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Harley Davidson 2005 MOTORCYCLE. PREDELIVERY AND SETUP MANUAL - page 1

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UNCRATING AND GENERAL SETUP: ALL MODELS

1.1

2.

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

VEHICLE CRATE INSPECTION

cardboard carton. Slide carton away from pallet as

shown. Set carton aside for recycling.

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-

10426

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

Figure 1-2. Remove Cardboard Carton from Pallet.

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

3.

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

SOFTAIL models are shipped with the front wheel turned to

FLSTC crates have three uprights) by lifting upward. Set

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

uprights aside for recycling.

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.

8798

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.

8796

Figure 1-3. Remove Uprights from Pallet

4.

Open plastic bag enclosing motorcycle and push it down

off motorcycle. Remove protective tape and elastic pro-

tective netting, if present, from chrome and painted parts

of motorcycle.

Figure 1-1. Removing Screws

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NOTE

HANDLEBAR INSTALLATION-

Always install/adjust handlebars before removing motorcycle

from pallet. See HANDLEBAR INSTALLATION-FLSTSC,

FLSTSC, FLSTN AND FXDWG

FLSTN AND FXDWG MODELS and ADJUSTING HANDLE-

MODELS

BARS- ALL MODELS.

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

separate items by comparing with parts list in shipping

FLSTSC

crate.

After removing carton and protective plastic wrap:

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

1.

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

the factory, submit warranty claim form. Accurately

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

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

risers. Retain the four bolts, discard washers.

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

2.

While holding the handlebar shipping cradle, cut cable

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

1WARNING

discard protective block (4) from left handlebar grip.

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

3.

Route handlebar switch conduits between and behind

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

risers.

environmental devices or systems must be left intact as

4.

Position handlebar on top of risers, secure with riser

designed and built at the factory. Tampering with safety

caps and riser bolts.

and environmental devices or systems could result in

5.

See ADJUSTING HANDLEBARS- ALL MODELS and

death or serious injury.

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

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

1WARNING

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

(16.3-20.3 Nm) in the sequence given.

The automatic-on headlamp feature provides increased

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

6.

Push the four plastic wire retainers on the handlebar

switch conduits into the holes in the handlebars. Replace

Low visibility of rider can result in death or serious

injury. (00030a).

any broken wire retainers.

7.

Attach hand control and directional wire harnesses to

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

1WARNING

8.

Insert the clutch cable into the retaining clip on the left

Some motorcycles are shipped with the hand brake lever

frame downtube.

wrapped tight against the hand grip. Remove plastic

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

lever 3-4 times before moving motorcycle from pallet.

10612

Failure to pump brake lever could result in an inoperable

1

front brake which could result in death or serious injury.

pd0171

WARNING:

3

2

4

5

PUMP BRAKE LEVER

1.

Handlebar shipping cradle

3-4 TIMES BEFORE

2.

Riser bolt (4)

USING BRAKES

3.

Cable strap (4)

4.

Protective block

5.

Protective pad

Figure 1-4. Warning Label

Figure 1-5. FLSTSC

1-2

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FLSTN

10614

3

After removing carton and protective plastic wrap:

4

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

1

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

3

riser caps, and bolts removed in step 2.

2

5. See ADJUSTING HANDLEBARS- ALL MODELS and

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

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

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

(16.3-20.3 Nm) in the sequence given.

6. Push the four plastic wire retainers on the handlebar

switch conduits into the holes in the handlebars. Replace

any broken wire retainers.

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

frame downtube.

5

10613

1

6

2

10615

3

1. Front brake line

2. Clamp (2)

3. Screw (2)

4

4. Fork stem cover

5. Clamp

6. Screw

1.

Shipping clamp

2.

Riser bolts

Figure 1-7. Attaching Front Brake Line-FLSTN

3.

Cloth tie

4.

Protective block

Figure 1-6. FLSTN

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

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

Tighten screws to 30-50 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).

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FXDWG

4.

Retrieve riser caps from passenger backrest.

5.

Position the handlebar on top of the risers and fasten the

After removing carton and protective plastic wrap:

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

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

6.

See ADJUSTING HANDLEBARS- ALL MODELS and

ing handlebar.

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

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

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

bolts.

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

3. Reroute the left hand switch wire conduit from between

(16.3-24.4 Nm) in the sequence given.

the riser to a position in front of the riser.

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

6052

(3.4-6.8 Nm).

6062

1

3

2

6059

1

4

6053

3

4

5

1. Clamp

4.

Clamp

2. Brake line

5.

Screw

3. Ground wire

2

Figure 1-9. FXDWG Brake Line and Ground Wire

1.

Cloth tie

2.

Riser bolts (4)

3.

Shipping clamps

4.

Protective block

Figure 1-8. FXDWG

1-4

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pd0031d

CAUTION

Tighten

4

first

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

5

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

could be pinched and damaged in front fork stop.

3

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

6

(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-

2

card shipping clamps and protective block.

10. Install clutch cable in clip on left downtube.

1

11. Install the plastic wire retainers on the handlebar switch

conduits and push into the holes in the handlebars.

FRONT

Replace any broken wire retainers.

1. Lower clamp (2)

2. Cast-in spacers (2)

ADJUSTING HANDLEBARS-

3. Rear screw (2)

4. Front screw (2)

ALL MODELS

5. Instrument bracket (if equipped)

6. Upper clamp

General

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

Dyna Glide and Some Softail Models

CAUTION

NOTE

Never adjust handlebars using excessive force. Doing so

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

may result in damage to handlebar or clamp.

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

ble at all when handlebar is centered properly.

NOTE

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

3.

Raise handlebars to normal riding position and hold in

pone adjustment until customer has checked their position. If

position.

customer requests changing handlebar position, perform the

4.

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

adjustment before delivering the motorcycle to the customer.

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

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

contact handlebar lower clamps (1).

dlebar clamps.

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

Before removing motorcycle from pallet, adjust handlebars

to

12-18 ft-lbs

(16.3-24.4 Nm). Softail models:

according to the following procedures:

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

Nm).

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

c. Dyna and Sportster models: final tighten rear

XL 1200R Models

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-

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

20.3 Nm). Slight gap between upper and lower

dlebar upper clamp (6).

clamps should exist at front.

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

5.

Models without cast-in spacers in upper clamps:

equal amounts of knurled areas on handlebar protrude

from outboard sides of upper handlebar clamp.

a. Tighten all four screws finger-tight, maintaining

equal gaps between upper and lower clamps front to

back.

b. Dyna and Sportster models: tighten rear screws to

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

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

c. Dyna and Sportster models: tighten front screws to

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

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

2005 PDI: All Models

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XL 883C and XL 1200C Models

FLHT, FLHTC, FLHTCU and FLHTP

1.

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

1.

Remove ignition switch knob and inner fairing cap

upper clamp (3).

according to appropriate Touring Models Service Manual

).

instructions.

pd0031f

2.

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

1

Tighten

first

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.

2

4

pd0021a

4

2

3

1

3

1. Front screw (2)

FRONT

2. Rear screw (2)

3. Upper clamp

FRONT

4. Lower clamp

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

1. Lower clamp (2)

2. Upper clamp (2)

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

3. Rear screw (2)

equal amounts of knurled areas on handlebar protrude

4. Front screw (2)

from outboard sides of upper handlebar clamp.

NOTE

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

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

4.

Raise handlebars to normal riding position. To be sure

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

handlebars are properly centered, verify that equal

ble at all when handlebar is centered properly.

amounts of knurled areas on handlebar protrude from

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

outboard sides of both handlebar clamps.

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

5.

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

24.4 Nm).

gap should exist between upper and lower clamps at

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

rear.

6.

Check torque on front handlebar clamp screws. Tighten

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

7.

Reinstall inner fairing cap and ignition switch knob

according to appropriate Touring Models Service Manual

instructions.

1-6

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

7. Loosen four acorn nuts securing nacelle halves to fork

studs. Spread nacelle halves slightly and remove handle-

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

bar clamp shroud.

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

8. Adjust handlebars following steps

2.-6. of the FLHT,

2.

Remove eight screws (10) securing headlamp assembly

FLHTC, FLHTCU and FLHTP procedure given on previ-

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

ous page.

wire connector at back of headlamp bulb. Remove head-

9. Reinstall handlebar clamp shroud. Tighten acorn nuts

lamp assembly from vehicle.

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

3.

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

(8.1-12.2 Nm).

4.

On Police models, disconnect tachometer lead.

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

5.

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

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

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

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

6.

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

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

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

lbs (1.1-2.3 Nm).

plate.

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).

pd0226

3

6

5

14. Connect wire connector to socket on back of headlamp

bulb. Install and secure headlamp assembly to nacelle

with eight fasteners.

8

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

(12).

NOTE

2

Check clearance between windshield and clutch cable and

7

handlebar position prior to completing assembly of vehicle.

9

1

11

4

10

12

1.

Nut

2.

Nacelle trim

3.

Front handlebar clamp shroud screw

4.

Nut and washer

5.

Fork lock plate

6.

Screw (2)

7.

Nacelle

8.

Handlebar clamp shroud

9.

Headlamp assembly

10. Screw (8)

11. Chrome headlamp ring

12. Screw

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

2005 PDI: All Models

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FLTR Road Glide

pd0201

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

1 PRO

2 HRS

3 MIN

4

SE SC

EJECT

HARLEY-DAVIDSON MOTOR COMPANY INC.

LO/DX

of instrument bezel.

POWER

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

40

50

60

70

80

30

40

50

front of bezel

(concealed behind decorative adhesive

30

90

20

60

2010

100110

10

70

0

MPH

120

0

RPMx100

80

strip). Move instrument bezel to one side.

CERTIFIED

N

N

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

Figure 1-14. FLTR Models-Instrument Bezel Screws

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

pd0195

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 1-15. FLTR Models-Front Handlebar Clamp Screws

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VRSCB

10059

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

Figure 1-16. Instrument Cluster Mounting Screw Location

from outboard sides of upper handlebar clamp.

pd0021b

NOTE

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

4

Tighten

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

first

ble at all when handlebar is centered properly.

6.

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

3

2

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).

5

1

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.

FRONT

9. Install instrument cluster.

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

1.

Lower clamp

(20-24 in-lbs).

2.

Cast-in spacers (2)

11. Install Maxi-Fuse.

3.

Rear screw (2)

4.

Front screw (2)

5.

Upper clamp

Figure 1-17. VRSCB Models

2005 PDI: All Models

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REMOVING VEHICLE FROM PALLET

b0458xpx

All Models

1WARNING

Always have someone steady motorcycle while each

strap is being removed to prevent tipping. Motorcycle

front suspension is secured in a compressed state by

two nylon straps. Releasing strap tension on one side of

motorcycle could result in the front of motorcycle rising

and leaning abruptly to opposite side, which could result

in death or serious injury.

Figure 1-18. Opening Ratchet Lever

1WARNING

Always wear safety glasses and gloves and keep

pd0051

bystanders at a safe distance when uncrating the motor-

cycle. When released, each strap will unwind rapidly from

its ratchet lever, and end of strap could recoil in an out-

ward direction, which could result in death or serious

injury.

1.

Remove crating straps.

a. Have an assistant hold the motorcycle’s handlebars.

b. See Figure 1-18. Start with the right side crating

strap. Depress (in opposite direction of spool) and

hold down the spring-loaded ratchet release.

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

release position; tensioned nylon strap will rapidly

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

unwind. remove strap and any protective padding

from pallet.

1CAUTION

On VRSC models, a third strap is located at the left rear.

After this rear strap is removed, unscrew the rear eye-

bolt to prevent tripping and falling over it. Falling could

result in minor or moderate injury. Also, if eyebolt is not

removed, the left radiator trim or other low-left-side com-

ponents could be damaged when motorcycle is rolled off

pallet.

1-10

2005 PDI: All Models

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

between steel cross braces (see arrow) behind front tire

1WARNING

to aid rolling motorcycle rearward off pallet.

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

3. Carefully roll vehicle off pallet.

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)

7770

1WARNING

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

Figure 1-20. Vehicle Pallet

necessary to clear fuel tank.

b. On models with turn signals mounted on handlebar

control housings, if turn signal contacts fuel tank,

1WARNING

adjust turn signals and/or handlebar control hous-

Always park motorcycle on a level, firm surface. An

ings according to appropriate Service Manual

unbalanced motorcycle can fall over which could result

instructions.

in death or serious injury. (00039a)

1WARNING

1WARNING

Throttle control must operate freely without binding.

Irregular or sticking throttle cables could cause a loss of

The jiffy stand locks when placed in the full forward

control, leading to an accident which could result in

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

death or serious injury.

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)

2005 PDI: All Models

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CLUTCH HAND LEVER

10702

2

1

NOTE

●

See Figure

1-21. All Dyna models have Maxi-Fuse

wrapped in plastic wrapping around clutch hand lever

and left handlebar grip.

●

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

have Maxi-Fuse and headlamp snap cap fitted into 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

3

mirror fitted into protective foam.

1.

Remove plastic wrapping or protective foam from clutch

hand lever and left handlebar grip.

1.

Clutch lever restraining foam

2.

If handlebar controls need to be adjusted, perform the

2.

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

following procedure.

3.

30-amp Maxi-Fuse

a.

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

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

control housing clamp screws (1) and handlebar

Clutch Hand Lever-All Sportster Models Except XL 883L

switch housing clamp screws (2).

b.

Rotate clutch control housing and handlebar switch

housing as necessary for correct position and rider

comfort.

10703

c.

Beginning with the top screw, tighten clutch control

5

1

housing clamp screws. All Sportster models: tighten

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

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

d.

Tighten handlebar switch housing clamp screws to

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

10616

4

3

2

1. Clutch lever restraining foam

2. Headlamp snap cap

3.

30-amp Maxi-Fuse

4.

Mirror

5.

Package of mirror mounting hardware

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

Clutch Hand Lever-Sportster XL 883L

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

pd0217

Hand Lever-Dyna Models

2

1

2

1. Clutch control housing clamp screw (2)

2. Handlebar switch housing clamp screw (2)

Figure 1-24. Left Hand Controls (Typical)

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FRONT BRAKE HAND LEVER

CAUTION

1

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

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

ing procedure.

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

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

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

master cylinder clamp screws (1) and handlebar switch

and get medical attention. Swallowing large amounts of

housing clamp screws (2).

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

swallowed, obtain medical attention. Use in well venti-

2. Rotate master cylinder housing and handlebar switch

lated area. KEEP OUT OF REACH OF CHILDREN.

housing as necessary for correct position and rider com-

(00144a)

fort.

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

cylinder clamp screws. All Sportster models: tighten to

1CAUTION

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

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

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

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

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

with large amounts of water and get medical attention.

in-lbs (4.0-5.1 Nm).

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

pd0218

REACH OF CHILDREN. (00240a)

4

3

CAUTION

2

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)

1

CAUTION

Cover handlebar switches with a shop towel before add-

2

ing brake fluid to front master cylinder reservoir. Spilling

1. Front brake master cylinder clamp screw (2)

brake fluid on handlebar switches may render them inop-

2. Handlebar switch housing clamp screw (2)

erative.

3. Reservoir sightglass (XL models)

NOTE

4. Reservoir sightglass (all models except XL)

AUSTRALIAN MODELS ONLY: Measure from tip of clutch

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

Figure 1-25. Right Hand Controls (Typical)

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

IMPORTANT NOTE

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

FRONT BRAKE MASTER CYLINDER

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

RESERVOIR

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

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

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

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

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

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.

2005 PDI: All Models

1-13

-------------------------------------------------------------------------------------------------------------------------------------------------------------

VEHICLE CLEANUP

RETURNING STEEL PALLETS

NOTE

1WARNING

International Dealers/Distributors should check with their H-D

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

office to determine whether or not to return pallets.

wet when washing your motorcycle. Allowing these com-

1.

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

ponents to get too wet can adversely affect their perfor-

(1).

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

7770

traffic. (00078b)

3

1

CAUTION

2

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,

2

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

1. Plastic motor shim

2. Eye-bolts

Paint Finish Inspection and Repair

3. Enclosed area

Under good lighting conditions, examine all painted parts for

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

Figure 1-26. Vehicle Pallet

dealer network in addressing quality concerns, Harley-David-

son Motor Company has developed a zoning and criteria pro-

2.

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

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

This will allow stacking pallets for shipment.

you discover any condition requiring repair, use Paint Repair

NOTE

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

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

following address, to correct the condition.

(3) of pallet.

Kent-Moore

3.

Place hold-down straps you are returning to factory in

28635 Mound Rd

enclosed area (3) of pallets.

Warren, Michigan 48092-3499

(phone) 1-800-345-2233

CAUTION

Instructions covering painted part repair are included with the

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

Paint repair Kit. Additional paint repair information is available

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

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

pallets of different width could result in an unstable bun-

Additional cosmetic quality information is available in the Har-

dle and pallet damage.

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

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

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.

1-14

2005 PDI: All Models

-------------------------------------------------------------------------------------------------------------------------------------------------------------

MAINTENANCE-FREE BATTERIES

f1730x8x

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.

1WARNING

Figure 1-27. Warning Label

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

PROCEDURE

LOCATION

External

Flush with water

Internal

Drink large quantities of milk or water,

followed by milk of magnesia, vegetable oil

or beaten eggs. Call doctor immediately

Eyes

Flush with water, get immediate

medical attention.

f2180x3x

1

2

3

4

5

6

1. Contents are corrosive

4.

Keep flames away

2. Wear safety glasses

5.

Read instructions

3. Contents are explosive

6.

Keep away from children

Figure 1-28. Battery Warning Label

2005 PDI: All Models

1-15

-------------------------------------------------------------------------------------------------------------------------------------------------------------

DATE OF MANUFACTURE CODE

f1742x8x

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 Table 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-

Battery date of

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

manufacture code

age after battery has sat 1-2 hours.

CHARGING BATTERY

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

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

NOTE

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

The sealed AGM batteries do not need to be removed for

battery.

charging. Only remove battery if cable connection or marking

the Warranty Tag requires it.

5. Disconnect the red battery charger lead to the positive

(+) terminal of the battery.

1.

Connect the red battery charger lead to the positive ter-

minal of the battery and the black charger lead to the

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

negative terminal.

tag by removing the applicable month and year. If the

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

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

Table 1-2.

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

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

3. If battery gets hot, over

110˚F (44˚C) (warm to the

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

touch), discontinue charging and let battery cool down.

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

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

1WARNING

punched to signify the year 2005.

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)

1-16

2005 PDI: All Models

-------------------------------------------------------------------------------------------------------------------------------------------------------------

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

STATE OF CHARGE

BATTERY

3 AMP

6 AMP

10 AMP

20 AMP

AMP HOUR

CHARGER

CHARGER

CHARGER

CHARGER

VOLTAGE

% OF CHARGE

12.8

100%

-

-

-

-

12.6

75%

70 minutes

34 minutes

20 minutes

10 minutes

2 hours,

VRSC,

12.3

50%

70 minutes

40 minutes

20 minutes

20 minutes

SPORTSTER

12

3 hours,

1 hour,

12.0

25%

1 hour

30 minutes

20 minutes

40 minutes

4 hours,

2 hours,

1 hour,

11.8

0%

40 minutes

30 minutes

14 minutes

20 minutes

12.8

100%

-

-

-

-

12.6

75%

1.75 hours

50 minutes

30 minutes

15 minutes

DYNA,

12.3

50%

3.5 hours

1.75 hours

1 hour

30 minutes

SOFTAIL

18

12.0

25%

5 hours

2.5 hours

1.5 hours

45 minutes

6 hours,

3 hours,

11.8

0%

2 hours

1 hour

40 minutes

20 minutes

12.8 V

100%

-

-

-

-

12.6 V

75%

2.5 hours

1.25 hours

45 minutes

25 minutes

TOURING

12.3 V

50%

5 hours

2.5 hours

1.5 hours

50 minutes

28

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

NOTE

NOTE

The figures listed above assume that the battery is charging

The use of constant current chargers to charge sealed main-

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

tenance-free batteries is not recommended. Any overcharge

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

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

charging time.

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

charge times listed above and do not continue charging the

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

more than 30 minutes.

2005 PDI: All Models

1-17

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