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Harley Davidson 2005 MOTORCYCLE. PREDELIVERY AND SETUP MANUAL - page 4

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Windshield Installation: FLSTC

o0138xox

CAUTION

Be sure you position the windshield bracket notches in

the grooves in the mounting bushings. Incorrect mount-

ing could result in damage to the windshield.

1.

See Figure 4-3. Lower the windshield into position care-

fully inserting the side brackets between the headlamp

and the passing lamp supports until the bottom notches

are seated in the lower bushing grooves.

2. Standing at the front of the vehicle, gently push the top of

the windshield toward the rear until the upper notches

fully engage the upper bushings.

SEATS AND PASSENGER STRAP

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

senger strap removal and installation instructions.

Figure 4-3. Windshield Mounting

4-4

2005 PDI: Softail Models

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LUBRICATION SYSTEM

4.3

ENGINE OIL LEVEL

CHAINCASE LUBRICANT LEVEL

AND CLUTCH OPERATION

CAUTION

NOTE

The FLSTFSE model is shipped from the factory with

Do not remove the clutch cover on the FLSTFSE. It is not

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

necessary to check the primary chaincase lubricant level on

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

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

NOT use standard lubricants in the FLSTFSE model and

do not mix lubricants as damage to the motorcycle can

1. Remove five screws, clutch inspection cover and cover

result.

gasket.

Check engine oil level with engine turned off and motorcycle

2. See Figure 4-5. The primary chaincase lubricant level is

resting on side stand on level surface.

acceptable when lubricant is visible in bottom of chain-

case with motorcycle standing upright (not resting on jiffy

1.

Remove filler cap (with attached dipstick) from oil tank.

stand).

Wipe dipstick clean.

2.

Install filler cap onto oil tank. Make sure cap is fully

seated on tank.

pd0206

3.

See Figure 4-4. Remove filler cap, and check oil level on

dipstick. If oil level in tank is below lower mark on dip-

stick, add 3/4 quart (0.7 liter) of Harley Davidson oil to

tank. Refer to the Softail 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 Softail oil tank (with warm

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

flowed from tank to crankcase during shipping, filling oil tank

to full mark might result in overfilling of oil tank when engine is

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

after engine has reached normal operating temperature.

pd0219

Full mark with engine

at normal operating

temperature

Figure 4-5. Chaincase Lubricant Level

Add 1 quart mark

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

Figure 4-4. Engine Oil Dipstick

given in the Softail Models Service Manual.

NOTE

TRANSMISSION LUBRICANT LEVEL

The clutch inspection cover gasket may be reused ONLY

when checking chaincase lubricant level and reinstalling

NOTE

clutch inspection cover at PDI.

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 Softail Models Service Manual.

2005 PDI: Softail Models

4-5

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FUEL SYSTEM

4.4

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 4-6. 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.

o0046box

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 4-6. Fuel Supply Valve

4-6

2005 PDI: Softail Models

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ELECTRICAL SYSTEM

4.5

HEADLAMP

pd0104c

Check headlamp beam for proper height and lateral align-

ment in accordance with procedures given in the Softail 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

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 Softail Models Service Manual.

MIRRORS AND DIRECTIONAL

LAMPS

See Figure 4-7. 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.

1.

Mirror

2.

Star washer

3.

Acorn nut

4.

Front directional lamp

Figure 4-7. Mirrors And Turn Signals

2005 PDI: Softail Models

4-7

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TIRES

4.6

FRONT AND REAR TIRES

Table 4-3. Tire Pressures

RIDER AND

TIRES

SOLO RIDER

PASSENGER

1WARNING

MODEL

TIRE

PSI

kPA

PSI

kPA

Do not alter or modify front suspension/fender/tire type

on FXSTS models. The motorcycle handling characteris-

FLSTC/F/N/SC

Front

36

248

36

248

tics and front end structural integrity might be adversely

FXST/D/S/B

Front

30

207

30

207

affected. This may cause loss of control, which could

result in death or serious injury.

All models

Rear

36

248

40

276

1WARNING

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)

1WARNING

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 Table 4-3.

4-8

2005 PDI: Softail Models

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SPECIFICATIONS

5.1

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 5-1. Torque Values

ITEM

TORQUE

NOTES

Handlebar clamp screws (front and rear)

12-18 ft-lbs

16.3-24.4 Nm

Front brake master cylinder cover screws

9-17 in-lbs

1.0-2.0 Nm

Mirror fasteners

96-144 in-lbs

10.9-16.3 Nm

Battery terminal screw (positive and negative)

40-50 in-lbs

4.5-5.7 Nm

2005 SPORTSTER MODELS

SPECIFICATIONS

Table 5-2. Capacities

Component

ENGLISH

METRIC

Oil tank w/filter (Dry)

3.6 qt.

3.4 liters

Transmission/Primary

32 oz

946 ml

Chaincase

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 Sportster Models Service Manual at

Initial Maintenance check.

2005 PDI: Sportster Models

5-1

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INITIAL ASSEMBLY

5.2

3.

Place test probes of voltmeter on battery terminals and

BATTERY TESTING AND CHARGING

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

12.6 VDC.

1WARNING

4.

If the open circuit (disconnected) voltage reading is 12.6

VDC or greater the battery is ready for use.

Batteries contain sulfuric acid, which could cause severe

5.

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

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

by removing the applicable month and year. Month and

rubberized gloves and protective clothing when working

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

with batteries. KEEP BATTERIES AWAY FROM CHIL-

driver without removing battery.

DREN. (00063a)

6.

If the open circuit

(disconnected) voltage reading is

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

1WARNING

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

fied.

Never remove warning label attached to top of battery.

Failure to read and understand all precautions in warning

7.

Recheck battery voltage by repeating step 2 above. If

voltage now is 12 VDC or greater, perform steps 2 and 3

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

above.

8.

If the open circuit (disconnected) voltage reading is still

1WARNING

below 12.6 VDC, the battery must be replaced.

Battery posts, terminals and related accessories contain

9.

Place bottom of side cover with grommet onto mounting

lead and lead components, chemicals known in the State

tab on battery tray.

of California to cause cancer and birth defects or other

10.

Line up top of side cover with mounting clips aligning

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

with front clip first. Press top of side cover into clips until

1.

Grasp left side cover at upper corners and gently pull

snug.

away from plastic mounting clips on frame.

2. Lift cover up slightly so mounting grommet clears mount-

ing tab on battery tray. Remove cover.

x0628x1x

1

2

1.

Mounting slots (top)

2.

Mounting grommet (bottom)

Figure 5-1. Left Side Cover

5-2

2005 PDI: Sportster Models

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INSTALLING MAXI-FUSE

IDLE SPEED

The 30 amp Maxi-Fuse provides battery power to the ignition

See Figure 5-3. Set engine slow idle speed of 950 RPM with

switch and ICM. The Maxi-Fuse is not installed at the factory.

engine running at normal operating temperature and with

It is mounted in protective foam attached to the left handlebar

enrichment control knob pushed in fully. Turn carburetor idle

grip of the motorcycle in the crate.

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

counterclockwise to decrease speed.

See Figure 5-2. The Maxi-Fuse holder is located under the

left side cover, attached to the battery strap. See the Sports-

NOTE

ter Models Service Manual for the proper installation proce-

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

dure.

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

8946

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.

8948a

x0505a1x

5

1

2

3

Figure 5-2. Installing Maxi-Fuse

4

1. Throttle cam stop

2. Cable housing

3. Spring

4. Throttle cam

5. Idle speed adjusting screw

Figure 5-3. Carburetor adjustments

2005 PDI: Sportster Models

5-3

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MIRRORS

REAR SUSPENSION

See Figure 5-5. Check that spring preload is set the same on

NOTE

both rear shock absorbers. For a solo rider of average weight,

XL 883L model: righthand mirror is shipped in protective foam

adjust spring preload to softest setting using SPANNER

on left hand grip and must be installed.

TOOL (Part No. HD-94820-75A) for all models.

1. XL 883L models:

a. See Figure 5-4. Insert mirror (1) stem into hole in

master cylinder assembly (2).

10628

b. Install lock washer (3) and lock nut (4). Tighten to

96-144 in-lbs (10.9-16.3 Nm).

pd0225

1

2

Figure 5-5. Adjusting Spring Preload

DIRECTIONAL LAMPS

1.

Righthand mirror

2.

Front brake master

Adjust rear directional lamps so lenses are aimed directly

cylinder assembly

rearward. Verify that directional lamp fasteners are properly

3.

Lock washer

tightened.

3

4.

Lock nut

4

Figure 5-4. Installing Righthand Mirror on XL 883L

THROTTLE CONTROL CABLES

2. Adjust mirrors for proper rear view.

1WARNING

3. Adjust front directional lamps so lenses are aimed

directly forward.

Throttle cables must not pull tight when handlebars are

4. Verify that mirror and directional lamp fasteners are prop-

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

erly tightened.

throttle cables are clear of fork stops at steering head so

they will not be pinched when fork is turned against

NOTE

stops. Steering must be smooth and free with no binding

A 4 mm allen wrench will be needed to perform the front

or interference. Interference with steering could cause

directional adjustments.

loss of vehicle control which could result in death or

serious injury.

Check throttle cable adjustment in accordance with proce-

dure given in Section 1 of Sportster Models Service Manual.

SEATS AND PASSENGER STRAP

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

senger strap removal and installation instructions.

5-4

2005 PDI: Sportster Models

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LUBRICATION SYSTEM

5.3

ENGINE OIL LEVEL

10100

Check engine oil level in oil tank at least once every 500 miles

(800 km). Check level more frequently if engine uses more oil

than normal or if vehicle is operated under harsh conditions.

Oil tank capacity is 3.6 quarts (U.S.) (3.4 liters). Refer to

Owner’s Manual for recommended engine oil viscosity.

NOTE

It will be necessary to check engine oil with motorcycle lean-

ing on jiffy stand.

1. Run engine until engine oil is at normal operating tem-

perature. Turn engine off.

2. Remove filler cap from oil tank on right side of vehicle.

Figure 5-6. Filler Cap/Dipstick Slots

a. Press straight down on filler cap and release. Cap

will pop up.

b. Pull up on filler cap while turning counterclockwise

10099

one-quarter turn as if unscrewing filler cap.

3. Wipe attached dipstick clean.

NOTE

See Figure 5-6. Note that dipstick has a wide slot and a nar-

row slot and can only be inserted in oil tank one way.

4. Insert dipstick into tank. Press down on filler cap while

turning clockwise one-quarter turn as if screwing filler

cap into tank. When filler cap “snaps” slightly, it is fully

seated.

5. See Figure 5-7. Remove filler cap again and check warm

oil level on dipstick. Dipstick has two marks. If oil level in

Figure 5-7. Oil Level Marks

tank is at or below lower mark, add one quart (0.946 liter)

of Harley Davidson oil to tank.

6. Repeat step 4 to replace filler cap.

7. If you added oil in step 5, remove filler cap and verify cor-

rect engine oil level in oil tank. Do not fill oil tank to the

level above upper mark on dipstick. Repeat step 4 to

replace filler cap.

8. Press down on filler cap until it clicks in place.

CLUTCH OPERATION AND

PRIMARY CHAINCASE

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

smoothly through its entire range of travel.

2. Check clutch adjustment and primary chaincase lubri-

cant level according to the procedures in Chapter 1 of

the Sportster Models Service Manual.

2005 PDI: Sportster Models

5-5

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FUEL SYSTEM

5.4

GENERAL

FUEL TANK

Partially fill fuel tank with gasoline. Follow FUEL recommen-

CAUTION

dations found in the Owner’s Manual. Use unleaded gasoline,

91 octane or higher on all 1200 Roadster and Custom mod-

Some fuel suppliers sell gasoline which has been

els, and 87 octane or higher on 883 Standard and Custom

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

models.

of alcohol or ether added to the fuel is important.

See Figure 5-8. After adding gasoline, check for smooth oper-

ation of the fuel valve. Inspect fuel valve and fuel lines for

CAUTION

leaks.

Do not use gasoline that contains methanol. Doing so

can result in fuel system component failure, engine dam-

age and/or equipment malfunction. (00148a)

o0046box

● 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

Figure 5-8. Fuel Supply Valve

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).

5-6

2005 PDI: Sportster Models

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ELECTRICAL SYSTEM

5.5

HEADLAMP ALIGNMENT

4911

1

8

Check headlamp beam for proper height and lateral align-

ment in accordance with procedures given in Section 1 of the

Sportster Models 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

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

2

INDICATOR LAMPS/CONTROLS

3

5

4

6

7

1.

See Figure 5-9. Turn ignition switch to IGNITION posi-

1200 Roadster shown, other Sportster models not origi-

tion, and check that oil pressure indicator lamp (6) turns

nally equipped with tachometer.

on (before engine is started).

1.

Speedometer

2.

Shift transmission to neutral position, and verify that neu-

2.

Odometer and trip odometer

tral indicator lamp (5) turns on.

3.

Left directional (turn signal) indicator lamp

3.

Start engine; check operation of starter.

4.

High beam indicator lamp

4.

Check that oil pressure indicator lamp (6) turns off when

5.

Neutral indicator lamp

engine is running above 1000 RPM.

6.

Oil pressure indicator lamp

7.

Right directional (turn signal) indicator lamp

5.

Disengage clutch (depress clutch lever), and verify that

8.

Tachometer (1200 Roadster only)

neutral indicator lamp (5) turns off when transmission is

shifted to any forward gear.

Figure 5-9. Instruments (Typical)

6.

Shift transmission to neutral position, and verify that neu-

tral indicator lamp turns on again.

10.

After engine has reached normal operating temperature,

turn engine off.

7.

Check operation of tachometer (8) (1200 Roadster only).

11.

Check engine oil level in manner previously specified.

8.

Check horn operation.

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

9.

Check operation of all remaining lamps:

● Headlamp-low and high beams

● Headlamp high beam indicator lamp (4)

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

● Left directional (turn signal) indicator lamp (3)

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

● Right directional (turn signal) indicator lamp (7)

● Left front running lamp

● Right front running lamp

● Tail lamp-running lamp and brake lamp filaments

● Speedometer (1) illumination lamp

● Tachometer (8) illumination lamp (1200 Roadster

only)

2005 PDI: Sportster Models

5-7

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BRAKE SYSTEM

5.7

REAR BRAKE

8967

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)

1. With vehicle upright (not on sidestand), check that fluid

level is between the upper and lower marks on reservoir.

If brake fluid level is low, add brake fluid. See Sportster

Figure 5-10. Rear Brake Master Cylinder

Models Service Manual. Use only D.O.T. 5 SILICONE

Remote Reservoir

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

99901-77: 1 gal.).

2005 PDI: Sportster Models

5-9

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