to 96-120 in-lbs (10.9-13.6

Nm).

Figure 1-6. FLSTN

1. Shipping clamp

2. Riser bolts

3. Cloth tie

4. Protective block

10613

Figure 1-7. Attaching Front Brake Line–FLSTN

1. Front brake line

2. Clamp (2)

3. Screw (2)

4. Fork stem cover

5. Clamp

6. Screw

10614

10615

1-4 2005 PDI: All Models

FXDWG

After removing carton and protective plastic wrap:

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

ing handlebar.

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

bolts.

3. Reroute the left hand switch wire conduit from between

the riser to a position in front of the riser.

4. Retrieve riser caps from passenger backrest.

5. Position the handlebar on top of the risers and fasten the

riser caps in place using the bolts removed in step 2.

6. See and ADJUSTING HANDLEBARS– ALL MODELS

Figure 1-10. Following the Dyna Glide, Softail, XL 883,

XL 883L and XL 1200R Models procedure, adjust the

handlebars and tighten the riser bolts to 12-18 ft-lbs

(16.3-24.4 Nm) in the sequence given.

7. See Figure 1-9. Attach brake line (2) and ground wire (3)

on upper triple clamp with clamp (1). Position brake line

inboard from fastener. Tighten fastener to 30-60 in-lbs

(3.4-6.8 Nm).

Figure 1-8. FXDWG

1. Cloth tie

2. Riser bolts (4)

3. Shipping clamps

4. Protective block

6052

6053

Figure 1-9. FXDWG Brake Line and Ground Wire

6062

1. Clamp

2. Brake line

3. Ground wire

4. Clamp

5. Screw

6059

2005 PDI: All Models 1-5

CAUTION

See Figure 1-9. Attach brake line as shown before remov-

ing motorcycle from pallet. If brake line is not secured, it

could be pinched and damaged in front fork stop.

8. Attach brake line to bottom of steering stem with clamp

(4) and screw (5). Tighten to 96-120 in-lbs (10.9-13.6

Nm).

9. See Figure 1-8. Remove shipping clamps (3) from the

handlebar. Remove protective block (4) on throttle. Dis-

card shipping clamps and protective block.

10. Install clutch cable in clip on left downtube.

11. Install the plastic wire retainers on the handlebar switch

conduits and push into the holes in the handlebars.

Replace any broken wire retainers.

ADJUSTING HANDLEBARS–

ALL MODELS

General

CAUTION

Never adjust handlebars using excessive force. Doing so

may result in damage to handlebar or clamp.

NOTE

If handlebars are positioned for a rider of normal size, post-

pone adjustment until customer has checked their position. If

customer requests changing handlebar position, perform the

adjustment before delivering the motorcycle to the customer.

Always center the handlebar laterally (sideways) in the han-

dlebar clamps.

Before removing motorcycle from pallet, adjust handlebars

according to the following procedures:

Dyna Glide, Softail, XL 883, XL 883L and

XL 1200R Models

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

dlebar upper clamp (6).

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

equal amounts of knurled areas on handlebar protrude

from outboard sides of upper handlebar clamp.

NOTE

On some models, knurled areas of handlebar will be com-

pletely hidden by upper handlebar clamp and will not be visi-

ble at all when handlebar is centered properly.

3. Raise handlebars to normal riding position and hold in

position.

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

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

contact handlebar lower clamps (1).

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

to 12-18 ft-lbs (16.3-24.4 Nm). Softail models:

tighten front screws (4) to 12-15 ft-lbs (16.3-20.3

Nm).

c. Dyna and Sportster models: ﬁnal tighten rear

screws to 12-18 ft-lbs (16.3-24.4 Nm). Softail mod-

els: ﬁnal tighten rear screws to 12-15 ft-lbs (16.3-

20.3 Nm). Slight gap between upper and lower

clamps should exist at front.

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

a. Tighten all four screws ﬁnger-tight, maintaining

equal gaps between upper and lower clamps front to

back.

b. Dyna and Sportster models: tighten rear screws to

12-18 ft-lbs (16.3-24.4 Nm). Softail models: tighten

rear screws to 12-15 ft-lbs (16.3-20.3 Nm).

c. Dyna and Sportster models: tighten front screws to

12-18 ft-lbs (16.3-24.4 Nm). Softail models: tighten

front screws to 12-15 ft-lbs (16.3-20.3 Nm).

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

Dyna Glide and Some Softail Models

pd0031d

1. Lower clamp (2)

2. Cast-in spacers (2)

3. Rear screw (2)

4. Front screw (2)

5. Instrument bracket (if equipped)

6. Upper clamp

Tighten

ﬁrst

FRONT

1-6 2005 PDI: All Models

XL 883C and XL 1200C Models

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

upper clamp (3).

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

equal amounts of knurled areas on handlebar protrude

from outboard sides of upper handlebar clamp.

NOTE

On some models, knurled areas of handlebar will be com-

pletely hidden by upper handlebar clamp and will not be visi-

ble at all when handlebar is centered properly.

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

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

24.4 Nm).

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

FLHT, FLHTC, FLHTCU and FLHTP

1. Remove ignition switch knob and inner fairing cap

according to appropriate Touring Models Service Manual

instructions.

2. See Figure 1-12. Loosen two rear screws (3) of handle-

bar upper clamps (2).

3. If there is a gap between either handlebar lower clamp

(1) and upper clamp at front, tighten front screw (4) only

enough to close gap. If handlebars do not move up and

down freely, loosen rear screws until they do.

4. Raise handlebars to normal riding position. To be sure

handlebars are properly centered, verify that equal

amounts of knurled areas on handlebar protrude from

outboard sides of both handlebar clamps.

5. Tighten rear screws to 12-16 ft-lbs (16.3-21.7 Nm). Slight

gap should exist between upper and lower clamps at

rear.

6. Check torque on front handlebar clamp screws. Tighten

screws to 12-16 ft-lbs (16.3-21.7 Nm).

7. Reinstall inner fairing cap and ignition switch knob

according to appropriate Touring Models Service Manual

instructions.

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

1. Front screw (2)

2. Rear screw (2)

3. Upper clamp

4. Lower clamp

pd0031f

FRONT

Tighten

ﬁrst

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

1. Lower clamp (2)

2. Upper clamp (2)

3. Rear screw (2)

4. Front screw (2)

FRONT

pd0021a

2005 PDI: All Models 1-7

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

1. See Figure 1-13. Remove screw (12) securing chrome

ring (11) to headlamp nacelle (7). Remove chrome ring.

2. Remove eight screws (10) securing headlamp assembly

(9). Squeeze two external tabs (if present) to remove

wire connector at back of headlamp bulb. Remove head-

lamp assembly from vehicle.

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

4. On Police models, disconnect tachometer lead.

5. Remove nacelle trim. Loosen (but do not remove) front

handlebar clamp shroud screw (3), nut and washer (4).

6. Gently pry off fork lock plate (5) at rear of handlebar

clamp shroud (8). Remove two screws (6) beneath lock

plate.

7. Loosen four acorn nuts securing nacelle halves to fork

studs. Spread nacelle halves slightly and remove handle-

bar clamp shroud.

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

FLHTC, FLHTCU and FLHTP procedure given on previ-

ous page.

9. Reinstall handlebar clamp shroud. Tighten acorn nuts

securing nacelle halves to fork studs to 72-108 in-lbs

(8.1-12.2 Nm).

10. Install two screws (6) to handlebar clamp shroud and

tighten to 10-20 in-lbs (1.1-2.3 Nm). Gently press fork

lock plate (5) into place on handlebar clamp shroud.

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

in-

lbs (1.1-2.3 Nm).

12. On police models, connect tachometer lead.

13. Install nacelle trim (2). Install nut (1) (inside nacelle) secur-

ing nacelle trim. Tighten to 15-20

in-lbs (1.7-2.3 Nm).

14. Connect wire connector to socket on back of headlamp

bulb. Install and secure headlamp assembly to nacelle

with eight fasteners.

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

(12).

NOTE

Check clearance between windshield and clutch cable and

handlebar position prior to completing assembly of vehicle.

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

pd0226 3

1. Nut

2. Nacelle trim

3. Front handlebar clamp shroud screw

4. Nut and washer

5. Fork lock plate

6. Screw (2)

7. Nacelle

8. Handlebar clamp shroud

9. Headlamp assembly

10. Screw (8)

11. Chrome headlamp ring

12. Screw

1-8 2005 PDI: All Models

FLTR Road Glide

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

of instrument bezel.

2. Carefully push tab at rear of instrument bezel from slot

above ignition switch. Gently raise free side of bezel until

tabs at front of instrument nacelle disengage from slot at

front of bezel (concealed behind decorative adhesive

strip). Move instrument bezel to one side.

3. See Figure 1-15. Loosen two front screws securing han-

dlebar upper clamps (Instrument bezel has been

removed in drawing for clarity).

4. Raise handlebars to normal riding position. Tighten front

handlebar clamp screws to 12-16 ft-lbs (16.3-21.7 Nm).

5. Verify that left and right sides of instrument nacelle are

properly mated. Pins on left side of nacelle must fully

engage holes on right.

6. Insert tab at rear of bezel into slot of instrument nacelle

just above ignition switch. Holding left and right sides of

nacelle together, place bezel over instrument nacelle

ﬂange. when properly mated, tabs at front of instrument

nacelle engage lip in slot at front of bezel behind decora-

tive adhesive strip.

NOTE

If tabs do not properly engage slot at front of bezel, a loose ﬁt

will result. Remove decorative adhesive strip by gently prying

up outer edges. Using a ﬂat bladed screwdriver, carefully

raise tabs so they engage lip in slot. If damaged, install

new

decorative adhesive strip.

Figure 1-14. FLTR Models-Instrument Bezel Screws

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

40 50

RPM x100

110

120

60 70 80

100

MPH

CERTIFIE D

SE SC

HARLEY-DAVI DSON MOTOR COMPANY INC.

1 PRO

2 HRS

3 MIN

EJECT

LO/DX

POWER

pd0201

pd0195

2005 PDI: All Models 1-9

VRSCB

NOTE

To gain access to the handlebar adjusting screws, the follow-

ing steps will be necessary:

1. Remove Maxi-Fuse.

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

location shown and pivot instrument cluster away from

handlebars.

3. Remove wiring harness connector and remove screw on

bottom side of instrument cluster.

4. Remove instrument cluster.

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

equal amounts of knurled areas on handlebar protrude

from outboard sides of upper handlebar clamp.

NOTE

On some models, knurled areas of handlebar will be com-

pletely hidden by upper handlebar clamp and will not be visi-

ble at all when handlebar is centered properly.

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

tion; hold in position. Tighten two front screws (4) until

cast-in spacers (2) of upper clamp contact handlebar

lower clamp (1).

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

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

Slight gap between upper and lower clamps should exist

at rear.

9. Install instrument cluster.

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

(20-24 in-lbs).

11. Install Maxi-Fuse.

Figure 1-16. Instrument Cluster Mounting Screw Location

Figure 1-17. VRSCB Models

10059

1. Lower clamp

2. Cast-in spacers (2)

3. Rear screw (2)

4. Front screw (2)

5. Upper clamp

pd0021b

Tighten

ﬁrst

FRONT

2005 PDI: All Models 1-11

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

between steel cross braces (see arrow) behind front tire

to aid rolling motorcycle rearward off pallet.

3. Carefully roll vehicle off pallet.

1WARNING1WARNING

Always park motorcycle on a level, ﬁrm surface. An

unbalanced motorcycle can fall over which could result

in death or serious injury. (00039a)

1WARNING1WARNING

The jiffy stand locks when placed in the full forward

(down) position with vehicle weight on it. If the jiffy stand

is not in the full forward (down) position with vehicle

weight on it, the vehicle can fall over which could cause

death or serious injury. (00006a)

1WARNING1WARNING

Be sure jiffy stand is fully retracted before riding. If jiffy

stand is not fully retracted, it can contact the road sur-

face causing loss of vehicle control, which could result

in death or serious injury. (00007a)

1WARNING1WARNING

Improperly aligned or adjusted handlebars can contact

fuel tank when turned to left or right fork stops. Contact

with fuel tank while riding can cause loss of vehicle con-

trol resulting in death or serious injury.

4. Slowly turn handlebars back and forth to the full right and

full left fork stops to be sure handlebars (and/or turn sig-

nals on some models) do not contact fuel tank. Also be

sure cables and wiring are not pinched or stretched as

handlebars are turned back and forth.

a. If contact between handlebars and fuel tank occurs

and handlebars are properly centered, perform han-

dlebar adjustment again (see ADJUSTING HAN-

DLEBARS– ALL MODELS), raising handlebars as

necessary to clear fuel tank.

b. On models with turn signals mounted on handlebar

control housings, if turn signal contacts fuel tank,

adjust turn signals and/or handlebar control hous-

ings according to appropriate Service Manual

instructions.

1WARNING1WARNING

Throttle control must operate freely without binding.

Irregular or sticking throttle cables could cause a loss of

control, leading to an accident which could result in

death or serious injury.

Figure 1-20. Vehicle Pallet

7770

1-12 2005 PDI: All Models

CLUTCH HAND LEVER

NOTE

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

wrapped in plastic wrapping around clutch hand lever

and left handlebar grip.

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

have Maxi-Fuse and headlamp snap cap ﬁtted into pro-

tective foam on clutch hand lever and left handlebar grip.

Save snap cap for installation after headlamp has been

adjusted. Sportster model XL 883L also has righthand

mirror ﬁtted into protective foam.

1. Remove plastic wrapping or protective foam from clutch

hand lever and left handlebar grip.

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

following procedure.

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

control housing clamp screws (1) and handlebar

switch housing clamp screws (2).

b. Rotate clutch control housing and handlebar switch

housing as necessary for correct position and rider

comfort.

c. Beginning with the top screw, tighten clutch control

housing clamp screws. All Sportster models: tighten

to 108-132 (12.2-14.9 Nm). All other models:in-lbs

tighten to 60-80 in-lbs (6.8-9.0 Nm).

d. Tighten handlebar switch housing clamp screws to

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

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

Hand Lever–Dyna Models

10616

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

Clutch Hand Lever–All Sportster Models Except XL 883L

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

Clutch Hand Lever–Sportster XL 883L

Figure 1-24. Left Hand Controls (Typical)

10702

1. Clutch lever restraining foam

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

3. 30-amp Maxi-Fuse

1. Clutch lever restraining foam

2. Headlamp snap cap

3. 30-amp Maxi-Fuse

4. Mirror

5. Package of mirror mounting hardware

10703

pd0217

1. Clutch control housing clamp screw (2)

2. Handlebar switch housing clamp screw (2)

2005 PDI: All Models 1-13

FRONT BRAKE HAND LEVER

If handlebar controls need to be adjusted, perform the follow-

ing procedure.

1. See Figure 1-25. Loosen, but do not remove, front brake

master cylinder clamp screws (1) and handlebar switch

housing clamp screws (2).

2. Rotate master cylinder housing and handlebar switch

housing as necessary for correct position and rider com-

fort.

3. Beginning with the top screw, tighten front brake master

cylinder clamp screws. All Sportster models: tighten to

108-132 in-lbs (12.2-14.9 Nm). All other models: tighten

to 60-80 in-lbs (6.8-9.0 Nm).

4. Tighten handlebar switch housing clamp screws to 35-45

in-lbs (4.0-5.1 Nm).

IMPORTANT NOTE

All Touring model motorcycles use D.O.T. 4 HYDRAULIC

BRAKE FLUID (Part No. 99953-99A). All Dyna, Softail,

VRSC and Sportster models use D.O.T 5 SILICONE

HYDRAULIC BRAKE FLUID (Part No. 99902-77: 12 oz.,

99901-77: 1 gal.). If it is necessary to top off the brake

ﬂuid in the reservoir, make sure you add the correct type.

1CAUTION

Direct contact of D.O.T. 5 brake ﬂuid with eyes can cause

eye irritation, swelling, and redness. Avoid eye contact.

In case of eye contact, ﬂush with large amounts of water

and get medical attention. Swallowing large amounts of

D.O.T. 5 brake ﬂuid can cause digestive discomfort. If

swallowed, obtain medical attention. Use in well venti-

lated area. KEEP OUT OF REACH OF CHILDREN.

(00144a)

1CAUTION

Direct contact of D.O.T. 4 brake ﬂuid with eyes can cause

irritation. Avoid eye contact. In case of eye contact ﬂush

with large amounts of water and get medical attention.

Swallowing large amounts of D.O.T. 4 brake ﬂuid can

cause digestive discomfort. If swallowed, obtain medical

attention. Use in well ventilated area. KEEP OUT OF

REACH OF CHILDREN. (00240a)

CAUTION

D.O.T. 4 brake ﬂuid will damage painted and molded-in

color surfaces it comes in contact with. Always use cau-

tion and protect surfaces from spills whenever brake

work is performed. Failure to comply can result in cos-

metic damage. (00239a)

CAUTION

Cover handlebar switches with a shop towel before add-

ing brake ﬂuid to front master cylinder reservoir. Spilling

brake ﬂuid on handlebar switches may render them inop-

erative.

NOTE

AUSTRALIAN MODELS ONLY: Measure from tip of clutch

lever to tip of brake lever. Measurement must not exceed 1

meter in length. If it does, re-adjust accordingly.

FRONT BRAKE MASTER CYLINDER

RESERVOIR

See Figure 1-25. View reservoir sightglass (3 or 4) and verify

ﬂuid presence. Sightglass should appear dark if ﬂuid is

present. If sightglass is not dark, add brake ﬂuid. See Service

Manual. Use only D.O.T. 5 SILICONE HYDRAULIC BRAKE

FLUID (Part No. 99902-77: 12 oz., 99901-77: 1 gal.). for all

Dyna, Softail, VRSC and Sportster models. Use only D.O.T. 4

HYDRAULIC BRAKE FLUID (Part No. 99953-99A) for all

Touring models. Wash all residue of D.O.T. 4 brake ﬂuid spills

off vehicle with water.

Figure 1-25. Right Hand Controls (Typical)

pd0218

1. Front brake master cylinder clamp screw (2)

2. Handlebar switch housing clamp screw (2)

3. Reservoir sightglass (XL models)

4. Reservoir sightglass (all models except XL)

1-14 2005 PDI: All Models

VEHICLE CLEANUP

1WARNING1WARNING

Do not let the brakes, engine, mufﬂers or air cleaner get

wet when washing your motorcycle. Allowing these com-

ponents to get too wet can adversely affect their perfor-

mance, which could result in death or serious injury.

Start engine immediately after washing, and make sure

brakes and engine are operating properly before riding in

trafﬁc. (00078b)

CAUTION

Avoid spraying water directly on handlebar switches. Wet

handlebar switches may be inoperative.

Remove protective shipping tape from motorcycle. Wash

entire motorcycle before beginning actual predelivery inspec-

tion. If vehicle is equipped with frame downtube reﬂectors,

remove any plastic cable straps wrapped around reﬂectors

(cable straps are used during assembly at factory for retain-

ing reﬂectors to downtubes while reﬂector adhesive cures).

COSMETIC QUALITY

Paint Finish Inspection and Repair

Under good lighting conditions, examine all painted parts for

any damage or irregularities in the paint ﬁnish. To aid the

dealer network in addressing quality concerns, Harley-David-

son Motor Company has developed a zoning and criteria pro-

tocol, which enables us to exceed customer’s expectations. If

you discover any condition requiring repair, use Paint Repair

Kit (Part No. HD-39994); available through Kent-Moore, at the

following address, to correct the condition.

Kent-Moore

28635 Mound Rd

Warren, Michigan 48092-3499

(phone) 1-800-345-2233

Instructions covering painted part repair are included with the

Paint repair Kit. Additional paint repair information is available

from Harley-Davidson on the PHD training videotape No. 136.

Additional cosmetic quality information is available in the Har-

ley-Davidson Cosmetic Booklet (Part No. HD-99514-05) and

on-line Cosmetic Training located on HDU On-line.

RETURNING STEEL PALLETS

NOTE

International Dealers/Distributors should check with their H-D

ofﬁce to determine whether or not to return pallets.

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

(1).

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

This will allow stacking pallets for shipment.

NOTE

On VRSC pallets place eye-bolt from rear in enclosed area

(3) of pallet.

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

enclosed area (3) of pallets.

CAUTION

Do not mix 29 in. (736.6 mm) width pallets with 43 in.

(1.09 m) width pallets on the same 7-pallet stack. Mixing

pallets of different width could result in an unstable bun-

dle and pallet damage.

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

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

end cross members of top and bottom pallets. (If neces-

sary connect two straps together.)

6. Tighten straps to secure pallet bundles.

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

pallet return to Harley-Davidson.

Figure 1-26. Vehicle Pallet

1. Plastic motor shim

2. Eye-bolts

3. Enclosed area

7770

2005 PDI: All Models 1-15

MAINTENANCE-FREE BATTERIES

All models are equipped with maintenance-free batteries that

are permanently sealed, valve-regulated, lead/calcium and

sulfuric acid electrolyte batteries. The electrolyte is immobi-

lized in a glass ﬁbre separator. Therefore, the batteries are

identiﬁed as “Type AGM” which is the acronym for Absorbed

Glass Mat technology. The batteries are shipped pre-charged

and ready to be put into service. Do not attempt to open

these batteries for any reason. These batteries do not have a

vent tube. Perform Voltmeter Test to check if battery requires

charging.

1WARNING1WARNING

Batteries contain sulfuric acid, which could cause severe

burns to eyes and skin. Wear a protective face shield,

rubberized gloves and protective clothing when working

with batteries. KEEP BATTERIES AWAY FROM CHIL-

DREN. (00063a)

Table 1-1. Battery Electrolyte Antidote

PHYSICAL

LOCATION PROCEDURE

External Flush with water

Internal Drink large quantities of milk or water,

followed by milk of magnesia, vegetable oil

or beaten eggs. Call doctor immediately

Eyes Flush with water, get immediate

medical attention.

Figure 1-27. Warning Label

M A D E I N U S A

Y-D A

VID S

IL W

W I

5 32

U.S

WARR A

NTY AN D ADJU S

TMENT POLIC Y

is ba tte

ry will be rep

lace d with out ch a

rge

un d

e i n

ri a

s o

man

s fr

cl e p

6 m o

fro

f o

-th

e. A

fte

th s,

ith

1 2 m

over

-th e- coun ter purchas e, th e bat tery w

ill

se r c

on ly f or t

h e peri od of own ersh i p bas ed on

re g

ula

o f r

at ed

m o

warran ty. This war

ranty i s not tran sf erabl e

d i

re ju

ro pe

tro

, n

eg le

o r a

1234567890

JA FE M A AP MY JU JY AU SE OC NO D E

f1730x8x

Figure 1-28. Battery Warning Label

1. Contents are corrosive

2. Wear safety glasses

3. Contents are explosive

4. Keep ﬂames away

5. Read instructions

6. Keep away from children

1 2 3 4 5 6

f2180x3x

1-16 2005 PDI: All Models

DATE OF MANUFACTURE CODE

See Figure 1-29. The battery date code sticker has a number

and two letters. The number signiﬁes the year the battery was

manufactured.

9 – 1999

0 – 2000

1 – 2001

2 – 2002

3 – 2003

4 – 2004

5 – 2005

The letters signify the month the battery was activated.

JA–January MY–May SE–September

FE–February JU–June OC–October

MA–March JY–July NO–November

AP–April AU–August DE–December

VOLTMETER TEST

Refer to Ta ble 1-2. The voltmeter test provides a general indi-

cator of battery condition. Check the voltage of the battery to

make sure it is 12.6 V. If the open circuit (disconnected) volt-

age reading is below 12.6 V, charge battery and recheck volt-

age after battery has sat 1-2 hours.

CHARGING BATTERY

NOTE

The sealed AGM batteries do not need to be removed for

charging. Only remove battery if cable connection or marking

the Warranty Tag requires it.

1. Connect the red battery charger lead to the positive ter-

minal of the battery and the black charger lead to the

negative terminal.

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

Tabl e 1-2.

3. If battery gets hot, over 110˚F (44˚C) (warm to the

touch), discontinue charging and let battery cool down.

1WARNING1WARNING

Unplug or turn OFF battery charger before disconnecting

charger cables from battery. Disconnecting clamps with

charger ON can cause a spark and battery explosion,

which could result in death or serious injury. (00067a)

4. After the battery is fully charged, disconnect the black

battery charger lead to the negative (–) terminal of the

battery.

5. Disconnect the red battery charger lead to the positive

(+) terminal of the battery.

6. See Figure 1-29. Mark the date on the battery warranty

tag by removing the applicable month and year. If the

date is after the 15th day of the month, advance the date

to the next month. For example, if the battery is put in

use July 22, punch out the month of August, which is

abbreviated on the tag as “AU.” To determine the correct

number to punch out for the year, just reference the last

digit of the current year. Therefore, the number “5” is

punched to signify the year 2005.

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

Battery date of

manufacture code

f1742x8x

2005 PDI: All Models 1-17

NOTE

The ﬁgures listed above assume that the battery is charging

at room temperature. If warmer than room temperature, use a

slightly shorter charging time. If colder, use a slightly longer

charging time.

NOTE

The use of constant current chargers to charge sealed main-

tenance-free batteries is not recommended. Any overcharge

will cause dry-out and premature battery failure. If a constant

current charger is the only type available, do not exceed the

charge times listed above and do not continue charging the

battery if it gets hot. When charging, never exceed 15 volts for

more than 30 minutes.

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

BATTERY

AMP HOUR

STATE OF CHARGE 3 AMP

CHARGER

6 AMP

CHARGER

10 AMP

CHARGER

20 AMP

CHARGER

VOLTAGE % OF CHARGE

VRSC,

SPORTSTER

12.8 100% - - - -

12.6 75% 70 minutes 34 minutes 20 minutes 10 minutes

12.3 50% 2 hours,

20 minutes 70 minutes 40 minutes 20 minutes

12.0 25% 3 hours,

20 minutes

1 hour,

40 minutes 1 hour 30 minutes

11.8 0% 4 hours,

30 minutes

2 hours,

14 minutes

1 hour,

20 minutes 40 minutes

DYNA,

SOFTAIL

12.8 100% - - - -

12.6 75% 1.75 hours 50 minutes 30 minutes 15 minutes

12.3 50% 3.5 hours 1.75 hours 1 hour 30 minutes

12.0 25% 5 hours 2.5 hours 1.5 hours 45 minutes

11.8 0% 6 hours,

40 minutes

3 hours,

20 minutes 2 hours 1 hour

TOURING

12.8 V 100% - - - -

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

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

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

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

1-18 2005 PDI: All Models

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 cus-

tomer. A sheet of warning labels (Part No. 99942-05) is pro-

vided 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 lan-

guage is not represented on this label sheet, use the English

language label.

All EFI Big Twin Models

See Figure 1-30. Peel appropriate label from sheet. Apply

label on top of air cleaner cover, centered on cover and lined

up with edge of air cleaner back plate.

All 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.

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.

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.

Figure 1-30. Warning Label Placement–

All Big Twin EFI (Typical)

Figure 1-31. Warning Label Placement–

All Big Twin Carbureted (Typical)

10683

10684

Figure 1-32. Warning Label Placement–

All Sportster Models (Typical)

Figure 1-33. Warning Label Placement–

All VRSC Models (Typical)

10685

10686

1.0 in

(25.4 mm)

1-20 2005 PDI: All Models

NOTES

SUBJECT PAGE NO.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

PREDELIVERY: TOURING MODELS

2005 PDI: Touring Models 2-1

SPECIFICATIONS 2.1

TORQUE VALUES

The following torque values are included for fasteners that

may be loosened and tightened during Predelivery and

Setup. Any fasteners that are not loosened/removed do not

need to be checked during predelivery and setup.

2005 TOURING MODELS

SPECIFICATIONS

Idle Speed: 950 RPM at

Operating Temperature

Use 950 RPM during Predelivery and Setup adjustments.

Engine idle speed may increase during engine break-in. Use

idle speed listed in the Touring Models Service Manual at Ini-

tial Maintenance check.

NOTE

The idle speed on electronic fuel injected models can only be

set using a diagnostic tool such as DIGITAL TECHNICIAN

(Part No. HD-44750).

Table 2-1. Torque Values

ITEM TORQUE NOTES

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

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

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

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

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

Tour-Pak ® mounting bolts 96-120 10.8-13.5 Nmin-lbs

FLHR/

FLHP

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

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

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

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

Table 2-2. Capacities

Component ENGLISH METRIC

Oil tank w/lter (Dry) 4 qt. 3.79 liter

Transmission (Wet) 20-24 oz 591-710 ml

Primary Chaincase 32 oz 946 ml

All touring models except FLHTCSE 2 are shipped with

20W50 Harley-Davidson 360 Motor oil. The FLHTCSE 2

model ships with Syn-3 ® lubricant in the engine, primary

and transmission.

2-2 2005 PDI: Touring Models

INITIAL ASSEMBLY 2.2

BATTERY TESTING AND CHARGING

1WARNING1WARNING

Batteries contain sulfuric acid, which could cause severe

burns to eyes and skin. Wear a protective face shield,

rubberized gloves and protective clothing when working

with batteries. KEEP BATTERIES AWAY FROM CHIL-

DREN. (00063a)

1WARNING1WARNING

Never remove warning label attached to top of battery.

Failure to read and understand all precautions in warning

could result in death or serious injury. (00064a)

1WARNING1WARNING

Battery posts, terminals and related accessories contain

lead and lead components, chemicals known in the State

of California to cause cancer and birth defects or other

reproductive harm. Wash hands after handling. (00019a)

NOTE

It will be necessary to remove the left saddlebag and left side-

cover to gain access to the Maxi-Fuse connector.

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

removed, place red voltmeter probe on battery side (ter-

minal A) of Maxi-Fuse plug, and black voltmeter probe on

a suitable ground.

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

VDC or greater the battery is ready for use.

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

by removing the applicable month and year. Month and

year punches may be removed with the point of a screw-

driver without removing battery.

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

below 12.6 VDC, refer to Table 1-2, 28 amp-hour battery,

in Section 1 and charge battery at rate and time speci-

ed.

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

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

3 above.

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

below 12.6 VDC, the battery must be replaced.

INSTALLING MAXI-FUSE

The 40 amp Maxi-Fuse provides battery power to the ignition

switch and ECM. The 40 amp Maxi-Fuse is not installed at

the factory. It is shipped in the saddlebag of the motorcycle.

and is to be installed under the left sidecover. Cut the cable

tie securing the Maxi-Fuse wire to the frame. See Service

Manual for Maxi-Fuse installation procedure.

INSTALLING FUEL PUMP FUSE

NOTE

It will be necessary to remove the right saddlebag and right

sidecover to gain access to the fuel pump fuse.

For fuel-injected vehicles, it will be necessary to install the 15-

amp fuel pump fuse that is located in the spare fuse slot of

the fuse-block located under the right sidecover. See Service

Manual.

2005 PDI: Touring Models 2-3

INSTALLING DATA LINK

CONNECTOR

See Figure 2-1. The data link connector [91] (2) mounts in a

clip on the electrical bracket (1) under the right side cover.

Cut the cable tie securing the data link connector harness to

the frame and snap the connector into its clip on the electrical

bracket.

INSTALLING TOUR-PAK ®

NOTE

The seat screw is not factory installed on models with Tour-

Paks. The seat screw is in the Parts Kit, Part No. 53318-99.

On Ultra models, see Figure 2-2. Remove map pouch and

molded Tour-Pak liner from Tour-Pak prior to performing the

following procedures. Install both after work is completed.

Five Bolt Mounting

Note that Tour-Pak has seven mounting holes which allow it

to be positioned forward on luggage rack for shipping

only. Mount Tour-Pak in the rearward position (front four

holes and rear center hole) so seat access screw can be

reached.

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

the radio antenna cable and Tour-Pak lights connectors

and feed wiring out through hole at front of Tour-Pak

(after removing grommet). On Ultra models, repeat the

procedure to release the CB antenna cable and connec-

tor.

2. If not already removed, remove seat.

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

seat area.

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

shipping washers and then lift the Tour-Pak off the

mounting bolts setting it on the blanket. Retain nuts for

use later, discard large shipping washers.

Figure 2-1. Data Link Connector

1. Electrical bracket

2. Data link connector [91]

pd0215

Carbureted

Fuel injected

pd0216

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

5029

2005 PDI: Touring Models 2-5

Figure 2-4. Tour-Pak Mounting

Bottom view showing

spacer (4) between license

plate bracket (5) and top

support tube (3).

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

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

3. Top support tube

4. Luggage rack spacer (5)

5. License plate bracket

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

pd0187e

Figure 2-5. Antenna Cable Clip

(CB Antenna Cable Shown)

f1467b2x

2-6 2005 PDI: Touring Models

RADIO ANTENNA MAST

INSTALLATION

Open the Tour-Pak lid.

FLHTC models are equipped with one antenna mast. Thread

the mast securely over the antenna mounting stud and

tighten the set screw.

FLHTCU models are equipped with two antenna masts —

one with loading coil for CB radio for right side mounting, the

other for AM/FM radio for left side.

On Ultra models only, use soapy water as a lubricant to install

a protective rubber boot (provided with vehicle) over tip of

AM/FM antenna mast; slide boot down mast and over spring-

loaded base. Repeat for CB antenna, but, loosen upper set-

screw in base, slide mast from base and slide boot onto mast

below loading coil. Reassemble mast to base and adjust dis-

tance between bottom of loading coil to top of base to 1 in.

Thread each mast securely over its antenna mounting stud.

Tighten the two (3 on CB) set screws (one for antenna mast,

the other for antenna mounting stud) located in the spring-

loaded base of each antenna and one at top of loading coil.

NOTE

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

procedures.

REAR SPEAKER HARNESSES

1. See Figure 2-6. Cut cable straps securing rear speaker

harnesses to passenger handrail (both right and left

sides). Locate plastic grommets packed in Tour-Pak.

2. Press down on seat cushion, slide harness and connec-

tor into speaker box.

3. Install split plastic grommet on harness and push grom-

met into hole in speaker box.

4. Repeat steps 2 and 3 for left side.

Figure 2-6. Rear Speaker Harness Grommets

(Seat removed for clarity)

1. Right speaker harness

2. Plastic grommet (shown partially installed)

6712

6711

2005 PDI: Touring Models 2-7

INSTALLING WINDSHIELD

FLHTC, FLHTCU, FLHTCSE 2 (Wind Deec-

tor) and FLHTP (Fairing)

1. See Figure 2-7. Loosen the three fasteners along the top

of the outer fairing. It is not necessary to remove the fas-

teners.

2. Slide windshield down between the inner and outer fair-

ing over the fasteners. Position on the raised boss on the

inner fairing.

CAUTION

Overtightening windshield fasteners may crack wind-

shield and/or fairing.

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

Windshield Installation: FLTR

1. See Figure 2-8. Place black plastic washers (4) on the

ve mounting screws (3). Position rubber trim along bot-

tom of windshield. Insert screws through windshield

holes and thread loosely into ve Wellnuts (5) with rubber

washers (6).

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

3. Beginning with the center screw and working outward

toward the rear edges of windshield, tighten all screws to

6-13 in-lbs (0.7-1.5 Nm). Make certain that the four outer

screws are located at the upper end of the slots in the

windshield.

Figure 2-7. Windshield Installation–FLHT Models

pd0173x

Figure 2-8. Windshield Installation–FLTR Models

f2280x2x

1. Windshield

2. Outer fairing

3. Screw (5)

4. Flat washer (plastic) (5)

5. Wellnut (5)

6. Flat washer (rubber) (5)

2-8 2005 PDI: Touring Models

Windshield Installation: FLHR/C and

FLHP (Windshield)

CAUTION

Be sure you position the windshield bracket between the

rubber grommets. Incorrect mounting could result in

damage to the windshield.

See Figure 2-9. Insert your ngers into the wireform latch

springs at either side of the windshield and slide the BOT-

TOM windshield bracket notches onto the bottom grommets.

Slide the TOP bracket notches onto the top grommets.

NOTE

If windshield contacts clutch cable, reposition handlebars.

Seat Adjustment: FLHTP

Before applying load to the seat, refer to the Police Models

Owner’s Manual for adjustment procedures of the FLHTP air-

suspension seat. Conrm that air bladder is inated to 10-psi

(69 kPa) minimum.

Instrument Mounting Bracket

Installation: FLHP

The FLHP is provided with an instrument mounting bracket.

The bracket relocates the tachometer to allow the addition of

a radio speaker, and control panel.

1. See Figure 2-10. Remove screw (13) securing chrome

ring (12) to headlamp nacelle (8). Remove chrome ring.

2. Remove eight fasteners (11) securing headlamp assem-

bly (10). Squeeze two external tabs (if present) to

remove wire connector at back of headlamp bulb.

Remove headlamp assembly from vehicle.

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

OMF53

Figure 2-10. FLHP Headlamp Nacelle

pd0227

1. Nut

2. Nacelle trim

3. Screw

4. Nut

5. Flat washer

6. Fork lock plate

7. Screw (2)

8. Nacelle

9. Handlebar clamp shroud

10. Headlamp assembly

11. Screw (8)

12. Chrome headlamp ring

13. Screw

14. Stud plate

15. Acorn nut (2)

16. Tachometer bracket

2-10 2005 PDI: Touring Models

MIRRORS

See Figure 2-13. Adjust mirrors for proper rear view. Verify

that mirror fasteners are properly tightened.

THROTTLE CONTROL CABLES

All Non-Ultra Models

Check throttle cable adjustment in accordance with proce-

dure given in Section 1 of Touring Models Service Manual.

Ultra Models

Check throttle cable adjustment in accordance with proce-

dure given in Section 8 of Touring Models Service Manual.

Figure 2-13. Mirror Installation

pdoo72b

2005 PDI: Touring Models 2-11

REAR SUSPENSION

AIR PRESSURE

CAUTION

Do not exceed maximum air pressure for rear suspen-

sion. Air components ll rapidly. Therefore, use low air

line pressure. Failure to do so may result in possible

damage to components. (00165a)

IMPORTANT NOTE

Maximum air pressure of rear suspension system is 50

psi (345 kPa).

See Figure 2-14. Check rear suspension air pressure at air

valve located on the left side of the motorcycle below the

frame cover, above the left saddlebag. Refer to Table 2-3.

These are recommended starting points, adjust to suit load

conditions, riding style and comfort desired. Less initial pres-

sure does not necessarily result in a softer ride. Use a no-loss

gauge, add 3-5 psi (20.68-34.48 kPa) to clear line and adjust

for application.

Figure 2-14. Rear Suspension Air Pressure Valve

8472

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

Pressure

psi kPa

Solo rider -150 lbs (68.0 kg) maximum 0 0

Solo rider 150-200 lbs (68.0-90.7 kg) 0-10 0-69

Solo rider 200-250 lbs (90.7-113.4 kg) 5-15 35-103

Rider and 150 lbs (68.0 kg) passenger 10-15 69-103

Rider and 200 lbs (90.7 kg) passenger 20-25 138-172

Gross vehicle weight rating (GVWR) 20-35 138-241

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

Pressure

psi kPa

Solo rider -160 lbs (73.0 kg) maximum 0-5 0-35

Solo rider 160-200 lbs (73.0-90.7 kg) 0-10 0-69

Solo rider 200-250 lbs (90.7-113.4 kg) 5-10 35-69

Rider and 150 lbs (68.0 kg) passenger 20-30 138-207

Rider and Over 150 lbs (68 kg) passenger 25-35 172-241

Gross vehicle weight rating (GVWR) 40-50 276-345

2-12 2005 PDI: Touring Models

LUBRICATION SYSTEM 2.3

ENGINE OIL LEVEL

CAUTION

The FLHTCSE 2 model is shipped from the factory with

SYN-3® lubricant exclusively in the engine, primary and

transmission. If there is a need to top off lubricants, DO

NOT use standard lubricants in the FLHTCSE 2 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. For preride inspection with motorcycle leaning

on jiffy stand on level ground, oil should register on dip-

stick between arrows when engine is cold. Do NOT add

oil to bring the level to the FULL mark on a COLD engine.

Perform engine oil level COLD CHECK as follows:

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

remove the dipstick, wipe it off and insert it back into the

oil pan with the plug pushed completely into the ll spout.

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

should register on the dipstick. See Figure 2-15. If oil

level is at or below the lower arrow, add only enough oil

to bring the level to the add arrow on the dipstick.

NOTE

Once the predelivery inspection procedure is complete and

the vehicle has been road-tested, the engine oil level should

be checked again as described in the following procedure.

Perform engine oil level HOT CHECK as follows:

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

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

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

oil pan with the plug pushed completely into the ll spout.

3. Remove the dipstick and note the level of the oil. Add

only enough oil to bring the level to the FULL mark on the

dipstick. See Do not overll.Figure 2-15.

4. Start engine and carefully check for oil leaks around

drain plug and oil lter.

ENGINE OIL LEVEL (SIDE CAR

EQUIPPED VEHICLES)

NOTE

Since a motorcycle equipped with a sidecar is xed in an

upright position, the engine oil level reading must be adjusted

in this case; the actual FULL engine oil level will be about 1/2

inch above the original FULL mark on the oil tank dipstick.

To insure the correct oil level with sidecar attached perform

the following:

1. Without sidecar attached, check engine oil level with

engine at normal operating temperature. See HOT

CHECK procedure above.

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

needed).

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

operating temperature.

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

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

above. The scribed line is the FULL mark for sidecar

operation.

Figure 2-15. Engine Oil Dipstick

f1254b3x

COLD CHECK

HOT CHECK

2005 PDI: Touring Models 2-13

TRANSMISSION LUBRICANT

NOTE

Allow vehicle to stand upright for a moment before checking

transmission lubricant level. This will allow lubricant level to

normalize.

Check the transmission lubricant level with the motorcycle

standing upright in accordance with the procedure given in

the Touring Models Service Manual.

CHAINCASE LUBRICANT LEVEL

AND CLUTCH OPERATION

NOTE

Do not remove the clutch cover on the FLHTCSE 2. It is not

necessary to check the primary chaincase lubricant level on

this vehicle. Also, the hydraulic clutch is not adjustable.

1. Remove ve screws, clutch inspection cover and cover

gasket.

2. See Figure 2-16. The primary chaincase lubricant level is

acceptable when lubricant is visible in bottom of chain-

case with motorcycle standing upright (not resting on jiffy

stand).

3. Check clutch action. Clutch lever should move freely and

smoothly through its entire range of travel.

4. Check clutch adjustment according to the procedures

given in the Touring Models Service Manual.

NOTE

The clutch inspection cover gasket may be reused ONLY

when checking chaincase lubricant level and reinstalling

clutch inspection cover at PDI.

5. Reinstall cover gasket and clutch inspection cover, and

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

12.2 Nm).

Figure 2-16. Chaincase Lubricant Level

pd0206

2-14 2005 PDI: Touring Models

FUEL SYSTEM 2.4

GENERAL

CAUTION

Some fuel suppliers sell gasoline which has been

blended with an alcohol or an ether. The type and amount

of alcohol or ether added to the fuel is important.

CAUTION

Do not use gasoline that contains methanol. Doing so

can result in fuel system component failure, engine dam-

age and/or equipment malfunction. (00148a)

●Gasolines containing ETHANOL (ethyl alcohol or grain

alcohol) can be used. Gasoline/ethanol blends are a mix-

ture of 10% ethanol and 90% unleaded gasoline. They

are identiﬁed as “gasohol,” “ethanol enhanced,” or “con-

tains ethanol.”

●Gasolines containing METHYL TERTIARY BUTYL

ETHER (MTBE) can also be used. Gasoline/MTBE

blends are a mixture of gasoline and as much as 15%

MTBE.

●REFORMULATED OR OXYGENATED GASOLINES

(RFG): “Reformulated gasoline” is a term used to

describe gasoline blends that are speciﬁcally designed to

burn cleaner than other types of gasoline, leaving fewer

“tailpipe” emissions. They are also formulated to evapo-

rate less when you are ﬁlling your tank. Reformulated

gasolines use additives to “oxygenate” the gas. Your

motorcycle will run normally using this type of gas and

Harley-Davidson recommends you use it when possible,

as an aid to cleaner air in our environment

Because of their different chemical properties (which affect

fuel volatility and ignition characteristics), these blends may

adversely affect the starting, drivability, and fuel efﬁciency of

the motorcycle. If you experience these problems, Harley-

Davidson recommends using straight, unleaded gasoline.

CAUTION

Use only unleaded fuel in California model catalytic con-

verter-equipped motorcycles. Using leaded fuel will dam-

age the emission control system. (00150a).

CHECKING QUICK CONNECT FUEL

LINE FITTING–FUEL INJECTED

MODELS

1WARNING1WARNING

To avoid an uncontrolled discharge or spray of gasoline,

always be sure the quick-connect tting (under left side

of fuel tank) is properly mated. A slight tug on the fuel

line will verify this condition. Gasoline is extremely am-

mable and highly explosive. Inadequate safety precau-

tions could result in death or serious injury.

1. Tug on fuel supply line (under left side of fuel tank) to be

sure quick connect ﬁtting is properly mated.

2. If fuel line comes free, push up on sleeve of quick-con-

nect ﬁtting and insert neck of fuel supply line ﬁtting. While

pushing up on bottom of fuel supply line ﬁtting, pull down

on sleeve until it “clicks” into the locked position.

FUEL TANK

Make sure engine stop switch on the handlebar is switched to

the OFF position. Turn the ignition/light switch to the IGNI-

TION position. Fuel injected models: verify that Low Fuel

lamp is lit. Partially ﬁll fuel tank with gasoline. Follow FUEL

recommendations found in the Owner’s Manual. Use

unleaded gasoline, 91 octane or higher. Verify function of fuel

gauge as fuel tank is ﬁlling, then turn ignition/light switch OFF.

Inspect fuel lines for leaks.

Carbureted Models

See Figure 2-17. After adding gasoline, check for smooth

operation of the fuel valve. Inspect fuel valve for leaks.

Figure 2-17. Fuel Supply Valve

o0046box

2005 PDI: Touring Models 2-15

EVAPORATIVE EMISSIONS

CONTROL SYSTEM–CALIFORNIA

MODELS ONLY

See See Figure 2-18. Figure 2-19. Verify correct evaporative

emissions control system hose routing, connections, and fuel

tank venting to canister (if equipped).

Figure 2-18. Evaporative Emissions Control System Hose Connections

1. Carburetor (induction module on

fuel-injected models)

2. Vacuum tube

3. Fuel valve

4. Filler neck ﬁtting (Top of canopy on

FLHR/C/S)

5. Fuel tank

6. Fuel vapor vent tube

7. Vapor valve

8. Charcoal canister

9. Purge tube

10. Clean air inlet tube (not used on

fuel-injected models)

11. Air cleaner backplate

f1706x4x

Figure 2-19. Evaporative Emissions Control System Hose Routing

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

2. Purge tube to carburetor or induction module

3. Fuel vapor vent tube from fuel tank

4. Fuel vapor vent tube from vapor valve

f1884x4x

2-16 2005 PDI: Touring Models

ELECTRICAL SYSTEM 2.5

HEADLAMP

Check headlamp beam for proper height and lateral align-

ment in accordance with procedures given in Section 8 of the

Touring Models Service Manual.

1WARNING1WARNING

The automatic-on headlamp feature provides increased

visibility of the rider to other motorists. Be sure head-

lamp is on at all times. Poor visibility of rider to other

motorists can result in death or serious injury. (00030b)

AUXILIARY LAMPS

On models equipped with auxiliary lamps, check lamp beam

for proper height and lateral alignment in accordance with

procedures given in the Touring Models Service Manual.

DIRECTIONAL LAMPS

Adjust front directional lamps so lenses are aimed directly for-

ward. Verify that directional lamp fasteners are properly tight-

ened.

FRONT TURN SIGNALS

(FLHRS ONLY)

Adjust and tighten. Ensure that directionals do not contact

fuel tank.

INSTRUMENT PANEL

See Figure 2-20. The instrument panel has a Low Fuel,

Check Engine, Security (if equipped) Battery, Cruise Control

(if equipped) and ABS (if equipped) warning lamps.

●The Low Fuel Warning lamp comes on when approxi-

mately 0.9 gallon (3.4 liter) of gasoline remains.

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

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

is present.

Figure 2-20. Instrument Panel Warning Lamps

110

120

60 70

100

40 50

MPH

RPM x100

40 50

RPM x100

d0715x8x

FLHT and FLTR Models FLHR Models

f2185xax

1. Speedometer

2. Security system lamp

3. Tachometer

4. Cruise lamp

5. Odometer/trip-odometer

6. Low fuel warning lamp

7. Engine check lamp

8. Battery discharge lamp

9. ABS lamp (optional police equipment)

10. Pursuit lamp indicator (police)

FLHTP/FLHP Models Tachometer

pd0221

2005 PDI: Touring Models 2-17

INDICATOR LAMPS/CONTROLS

1. See Figure 2-21. Turn ignition/light switch to IGNITION

position, and check that Oil pressure indicator lamp turns

on (before engine is started). The Check Engine lamp

and if TSSM EQUIPPED, THE SECURITY LAMP will illu-

minate for approximately four seconds and then turn off.

NOTES

For any Systems problems, refer to the appropriate Electrical

Diagnostic manual for your model.

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

tral indicator lamp turns on.

3. Start engine; check operation of starter.

NOTE

On Police models, the clutch lever must be depressed to

operate the starter.

4. Check that oil pressure indicator lamp turns off when

engine is running above 1000 RPM.

5. Check operation of tachometer (if equipped).

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

neutral indicator lamp turns off when transmission is

shifted to any forward gear. Shift transmission to neutral

position, and verify that neutral indicator lamp turns on

again.

7. Check horn operation.

8. Check operation of all remaining lamps:

●Headlamp–low and high beams

●Headlamp high beam indicator lamp

●Passing/pursuit lamps

●Pursuit lamp indicator lamp (FLHTP)

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

●Left directional (turn signal) indicator lamp

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

●Right directional (turn signal) indicator lamp

●Left front running lamp

●Right front running lamp

●Tail lamp–running lamp and brake lamp laments

●Speedometer illumination lamp

●Tachometer illumination lamp (if equipped)

●License plate lamp (HDI only)

●Sound System Operation (if equipped)

9. After engine has reached normal operating temperature,

turn engine off.

10. Check engine oil level in manner previously specied.

This time, ll oil tank to upper mark on ller cap/dipstick.

Figure 2-21. Ignition Switches

pd0192

1. Ignition switch unlocked

2. Ignition switch locked

3. “Key ON” Ignition position

2-18 2005 PDI: Touring Models

TIRES 2.6

FRONT AND REAR TIRES

1WARNING1WARNING

Do not inate tire beyond maximum pressures specied

on sidewall. Over inated tires can blow out, which could

result in death or serious injury. (00027a).

1WARNING1WARNING

Harley-Davidson front and rear tires are not the same.

Interchanging front and rear tires can cause tire failure,

which could result in death or serious injury. (00026a)

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

are cold. Compare results against Ta ble 2-5.

Table 2-5. Tire Pressures

Tires

Front Rear

PSI kPA PSI kPA

Solo rider 36 248 36 248

Rider & passenger 36 248 40 276

2005 PDI: Touring Models 2-19

BRAKE SYSTEM 2.7

BRAKES

1CAUTION

Direct contact of D.O.T. 4 brake ﬂuid with eyes can cause

irritation. Avoid eye contact. In case of eye contact ﬂush

with large amounts of water and get medical attention.

Swallowing large amounts of D.O.T. 4 brake ﬂuid can

cause digestive discomfort. If swallowed, obtain medical

attention. Use in well ventilated area. KEEP OUT OF

REACH OF CHILDREN. (00240a)

CAUTION

D.O.T. 4 brake ﬂuid will damage painted and molded-in

color surfaces it comes in contact with. Always use cau-

tion and protect surfaces from spills whenever brake

work is performed. Failure to comply can result in cos-

metic damage. (00239a)

CAUTION

Cover handlebar switches with a shop towel before add-

ing brake ﬂuid to front master cylinder reservoir. Spilling

brake ﬂuid on handlebar switches may render them inop-

erative.

See Figure 2-22. View reservoir sightglass and verify ﬂuid

presence. Sightglass should appear dark if ﬂuid is present. If

sightglass is not dark, add brake ﬂuid. See Service Manual.

Use only D.O.T. 4 HYDRAULIC BRAKE FLUID (Part No.

99953-99A). Wash all residue of D.O.T. 4 brake ﬂuid spills off

vehicle with water.

ABS SYSTEM (POLICE VEHICLES–

OPTIONAL EQUIPMENT)

The ABS indicator lamp in the tachometer will ﬂash when the

ignition switch is turned on, and remains ﬂashing until the

motorcycle reaches 6 MPH (9.7 KPH). The lamp will then turn

off.

If the ABS lamp turns on solid at ignition-ON, or does not turn

off when vehicle exceeds 6 MPH (9.7 KPH), it is an indication

of a current fault condition in the ABS system. See the Police

Models Service Manual Supplement for instructions on plac-

ing the ABS system into test mode and extracting diagnostic

trouble codes from the ABS system computer.

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

glass (typical)

6628

2-20 2005 PDI: Touring Models

DEALER ROAD TEST 2.8

ROAD TEST

After you complete motorcycle inspection, take motorcycle for

a road test. Check all systems and overall operation of motor-

cycle: engine, transmission, clutch, brakes, handling, etc. On

Ultra models, check Cruise Control, rear speakers and rider/

passenger sound system controls. Refer to Touring Models

Owner’s Manual to check for proper operation.

After road test, return motorcycle to shop and thoroughly

clean off any road dirt. Check and correct any problems you

may have found during road test.

Before You Begin

Check the following items before road test of vehicle:

●Lamps and indicators.

●Check amount of gasoline in tank and add (if

needed).

●Adjust mirrors to proper riding positions.

●Check tire condition and pressure (adjust if neces-

sary).

●Check controls to verify proper function.

●Check all electrical equipment and switches includ-

ing stop lamp, turn signals and horn for proper oper-

ation.

Road Test of Vehicle: Low Speed

1. Shift from rst through third gear, checking clutch opera-

tion, throttle control, and transmission operation.

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

3. Handling under braking conditions.

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

left or right.

5. Check for any abnormal vibrations.

6. Check electrical lamps, indicators.

Road Test of Vehicle: Highway Speed

1. Shift from rst through fth gear, checking clutch opera-

tion, throttle control and transmission operation.

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

brakes.

3. Verify proper handling at highway speeds.

4. Check for any abnormal vibrations.

●Program Security System (if equipped)

●Engine Oil:

Check and correct hot level.

●Clean Vehicle

NOTE

Be sure to submit a Dealer Product Quality Audit (DPQA) on

ANY adjustments and/or warranty work performed required to

deliver the vehicle to the customer.

IDLE SPEED: CARBURETED ONLY

NOTE

The idle speed on fuel injected models can only be set using

a diagnostic tool such as DIGITAL TECHNICIAN (Part No.

HD-44750).

See Figure 2-23. Set engine slow idle speed of 950 RPM with

engine running at normal operating temperature and with

enrichment control knob pushed in fully. Turn carburetor idle

speed adjusting screw (5) clockwise to increase speed, or

counterclockwise to decrease speed.

NOTE

The C.V. carburetor has an enrichment circuit that will cause

the engine to idle above the normal idle range (950-1050

RPM) with the engine at normal operating temperature and

the enrichment knob pulled out fully. The increase in idle

speed is intended to alert the rider that the engine is warmed

up to normal operating temperature and that the enrichment

knob should be pushed in all the way. Continuing to use the

enrichener when the engine is at full operating temperature

will cause fouled plugs.

Be sure the engine is warmed up to normal operating temper-

ature and the enrichment knob is pushed all the way in before

adjusting engine idle speed. Be aware that, because there

are variations in individual components, it is possible for a

properly warmed-up engine to idle above the normal idle

range (950-1050 RPM) with the enrichment knob pulled out

partially.

Figure 2-23. Carburetor Adjustments

1. Carburetor stop plate

2. Cable housing

3. Spring

4. Throttle cam stop

5. Idle speed adjusting screw

f1381a2x

2005 PDI: Touring Models 2-21

CUSTOMER DELIVERY 2.9

NOTICE TO DEALER

Before delivering motorcycle to owner, perform the following:

1. Make sure vehicle owner receives, and is aware of

importance of reading Owner’s Manual, safety booklets

and viewing Welcome To The Family video included with

owner’s kit.

2. Review warranties with vehicle owner. Make sure owner

understands warranties. California dealers must give

customer a copy of Emissions Control System Warranty.

3. Give IMPORTANT sheet and other printed material in lit-

erature kit to vehicle owner.

4. Complete and sign warranty registration form. Have vehi-

cle owner sign it.

5. Explain operation of vehicle controls to vehicle owner.

6. Explain how turn signals and emergency ashers oper-

ate.

7. If motorcycle is equipped with a Sound System, explain

to customer that the Touring Models Owner’s Manual

contains detailed operating instructions for the system. In

addition, a video has been prepared to give the customer

operating instructions for the Sound System. On Ultra

models, tell customer helmet headset is shipped in sad-

dlebag.

8. Inform vehicle owner about changing TSM/TSSM to

sidecar or solo conguration as appropriate.

IMPORTANT NOTE

Make sure vehicle owner understands how to arm and

disarm security system. Explain how to disarm security

system with personal code if key fob is lost or not func-

tioning. Personal code should be written on the tear-out

card in Touring Models Owner’s Manual and kept on the

owner’s person. Also, verify both key fobs operate prop-

erly.

9. Whenever possible, introduce dealer Service Manager to

vehicle owner, and involve Service Manager in delivery

process. Supply owner with name(s) of dealer Service/

Parts Department personnel who should be contacted

regarding vehicle service/parts questions.

10. Inform vehicle owner about checking engine oil level,

checking tire pressure, and performing other basic main-

tenance functions. Review the Initial Scheduled Main-

tenance requirement with owner. Depending on owner’s

anticipated frequency of operating motorcycle, you may

wish to schedule the Initial Scheduled Maintenance

service appointment at this time.

2-22 2005 PDI: Touring Models

VEHICLE PDI CHECKLIST 2.10

PRIOR TO CUSTOMER DELIVERY

NOTE

Use this checklist for performing tasks related to this model

motorcycle setup.

❒Uncrate:

Check for damaged or missing parts.

❒Handlebars:

Verify proper position; tighten clamps to proper torque.

❒Jiffy Stand:

Verify proper function.

❒Note Any Additional Problems

(including cosmetic quality):

Perform Warranty repairs.

❒Battery:

Perform required voltmeter test on Maxi Fuse (main fuse)

and battery.

❒Install Maxi Fuse (main fuse).

❒Install Fuel Pump Fuse (EFI vehicles only).

❒Install Data Link Connector.

❒Position Tour-Pak and Install Seat and Seat Strap:

If equipped

❒Install Saddlebags and Side Covers:

Verify adequate saddlebag/side cover clearance.

❒Install Antenna Mast(s):

If equipped

❒Position Rear Speaker Harness.

❒Install Windshield.

❒Verify Proper Police Seat Air Bladder Pressure

(Police models).

❒Install Instrument Bracket (FLHP models).

❒Mirrors:

Inspect and adjust as necessary.

❒Throttle Control Cables:

Inspect and adjust as necessary.

❒Rear Air Suspension:

Inspect and adjust pressure as necessary.

❒Engine Oil:

Verify oil is present (cold level).

❒Lubrication System:

Inspect condition of oil lines and ﬁttings.

❒Transmission Lubricant:

Check and verify correct lubricant level.

❒Primary Chaincase:

Check and verify lubricant is present.

❒Clutch Operation:

Verify proper adjustment.

❒Fuel System:

a. Inspect fuel system for leaks.

b. Fill, verify sender operation.

c. Verify low fuel light operation (if equipped).

❒Fuel Outlet (valve or quick connect tting)

and Hoses:

Verify operation and connections.

❒Evaporative Control System:

Inspect hose routings, connections and fuel tank venting

to canister (if equipped).

❒Lighting, Gauges, Electrical Systems:

a. Verify correct operation.

b. Verify adequate directional-to-fuel tank clearance

(FLHRS only).

❒Tires:

Inspect condition and air pressure.

❒Brake Systems (front and rear):

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

only for 2005 FL models.

b. Verify proper ABS indicator function (Police models

only, if equipped).

❒Road Test Vehicle: Low Speed.

a. Shift from ﬁrst through third gear, checking clutch

operation, throttle control and transmission operation.

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

c. Verify handling under braking conditions.

d. Verify low-speed handling. Verify that vehicle does

not pull to left or right.

e. Check for any abnormal vibrations.

f. Check electrical lamps, indicators.

❒Road Test Vehicle: Highway Speed.

a. Shift from ﬁrst through ﬁfth gear, checking clutch

operation, throttle control and transmission operation.

b. Verify highway speed braking operation of front and

rear brakes.

c. Verify proper handling at highway speeds.

d. Check for any abnormal vibrations.

❒Engine Oil:

Check and correct hot level.

❒Create Vehicle Birth-Certicate Using

Digital Technician (optional).

❒Clean Vehicle.

❒Program Security System.

AT POINT OF CUSTOMER DELIVERY

❒Suspension Adjustments.

❒Shift Linkage Adjustment.

❒Brake Hand Lever Adjustment.

❒Review Vehicle Care and Maintenance Requirements.

NOTE

Be sure to submit a Dealer Product Quality Audit (DPQA) on

ANY adjustments and/or warranty work performed required to

deliver the vehicle to the customer.

SUBJECT PAGE NO.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

III

PREDELIVERY: DYNA MODELS

2005 PDI: Dyna Models 3-1

SPECIFICATIONS 3.1

TORQUE VALUES

The following torque values are included for fasteners that

may be loosened and tightened during Predelivery and

Setup. Any fasteners that are not loosened/removed do not

need to be checked during predelivery and setup.

2005 DYNA MODELS

SPECIFICATIONS

Idle Speed: 950 RPM at

Operating Temperature

Use 950 RPM during Predelivery and Setup adjustments.

Engine idle speed may increase during engine break-in. Use

idle speed listed in the Dyna Models Service Manual at Initial

Maintenance check.

NOTE

The idle speed on electronic fuel injected models can only be

set using a diagnostic tool such as DIGITAL TECHNICIAN

(Part No. HD-44750).

Table 3-1. Torque Values

ITEM TORQUE NOTES

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

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

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

Mirror fasteners 12 ft-lbs 16.3 Nm

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

Table 3-2. Capacities

Component ENGLISH METRIC

Oil tank w/ﬁlter (Dry) 3 qt. 2.84 liter

Transmission (Wet) 20-24 oz 591-710 ml

Primary Chaincase 26 oz 769 ml

All motorcycles are shipped with 20W50 Harley-Davidson

360 Motor oil

3-2 2005 PDI: Dyna Models

INITIAL ASSEMBLY 3.2

BATTERY TESTING AND CHARGING

1WARNING1WARNING

Batteries contain sulfuric acid, which could cause severe

burns to eyes and skin. Wear a protective face shield,

rubberized gloves and protective clothing when working

with batteries. KEEP BATTERIES AWAY FROM CHIL-

DREN. (00063a)

1WARNING1WARNING

Never remove warning label attached to top of battery.

Failure to read and understand all precautions in warning

could result in death or serious injury. (00064a)

1WARNING1WARNING

Battery posts, terminals and related accessories contain

lead and lead components, chemicals known in the State

of California to cause cancer and birth defects or other

reproductive harm. Wash hands after handling. (00019a)

NOTE

It will be necessary to remove the battery sidecover to gain

access to the battery.

1. Place test probes of voltmeter on battery terminals and

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

12.6 VDC.

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

VDC or greater the battery is ready for use.

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

by removing the applicable month and year. Month and

year punches may be removed with the point of a screw-

driver without removing battery.

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

below 12.6 VDC, refer to Table 1-2, 12 amp-hour battery,

in Section 1 and charge battery at rate and time speci-

ﬁed.

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

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

3 above.

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

below 12.6 VDC, the battery must be replaced.

INSTALLING MAXI-FUSE

The 40 amp Maxi-Fuse provides battery power to the ignition

switch and ECM. The 40 amp Maxi-Fuse is not installed at

the factory. It is shipped attached to the motorcycle. See Ser-

vice Manual.

INSTALLING FUEL PUMP FUSE

For non-carbureted vehicles, install the 15-amp fuel pump

fuse that is located in the spare fuse slot in the fuse block per

procedure in the appropriate Service Manual.

IDLE SPEED: CARBURETED ONLY

NOTE

The idle speed on fuel injected models can only be set using

a diagnostic tool such as DIGITAL TECHNICIAN (Part No.

HD-44750).

See Figure 3-1. Set engine slow idle speed of 950 RPM with

engine running at normal operating temperature and with

enrichment control knob pushed in fully. Turn carburetor idle

speed adjusting screw (5) clockwise to increase speed, or

counterclockwise to decrease speed.

NOTE

The C.V. carburetor has an enrichment circuit that will cause

the engine to idle above the normal idle range (950-1050

RPM) with the engine at normal operating temperature and

the enrichment knob pulled out fully. The increase in idle

speed is intended to alert the rider that the engine is warmed

up to normal operating temperature and that the enrichment

knob should be pushed in all the way. Continuing to use the

enrichener when the engine is at full operating temperature

will cause fouled plugs.

Be sure the engine is warmed up to normal operating temper-

ature and the enrichment knob is pushed all the way in before

adjusting engine idle speed. Be aware that, because there

are variations in individual components, it is possible for a

properly warmed-up engine to idle above the normal idle

range (950-1050 RPM) with the enrichment knob pulled out

partially.

2005 PDI: Dyna Models 3-3

THROTTLE CABLES

Twist and release throttle control grip a few times to verify

proper operation of throttle control system. With throttle fric-

tion screw loosened, carburetor throttle must return to idle

position each time throttle control grip is released.

1WARNING1WARNING

Throttle cables must not pull tight when handlebars are

turned fully to left or right fork stops. Be sure wires and

throttle cables are clear of fork stops at steering head so

they will not be pinched when fork is turned against

stops. Steering must be smooth and free with no binding

or interference. Interference with steering could cause

loss of vehicle control which could result in death or

serious injury.

Check throttle cable adjustment. With engine running, turn

handlebars through full range of travel. If engine speed

changes during this maneuver, adjust throttle cables as fol-

lows:

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

cable adjuster.

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

3. Turn adjusters in direction which will shorten cable hous-

ings to minimum length.

4. Point front wheel straight ahead. Twist throttle control

grip to fully open position; hold in position.

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

until throttle cam stop (4) touches carburetor stop plate

(1).

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

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

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

adjuster on idle control cable until end of cable housing

(2) just touches spring (3) within carburetor cable guide.

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

twist and release throttle control grip a few times. Carbu-

retor throttle must return to idle position each time throt-

tle grip is released. If this is not the case, turn adjuster

(4) on idle control cable (3) (shortening cable housing)

until throttle control functions properly.

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

Recheck operation of throttle control (Step 7).

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

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

Figure 3-1. Carburetor Adjustments

1. Carburetor stop plate

2. Cable housing

3. Spring

4. Throttle cam stop

5. Idle speed adjusting screw

f1381a2x

Figure 3-2. Throttle Cable Adjustment

5428

1. Throttle friction screw

2. Throttle control cable

3. Idle control cable

4. Adjuster

5. Jam nut

3-4 2005 PDI: Dyna Models

SUSPENSION ADJUSTMENT FOR

FXDX MODEL

Refer to the Dyna Models Owner’s Manual for suspension

adjustment instructions for FXDX model.

SHIFT LEVER

Inspect shift linkage for free movement. Check shift lever

adjustment; rider’s foot must be able to ﬁt easily under shift

lever. Adjust shift lever if required.

SEATS AND PASSENGER STRAP

Refer to the Dyna Models Owner’s Manual for seat and pas-

senger strap removal and installation instructions.

2005 PDI: Dyna Models 3-5

LUBRICATION SYSTEM 3.3

ENGINE OIL LEVEL

Check engine oil level with engine turned off and motorcycle

resting on jiffy stand on level surface.

1. Remove ﬁller cap with attached dipstick. Wipe dipstick

clean.

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

ﬁller neck.

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

dipstick. If oil level in pan is below lower mark on dipstick,

add enough Harley-Davidson oil to bring level up

between lower mark (1) and cold check level (2) on dip-

stick. Refer to the Dyna Models Service Manual for rec-

ommended viscosity.

NOTE

Do not ﬁll oil tank to full (upper) mark on ﬁller cap/dipstick at

this time. Ordinarily, you would ﬁll a Dyna oil pan (with warm

engine) to this level. In this situation, however, if any oil has

ﬂowed from oil pan to crankcase during shipping, ﬁlling oil

pan to full mark might result in overﬁlling of oil pan when

engine is started. Final check of oil level must be made with

engine off, after engine has reached normal operating tem-

perature.

TRANSMISSION LUBRICANT LEVEL

NOTE

Allow vehicle to stand upright for a moment before checking

transmission lubricant level. This will allow lubricant level to

normalize.

Check the transmission lubricant level with the motorcycle

standing upright in accordance with the procedure given in

the Dyna Models Service Manual.

CHAINCASE LUBRICANT LEVEL

AND CLUTCH OPERATION

1. Remove ﬁve screws, clutch inspection cover and cover

gasket.

2. See Figure 3-4. The primary chaincase lubricant level is

acceptable when lubricant is visible in bottom of chain-

case with motorcycle standing upright (not resting on jiffy

stand).

3. Check clutch action. Clutch lever should move freely and

smoothly through its entire range of travel.

4. Check clutch adjustment according to the procedures

given in the Dyna Models Service Manual.

NOTE

The clutch inspection cover gasket may be reused ONLY

when checking chaincase lubricant level and reinstalling

clutch inspection cover at PDI.

5. Reinstall cover gasket and clutch inspection cover, and

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

12.2 Nm).

Figure 3-3. Engine Oil Dipstick

d0386x1x

NOTE

For cold check level do not exceed

this point when ﬁlling with oil.

1. Lower arrow (add oil)

2. Cold check level

3. Upper arrow (hot check level)

Figure 3-4. Chaincase Lubricant Level

pd0206

2005 PDI: Dyna Models 3-7

ELECTRICAL SYSTEM 3.5

HEADLAMP

Check headlamp beam for proper height and lateral align-

ment in accordance with procedures given in the Dyna Mod-

els Service Manual

1WARNING1WARNING

The automatic-on headlamp feature provides increased

visibility of the rider to other motorists. Be sure head-

lamp is on at all times. Poor visibility of rider to other

motorists can result in death or serious injury. (00030b)

NOTE

All FXDX/I models with a black-painted mounting bracket

above the headlamp have a snap cap taped to right rear turn

signal. Install snap cap after headlamp has been adjusted. All

other models are shipped in position.

INDICATOR LAMPS/CONTROLS

NOTE

See Figure 3-6. This ﬁgure shows instruments and indicators

on FXDX models. Instruments and indicators on remaining

Dyna models are located as follows:

●FXD Speedometer and indicators in handlebar bracket.

●FXDWG Speedometer and indicators in panel on gas

tank.

FXDL Speedometer and tachometer in console on gas tank,

indicators in headlamp bracket.

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

pressure indicator lamp turns on (before engine is

started) and check engine lamp illuminates for about four

seconds and goes off.

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

tral indicator lamp turns on.

3. Start engine; check operation of starter.

4. Check that oil pressure indicator lamp turns off when

engine is running above 1000 RPM.

5. Check operation of tachometer, if equipped.

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

neutral indicator lamp turns off when transmission is

shifted to any forward gear. Shift transmission to neutral

position, and verify that neutral indicator lamp turns on

again.

7. Check horn operation.

8. Check operation of all remaining lamps:

●headlamp–low and high beams

●headlamp high beam indicator lamp

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

●Ieft directional (turn signal) indicator lamp

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

●right directional (turn signal) indicator lamp

●Ieft front running lamp

●right front running lamp

●tail lamp–running lamp and brake lamp ﬁlaments

●speedometer illumination lamp

●tachometer illumination lamp

9. After engine has reached normal operating temperature,

turn engine off.

10. Check engine oil level in manner previously speciﬁed.

This time, ﬁll oil tank to upper mark on ﬁller cap/dipstick.

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

1. Speedometer

2. Odometer and trip odometer

3. Left directional (turn signal) indicator lamp

4. High beam indicator lamp

5. Neutral indicator lamp

6. Oil pressure indicator lamp

7. Right directional (turn signal) indicator lamp

8. Tachometer

9. Check engine lamp

10648

345

3-8 2005 PDI: Dyna Models

MIRRORS AND DIRECTIONAL

LAMPS

See Figure 3-7. Adjust mirrors for proper rear view. Adjust

front directional lamps so lenses are aimed directly forward;

adjust rear directional lamps so lenses are aimed directly

rearward. Verify that mirror and directional lamp fasteners are

properly tightened. Tighten mirror fasteners to 12 ft-lbs (16.3

Nm).

Figure 3-7. Mirror and Directional Lamp Mounting

pd0104c

1. Mirror

2. Star washer

3. Acorn nut

4. Front directional lamp

2005 PDI: Dyna Models 3-9

TIRES 3.6

FRONT AND REAR TIRES

1WARNING1WARNING

Do not inﬂate tire beyond maximum pressure as speci-

ﬁed on sidewall. Over inﬂated tires can blow out, which

could result in death or serious injury. (00027a)

1WARNING1WARNING

Harley-Davidson front and rear tires are not the same.

Interchanging front and rear tires can cause tire failure,

which could result in death or serious injury. (00026a)

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

are cold. Compare results against Ta ble 3-3.

Table 3-3. Tire Pressures

TIRES

SOLO RIDER RIDER & ONE

PASSENGER

PSI kPA PSI kPA

Front 30 207 30 207

Rear 36 248 40 276

Produktspecifikationer

Varumärke:	Harley Davidson
Kategori:	Motor
Modell:	Softail (2005)
Färg på produkten:	Zwart
Vikt:	3700 g
Förpackningens vikt:	4000 g
Förpackningens bredd:	493 mm
Djuppackning:	105 mm
Förpackningshöjd:	109 mm
Snäll:	Rekrail
Husmaterial:	Staal
Monteringsverktyg:	Ja
Maximal viktkapacitet:	45.3 kg
Certifiering:	CE, UL, REACH, TAA
Hållbarhetscertifikat:	RoHS
Inklusive skruvar:	Ja
Antal skruvar:	16
(Ytter) huvudpaketets höjd:	109 mm
(Ytter) huvudförpackningens bredd:	493 mm
(Ytre) huvudpaketets längd:	105 mm
Kvantitet per (yttre) huvudkartong:	1 stuk(s)
Rackkapacitet:	2U
Harmoniserad systemkod (HS):	85389099
Installationsdjup (max):	1054 mm
Installationsdjup (min):	420 mm
Burmuttrar ingår:	Ja
Skruv-typ:	M5
Antal burmuttrar:	16