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Harley Davidson 2005 MOTORCYCLE. PREDELIVERY AND SETUP MANUAL - page 3

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BRAKE SYSTEM

2.7

BRAKES

6628

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

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

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

glass (typical)

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

tion and protect surfaces from spills whenever brake

ABS SYSTEM (POLICE VEHICLES-

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

metic damage. (00239a)

OPTIONAL EQUIPMENT)

The ABS indicator lamp in the tachometer will flash when the

CAUTION

ignition switch is turned on, and remains flashing until the

Cover handlebar switches with a shop towel before add-

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

ing brake fluid to front master cylinder reservoir. Spilling

off.

brake fluid on handlebar switches may render them inop-

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

erative.

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

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

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

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

Models Service Manual Supplement for instructions on plac-

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

ing the ABS system into test mode and extracting diagnostic

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

trouble codes from the ABS system computer.

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

vehicle with water.

2005 PDI: Touring Models

2-19

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DEALER ROAD TEST

2.8

ROAD TEST

IDLE SPEED: CARBURETED ONLY

After you complete motorcycle inspection, take motorcycle for

NOTE

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

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

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

a diagnostic tool such as DIGITAL TECHNICIAN (Part No.

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

HD-44750).

passenger sound system controls. Refer to Touring Models

Owner’s Manual to check for proper operation.

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

engine running at normal operating temperature and with

After road test, return motorcycle to shop and thoroughly

enrichment control knob pushed in fully. Turn carburetor idle

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

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

may have found during road test.

counterclockwise to decrease speed.

Before You Begin

NOTE

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

Check the following items before road test of vehicle:

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

● Lamps and indicators.

RPM) with the engine at normal operating temperature and

● Check amount of gasoline in tank and add

(if

the enrichment knob pulled out fully. The increase in idle

needed).

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

● Adjust mirrors to proper riding positions.

up to normal operating temperature and that the enrichment

● Check tire condition and pressure (adjust if neces-

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

sary).

enrichener when the engine is at full operating temperature

● Check controls to verify proper function.

will cause fouled plugs.

● Check all electrical equipment and switches includ-

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

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

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

ation.

adjusting engine idle speed. Be aware that, because there

are variations in individual components, it is possible for a

Road Test of Vehicle: Low Speed

properly warmed-up engine to idle above the normal idle

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

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

tion, throttle control, and transmission operation.

partially.

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

3. Handling under braking conditions.

f1381a2x

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

left or right.

5

5. Check for any abnormal vibrations.

6. Check electrical lamps, indicators.

Road Test of Vehicle: Highway Speed

1. Shift from first through fifth gear, checking clutch opera-

tion, throttle control and transmission operation.

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

2

brakes.

3. Verify proper handling at highway speeds.

3

4. Check for any abnormal vibrations.

● Program Security System (if equipped)

4

● Engine Oil:

1

1. Carburetor stop plate

Check and correct hot level.

2. Cable housing

● Clean Vehicle

3. Spring

4. Throttle cam stop

NOTE

5. Idle speed adjusting screw

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.

Figure 2-23. Carburetor Adjustments

2-20

2005 PDI: Touring Models

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SPECIFICATIONS

3.1

TORQUE VALUES

The following torque values are included for fasteners that

may be loosened and tightened during Predelivery and

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

need to be checked during predelivery and setup.

Table 3-1. Torque Values

ITEM

TORQUE

NOTES

Battery terminal screws

60-96 in-lbs

6.8-10.9 Nm

Front brake master cylinder cover screws

6-8 in-lbs

0.7-0.9 Nm

Handlebar clamp screws (front and rear)

12-18 ft-lbs

16.3-24.4 Nm

Mirror fasteners

12 ft-lbs

16.3 Nm

Clutch inspection cover screws

84-108 in-lbs

9.5-12.2 Nm

2005 DYNA MODELS

SPECIFICATIONS

Table 3-2. Capacities

Component

ENGLISH

METRIC

Oil tank w/filter (Dry)

3 qt.

2.84 liter

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

Idle Speed: 950 RPM at

Operating Temperature

Use 950 RPM during Predelivery and Setup adjustments.

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

idle speed listed in the Dyna Models Service Manual at Initial

Maintenance check.

NOTE

The idle speed on electronic fuel injected models can only be

set using a diagnostic tool such as DIGITAL TECHNICIAN

(Part No. HD-44750).

2005 PDI: Dyna Models

3-1

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f1381a2x

5428

5

1

2

3

5

2

4

3

1. Throttle friction screw

2. Throttle control cable

4

3. Idle control cable

1

4. Adjuster

1. Carburetor stop plate

5. Jam nut

2. Cable housing

Figure 3-2. Throttle Cable Adjustment

3. Spring

4. Throttle cam stop

5.

See Figure 3-1. Turn adjuster on throttle control cable

5. Idle speed adjusting screw

until throttle cam stop (4) touches carburetor stop plate

(1).

Figure 3-1. Carburetor Adjustments

6.

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

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

THROTTLE CABLES

7.

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

adjuster on idle control cable until end of cable housing

Twist and release throttle control grip a few times to verify

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

proper operation of throttle control system. With throttle fric-

tion screw loosened, carburetor throttle must return to idle

8.

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

position each time throttle control grip is released.

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

1WARNING

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

until throttle control functions properly.

Throttle cables must not pull tight when handlebars are

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

9.

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

throttle cables are clear of fork stops at steering head so

Recheck operation of throttle control (Step 7).

they will not be pinched when fork is turned against

10.

Slide rubber boot (if applicable) over each cable adjuster

stops. Steering must be smooth and free with no binding

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

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.

2005 PDI: Dyna Models

3-3

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LUBRICATION SYSTEM

3.3

ENGINE OIL LEVEL

CHAINCASE LUBRICANT LEVEL

AND CLUTCH OPERATION

Check engine oil level with engine turned off and motorcycle

resting on jiffy stand on level surface.

1. Remove five screws, clutch inspection cover and cover

1. Remove filler cap with attached dipstick. Wipe dipstick

gasket.

clean.

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

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

acceptable when lubricant is visible in bottom of chain-

filler neck.

case with motorcycle standing upright (not resting on jiffy

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

stand).

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-

pd0206

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.

d0386x1x

NOTE

For cold check level do not exceed

1

2

this point when filling with oil.

3

Figure 3-4. Chaincase Lubricant Level

1. Lower arrow (add oil)

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

2. Cold check level

smoothly through its entire range of travel.

3. Upper arrow (hot check level)

4. Check clutch adjustment according to the procedures

Figure 3-3. Engine Oil Dipstick

given in the Dyna Models Service Manual.

NOTE

TRANSMISSION LUBRICANT LEVEL

The clutch inspection cover gasket may be reused ONLY

when checking chaincase lubricant level and reinstalling

clutch inspection cover at PDI.

NOTE

Allow vehicle to stand upright for a moment before checking

5. Reinstall cover gasket and clutch inspection cover, and

transmission lubricant level. This will allow lubricant level to

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

normalize.

12.2 Nm).

Check the transmission lubricant level with the motorcycle

standing upright in accordance with the procedure given in

the Dyna Models Service Manual.

2005 PDI: Dyna Models

3-5

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FUEL SYSTEM

3.4

GENERAL

CHECKING QUICK CONNECT FUEL

LINE FITTING-FUEL INJECTED

CAUTION

MODELS

Some fuel suppliers sell gasoline which has been

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

1WARNING

of alcohol or ether added to the fuel is important.

To avoid an uncontrolled discharge or spray of gasoline,

always be sure the quick-connect fitting (under left side

CAUTION

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

Do not use gasoline that contains methanol. Doing so

line will verify this condition. Gasoline is extremely flam-

can result in fuel system component failure, engine dam-

mable and highly explosive. Inadequate safety precau-

age and/or equipment malfunction. (00148a)

tions could result in death or serious injury.

● Gasolines containing ETHANOL (ethyl alcohol or grain

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

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

sure quick connect fitting is properly mated.

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

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

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

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

tains ethanol.”

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

● Gasolines containing METHYL TERTIARY BUTYL

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

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

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

FUEL TANK

MTBE.

● REFORMULATED OR OXYGENATED GASOLINES

Make sure engine stop switch on the handlebar is switched to

(RFG):

“Reformulated gasoline” is a term used to

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

describe gasoline blends that are specifically designed to

TION position. Fuel injected models: verify that Low Fuel

burn cleaner than other types of gasoline, leaving fewer

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

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

recommendations found in the Owner’s Manual. Use

rate less when you are filling your tank. Reformulated

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

gasolines use additives to “oxygenate” the gas. Your

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

motorcycle will run normally using this type of gas and

Inspect fuel lines for leaks.

Harley Davidson recommends you use it when possible,

as an aid to cleaner air in our environment

Carbureted Models

Because of their different chemical properties (which affect

See Figure 3-5. After adding gasoline, check for smooth oper-

fuel volatility and ignition characteristics), these blends may

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

adversely affect the starting, drivability, and fuel efficiency of

the motorcycle. If you experience these problems, Harley-

Davidson recommends using straight, unleaded gasoline.

o0046b

CAUTION

Use only unleaded fuel in California model catalytic con-

verter-equipped motorcycles. Using leaded fuel will dam-

age the emission control system. (00150a).

Figure 3-5. Fuel Supply Valve

3-6

2005 PDI: Dyna Models

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ELECTRICAL SYSTEM

3.5

HEADLAMP

10648

9

8

Check headlamp beam for proper height and lateral align-

1

ment in accordance with procedures given in the Dyna Mod-

els Service Manual

1WARNING

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

2

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

NOTE

3

5

7

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

4

6

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

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

1. Speedometer

other models are shipped in position.

2. Odometer and trip odometer

3. Left directional (turn signal) indicator lamp

INDICATOR LAMPS/CONTROLS

4. High beam indicator lamp

5. Neutral indicator lamp

6. Oil pressure indicator lamp

NOTE

7. Right directional (turn signal) indicator lamp

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

8. Tachometer

on FXDX models. Instruments and indicators on remaining

9. Check engine lamp

Dyna models are located as follows:

● FXD Speedometer and indicators in handlebar bracket.

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

● FXDWG Speedometer and indicators in panel on gas

7. Check horn operation.

tank.

8. Check operation of all remaining lamps:

FXDL Speedometer and tachometer in console on gas tank,

● headlamp-low and high beams

indicators in headlamp bracket.

● headlamp high beam indicator lamp

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

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

pressure indicator lamp turns on

(before engine is

started) and check engine lamp illuminates for about four

● Ieft directional (turn signal) indicator lamp

seconds and goes off.

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

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

● right directional (turn signal) indicator lamp

tral indicator lamp turns on.

● Ieft front running lamp

3. Start engine; check operation of starter.

● right front running lamp

4. Check that oil pressure indicator lamp turns off when

engine is running above 1000 RPM.

● tail lamp-running lamp and brake lamp filaments

5. Check operation of tachometer, if equipped.

● speedometer illumination lamp

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

● tachometer illumination lamp

neutral indicator lamp turns off when transmission is

9. After engine has reached normal operating temperature,

shifted to any forward gear. Shift transmission to neutral

turn engine off.

position, and verify that neutral indicator lamp turns on

10. Check engine oil level in manner previously specified.

again.

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

2005 PDI: Dyna Models

3-7

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MIRRORS AND DIRECTIONAL

pd0104c

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).

1.

Mirror

2.

Star washer

3.

Acorn nut

4.

Front directional lamp

Figure 3-7. Mirror and Directional Lamp Mounting

3-8

2005 PDI: Dyna Models

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BRAKE SYSTEM

3.7

BRAKES

4934

1CAUTION

Direct contact with D.O.T. 5 brake fluid can cause eye irri-

tation, swelling, and redness. Avid eye contact. In case of

eye contact flush with large amounts of water and get

medical attention. Swallowing large amounts of D.O.T. 5

brake fluid can cause digestive discomfort. If swallowed,

obtain medical attention. Use in well ventilated area.

KEEP OUT OF REACH OF CHILDREN. (00144a)

See Figure 3-8. View reservoir sightglass and verify fluid

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

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

Figure 3-8. Rear Master Cylinder Shown

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

3-10

2005 PDI: Dyna Models

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SPECIFICATIONS

4.1

TORQUE VALUES

The following torque values are included for fasteners that

may be loosened and tightened during Predelivery and

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

need to be checked during predelivery and setup.

Table 4-1. Torque Values

ITEM

TORQUE

NOTES

Handlebar clamp screws (front and rear)

12-15 ft-lbs

16.3-20.3 Nm

Brake master cylinder cover screws

6-8 in-lbs

0.7-0.9 Nm

(front and rear)

Battery terminal screws

60-96 in-lbs

6.8-10.9 Nm

Mirror fasteners

60-96 in-lbs

6.8-10-9 Nm

Clutch inspection cover screws

84-108 in-lbs

9.5-12.2 Nm

2005 SOFTAIL MODELS

SPECIFICATIONS

Table 4-2. Capacities

Component

ENGLISH

METRIC

Oil tank w/filter (Dry)

3.5 qt.

3.31 liter

Transmission (Wet)

20-24 oz

591-710 ml

Primary Chaincase

26 oz

769 ml

All Softail models except FLSTFSE are shipped with

20W50 Harley Davidson 360 Motor oil. The FLSTFSE

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

and transmission.

Idle Speed: 950 RPM at

Operating Temperature

Use 950 RPM during Predelivery and Setup adjustments.

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

idle speed listed in the Softail Models Service Manual at 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).

2005 PDI: Softail Models

4-1

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7. Check operation of all remaining lamps:

IDLE SPEED: CARBURETED ONLY

● headlamp-low and high beams

● headlamp high beam indicator lamp

NOTE

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

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

a diagnostic tool such as DIGITAL TECHNICIAN (Part No.

● Ieft directional (turn signal) indicator lamp

HD-44750).

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

See Figure 4-2. Set engine slow idle speed of 950 RPM with

● right directional (turn signal) indicator lamp

engine running at normal operating temperature and with

● Ieft front running lamp

enrichener control knob pushed in fully. Turn carburetor idle

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

● right front running lamp

counterclockwise to decrease speed.

● tail lamp-running lamp and brake lamp filaments

NOTE

8. After engine has reached normal operating temperature,

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

turn engine off.

the engine to idle at approximately 2000 RPM with the engine

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

at normal operating temperature and the enrichener knob

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

pulled fully out. The increase in idle speed is intended to alert

filler cap/dipstick.

the rider that the engine is warmed up to normal operating

temperature and that the enrichener knob should be pushed

in all the way. Continuing to use the enrichener circuit when

pd0189

the engine is at normal operating temperature will cause

7

1

fouled plugs.

8

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

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

50

60

70

adjusting engine idle speed. Be aware that, because there

40

80

30

90

are variations in individual components, it is possible for a

20

100

properly warmed-up engine to idle at 2000

RPM with the

10

110

enrichener knob pulled out partially.

0

MPH

120

E

F

TI

D

f1381a2x

9

5

2

3

4

5

6

1.

Speedometer

2.

Left turn signal

3.

High beam

4.

Neutral

2

5.

Oil pressure

6.

Right turn signal

3

7.

Check engine lamp

8.

Fuel gauge

9.

Security lamp

4

Figure 4-1. Indicator Lamps

1

IGNITION TIMING

1.

Carburetor stop plate

2.

Cable housing

3.

Spring

Ignition timing is not adjustable on The Twin

Cam 88B™

4.

Throttle cam stop

engine.

5.

Idle speed adjusting screw

Figure 4-2. Carburetor Adjustments

2005 PDI: Softail Models

4-3

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