Harley Davidson 2005 MOTORCYCLE. PREDELIVERY AND SETUP MANUAL

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PREDELIVERY: VRSC MODELS

SUBJECT

PAGE NO.

6.1 Specifications

6-1

Torque Values

6-1

2005 VRSC Models Specifications

6-1

6.2 Initial Assembly

6-2

Battery Testing And Charging

6-2

Installing Maxi-Fuse

6-3

Seats And Passenger Strap

6-3

6.3 Lubrication System

6-4

Engine Oil Level

6-4

Clutch Master Cylinder

6-6

6.4 Fuel System

6-7

General

6-7

6.5 Electrical System

6-8

Headlamp

6-8

Indicator Lamps/Controls

6-9

6.6 Tires

6-10

Front and Rear Tires

6-10

6.7 Brake System

6-11

Rear Brake Master Cylinder

6-11

6.8 Dealer Road Test

6-12

Road Test

6-12

6.9 Customer Delivery

6-13

Notice To Dealer

6-13

6.10 Vehicle PDI Checklist

6-14

Prior to Customer Delivery

6-14

At Point of Customer Delivery

6-14

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SPECIFICATIONS

6.1

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.

ITEM

TORQUE

NOTES

Front axle nut

68-75 Nm

50-55 ft-lbs

Rear axle nut

129-142.36 Nm

95-105 ft-lbs

All master cylinder cover screws

0.7-0.90 Nm

6-8 in-lbs

Battery terminal screws

6.8-10.9 Nm

60-96 in-lbs

Coolant air bleed plug

9-11 Nm

80-97 in-lbs

Radiator drain plug

Hand-tighten

2005 VRSC MODELS

SPECIFICATIONS

Table 6-1. Capacities

Component

Metric

English

Fuel tank total

14.0 liters

3.7 gal.

Oil sump

4.3 liters

4.5 qt.

Coolant

2.4 liters

2.54 qt.

2005 PDI: VRSC Models

6-1

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INITIAL ASSEMBLY

6.2

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

BATTERY TESTING AND CHARGING

by removing the applicable month and year. Month and

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

driver without removing battery.

1WARNING

If the open circuit

(disconnected) voltage reading is

Batteries contain sulfuric acid, which could cause severe

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

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

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

rubberized gloves and protective clothing when working

fied.

with batteries. KEEP BATTERIES AWAY FROM CHIL-

Recheck battery voltage by repeating step 1 above. If

DREN. (00063a)

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

above.

1WARNING

If the open circuit (disconnected) voltage reading is still

below

12.6 VDC, the battery must be replaced. To

Never remove warning label attached to top of battery.

remove battery, air cleaner and air cleaner bottom

Failure to read and understand all precautions in warning

must be removed. See appropriate Service Manual for

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

procedure.

IMPORTANT NOTE

1WARNING

Only remove air cleaner and air cleaner bottom if battery

could not be charged to 12.6 VDC and battery must be

Battery posts, terminals and related accessories contain

lead and lead components, chemicals known in the State

removed and replaced.

of California to cause cancer and birth defects or other

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

NOTES

● The engine is equipped with a compression release, so a

smaller (12 amp hour) battery provides adequate starting

current.

● It will be necessary to remove the airbox cover 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.

6-2

2005 PDI: VRSC Models

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2. See Figure 6-2. The fuse holder and boot is located just

INSTALLING MAXI-FUSE

forward of the coolant reservoir. Fold back the flap on the

fuse holder boot and insert the fuse into the fuse holder

NOTES

socket.

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

3. See Figure 6-1. Reinstall sidecover and secure with

ignition switch and ECM. The Maxi-Fuse is not installed

screw. Tighten to 4.1-6.8 Nm (30-60 in-lbs).

at the factory. It is shipped in the fuse holder boot next to

the socket.

● It will also be necessary to install the fuel pump fuse that

9020

is located in a spare fuse location. See Service Manual.

1. See Figure 6-1. Remove fastener at upper corner of lou-

vered cover and remove cover.

9010

Figure 6-2. Inserting Maxi-Fuse

SEATS AND PASSENGER STRAP

Refer to VRSC Models Owner’s Manual for seat and passen-

Figure 6-1. Removing Sidecover

ger strap removal and installation instructions.

2005 PDI: VRSC Models

6-3

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LUBRICATION SYSTEM

6.3

ENGINE OIL LEVEL

9015

CAUTION

Do NOT operate the engine when the oil level is below

the add mark on the dipstick at operating temperature.

Engine damage will result. (00187a)

CAUTION

To avoid over-filling the oil sump, wait approximately

three minutes after adding oil before checking the oil

level with the dipstick. An over-filled sump can cause

engine damage. (00188a)

Figure 6-3. Oil Filler Cap (Left Side Of Engine)

NOTE

This engine has a wet sump, an integral transmission, gear

driven primary drive and wet clutch. This design allows

o0239aox

engine oil in the sump to be used to lubricate the engine,

transmission and primary drive. The clutch and primary drive

Midpoint

housing is on the right side of the engine.

Cold Engine Oil Level Check

Check engine oil level with engine COLD as follows:

1. Stand motorcycle upright (not leaning on side stand) on

a level surface.

2. See Figure 6-3. Unscrew oil filler cap (with attached dip-

stick) by turning filler cap counterclockwise. Remove filler

Figure 6-4. Engine Oil Dipstick

cap and dipstick and wipe dipstick clean.

3. Screw filler cap into engine. Make sure cap is fully

Hot Engine Oil Level Check

seated on crankcase.

4. See Figure 6-4. Remove filler cap and check oil level on

Check engine oil level with engine at normal operating tem-

dipstick.

perature as follows:

5. If oil level is below midpoint on cross-hatched area on

Stop engine and allow oil to drain into sump for about

dipstick, add enough Harley Davidson oil to bring level

three minutes.

up to the midpoint shown in Figure 6-4.

Stand motorcycle upright (not leaning on side stand) on

a level surface.

See Figure 6-3. Unscrew filler cap (with attached dip-

stick) by turning filler cap counterclockwise. Remove filler

cap and dipstick and wipe dipstick clean.

Screw filler cap into engine. Make sure cap is fully

seated on crankcase.

See Figure 6-4. Remove filler cap and check oil level on

dipstick.

If oil level is below FULL mark on dipstick, add enough

Harley Davidson oil to bring level up to the FULL mark.

Observe “CAUTIONS” stated above.

6-4

2005 PDI: VRSC Models

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Pressure Cap Location

9032

NOTES

● See Figure 6-5. The pressure cap is located beneath

seat behind the air box. Normally the pressure cap does

not need to be removed. Coolant level can be checked at

the expansion tank located on right side behind steering

head. Coolant can be added at the expansion tank if

level is low. To verify that the coolant system has been

filled perform the check following these notes.

● See Figure 6-6. If the coolant system is drained, remove

the air bleed plug and then fill through filler neck at pres-

sure cap.

Verifying Coolant System Is Filled

Figure 6-6. Coolant System Air Bleed Plug

1. See Figure 6-5. Remove pressure cap.

2. See Figure 6-7. Gently squeeze center of hose (1) while

looking into coolant filler neck. Coolant should rise in

9098

filler neck.

3. If coolant is not visible in filler neck, remove air bleed

plug shown in Figure 6-6.

4. Add enough premixed HARLEY-DAVIDSON EXTENDED

LIFE ANTIFREEZE & COOLANT (Part No. 99822-02) so

coolant is visible in filler neck. Replace air bleed plug and

pressure cap. Tighten air bleed plug to 9-11 Nm (80-97

in-lbs).

9030

Hose

Hose (To thermostat housing)

Hose clamps (4) (2 on each hose)

Figure 6-7. Coolant Hoses (Engine right side)

Check Hose Clamps For Tightness

1. See Figure 6-7. Check the four hose clamps (two each

on hoses) for tightness.

2. With a long bladed screwdriver check two hose clamps

one at top left and one at top right of radiator.

Figure 6-5. Pressure Cap

NOTE

The engine ends of the radiator hoses are secured with a

plastic “shrink” clamp and do not require checking.

2005 PDI: VRSC Models

6-5

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Checking Coolant Level In

CLUTCH MASTER CYLINDER

Expansion Tank

View reservoir sightglass and verify fluid presence.

1. See Figure 6-8. Remove fastener at upper corner of lou-

Sightglass should appear dark if fluid is present. If sight-

vered cover and remove cover.

glass is not dark, add D.O.T. 5 SILICONE HYDRAULIC

BRAKE FLUID (Part No. 99902-77). See Service Man-

ual.

9010

NOTES

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

FLUID (Part No. 99902-77) in clutch master cylinder res-

ervoir.

● Do not overfill clutch master cylinder reservoir. As clutch

friction discs wear, the piston in the clutch cylinder will

force fluid back into the reservoir and this could cause

fluid overflow.

1CAUTION

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

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

Figure 6-8. Removing Cover to Check Coolant Level

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

2. See Figure 6-9. Check coolant level in expansion tank

swallowed, obtain medical attention. Use in well venti-

with coolant cold and vehicle resting on jiffy stand. If level

lated area. KEEP OUT OF REACH OF CHILDREN.

is below “COLD FULL” line on tank, remove cap from

(00144a)

tank and add premixed HARLEY-DAVIDSON

EXTENDED LIFE ANTIFREEZE & COOLANT (Part No.

99822-02) until fluid level reaches “COLD FULL” line.

CAUTION

D.O.T. 5 silicone hydraulic brake fluid is used in the

hydraulic clutch. Do not use other types of fluids as they

9019

are not compatible and could cause equipment damage.

(00204a)

Figure 6-9. Cold Full Line On Expansion Tank

NOTE

Do not reinstall louvered cover now. The 40 amp fuse will be

installed later in the fuse holder located just forward of the

expansion tank.

6-6

2005 PDI: VRSC Models

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FUEL SYSTEM

6.4

GENERAL

CAUTION

Use only unleaded fuel in California model catalytic con-

CAUTION

verter-equipped motorcycles. Using leaded fuel will dam-

age the emission control system. (00150a).

Some fuel suppliers sell gasoline which has been

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

Partially fill fuel tank with gasoline. Use unleaded gasoline, 91

of alcohol or ether added to the fuel is important.

octane or higher on all VRSC models. Inspect fuel system for

leaks.

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

2005 PDI: VRSC Models

6-7

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ELECTRICAL SYSTEM

6.5

HEADLAMP

b0008c7x

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)

Center of head-

Inspection

lamp to floor

See Figure 6-10. Check headlamp beam for proper height

and lateral alignment. Proceed as follows:

7.62 M

1. Verify correct front and rear tire inflation pressure.

(25 ft.)

2. Place motorcycle on level floor (or pavement) in an area

with minimum light.

Point front of motorcycle toward a screen or wall which is

Figure 6-10. Checking Headlamp Alignment

25 ft. (7.62 m) away from front tire contact patch on floor

(i.e. directly below front axle).

Adjustment

4. Measure the vertical distance from center of headlamp to

VRSCA models:

floor and draw a horizontal line, on screen or wall, at

same height above floor.

See Figure 6-11. Loosen headlamp adjustment screws,

one on each side of headlamp

5. Have a person, whose weight is roughly the same as that

of the principal rider, sit on motorcycle seat. Weight of

Tilt headlamp up or down to properly aim it in relation to

rider will compress vehicle suspension slightly.

the horizontal line.

6. Stand motorcycle upright with both tires resting on floor

Once the headlamp is properly adjusted, tighten both

and with front wheel held in straight alignment (directly

headlamp adjustment screws to 4.5-7.5 Nm (40-66 in-

forward).

lbs).

7. Turn ignition/light switch to “IGNITION” position. Set han-

NOTE

dlebar switch to high beam position.

The lateral headlamp alignment on VRSCA models is estab-

8. Check light beam for proper height alignment. Main

lished by the headlamp mounting and does not require

beam of light (broad, flat pattern of light) should be cen-

adjustment.

tered on horizontal line of screen or wall (i.e. equal area

of light above and below line).

9026

Figure 6-11. Headlamp Adjustment-VRSCA Model

6-8

2005 PDI: VRSC Models

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VRSCB models:

NOTE

For any systems problems, please refer to the appropriate

1. See Figure 6-12. Loosen headlamp clamp nut (1).

Electrical Diagnostic manual for your model.

Tilt headlamp (6) up or down to properly aim it in relation

Shift transmission to neutral position, and verify that neu-

to the horizontal line, and, at the same time, turn it right

or left to direct light beam straight ahead.

tral indicator lamp turns on.

Start engine; check operation of starter.

3. Tighten headlamp clamp nut to 13.6-20.3 Nm (120-180

in-lbs) after headlamp is properly positioned.

Check that oil pressure indicator lamp turns off when

engine is running above 1200 RPM. Check that battery

4. Locate headlamp bracket plug (4), packaged in traveler

icon turns off. Engine Coolant temperature icon must not

included with motorcycle in crate. Snap plug into place in

illuminate.

headlamp bracket (5).

Check that tachometer is functioning.

Disengage clutch (depress clutch lever), and verify that

pd0223

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.

Check horn operation.

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

1. Headlamp clamp nut

● Ieft front running lamp

2. Lock washer

3. Washer

● right front running lamp

4. Headlamp bracket plug

● tail lamp-running lamp and brake lamp filaments

5. Headlamp bracket

After engine has reached normal operating temperature,

6. Headlamp assembly

turn engine off.

Figure 6-12. Headlamp Adjustment-VRSCB Model

10.

Check engine oil level in manner previously specified.

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

INDICATOR LAMPS/CONTROLS

CAUTION

To avoid over-filling the oil sump, wait approximately

NOTES

three minutes after adding oil before checking the oil

● All VRSC models have an Instrument Module with self-

level with the dipstick. An over-filled sump can cause

diagnostic capabilities. Refer to VRSC Model Electrical

engine damage. (00188a)

Diagnostic Manual for service instructions.

● VRSCSE models are equipped with a separate speed-

ometer, tachometer and instrument console. See BAT-

TERY TESTING AND CHARGING under 7.1 VRSCSE

MODEL.

1. View instrument cluster and turn ignition switch to “IGNI-

TION” position. Check that the oil pressure indicator

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

Engine indicator lamp will illuminate for about four sec-

onds and then go off. If cycle is equipped with optional

Security System (TSSM), a key icon (Security lamp) will

illuminate for about four seconds and then go off. The

Battery icon will illuminate to indicate low voltage. Fuel

gauge should also indicate fuel tank level. Engine Cool-

ant temperature icon will illuminate to verify bulb filament

and then go off.

2005 PDI: VRSC Models

6-9

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BRAKE SYSTEM

6.7

REAR BRAKE MASTER CYLINDER

WARNING

See Figure 6-14. If master cylinder or reservoir hose does

1CAUTION

not have 1/4 in. clearance, item (1), from exhaust pipe,

loosen and reposition exhaust to obtain the 1/4 in. clear-

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

ance. Refer to VRSC Model Service Manual for exhaust

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

system instructions. Contact with the hot exhaust pipe

In case of eye contact flush with large amounts of water

could cause fluid leakage and reduced braking which

and get medical attention. Swallowing large amounts of

could result in loss of vehicle control and death or seri-

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

ous injury.

swallowed, obtain medical attention. Use in well venti-

lated area. KEEP OUT OF REACH OF CHILDREN.

See Figure 6-14. Check push rod length (3). Loosen jam

(00144a)

nut and turn push rod with a wrench placed on push rod

wrench flats if adjustment is required.

1. See Figure 6-13. Use a flashlight to view rear brake mas-

ter cylinder located behind radiator cover. Verify that fluid

level in rear brake master cylinder reservoir is 1/2 in.

9022

(12.7 mm) below reservoir top.

9022

6.4 mm (0.25 in.) clearance

Reservoir

Figure 6-13. Rear Brake Master Cylinder

Push rod length: 18-22 mm (0.690-0.890 in.)

(Radiator Cover Removed for Photo Clarity)

Figure 6-14. Rear Brake Pedal Adjustments

2. If level is low, remove cover screws and cover, and add

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

(Part No. 99902-77: 12 oz., 99901-77: 1 gal.). Replace

cover. Tighten cover screws to 0.68-0.90 Nm (6-8 in-

lbs).

2005 PDI: VRSC Models

6-11

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DEALER ROAD TEST

6.8

ROAD TEST

Road Test of Vehicle: Low Speed

Shift from first through third gear, checking clutch opera-

After you complete motorcycle inspection, take motorcycle for

tion, throttle control, and transmission operation.

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

Verify low speed braking for front and rear brakes.

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

Handling under braking conditions.

After road test, return motorcycle to shop, and thoroughly

Low speed handling. Verify that vehicle does not pull to

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

left or right.

may have found during road test.

Check for any abnormal vibrations.

Before You Begin

Check electrical lamps, indicators.

Check the following items before road test of vehicle:

Road Test of Vehicle: Highway Speed

● Lamps and indicators.

● Check amount of gasoline in tank and add

(if

Shift from first through fifth gear, checking clutch opera-

tion, throttle control, and transmission operation.

needed).

● Adjust mirrors to proper riding positions.

Verify highway speed braking operation of front and rear

● Check tire condition and pressure (adjust if neces-

brakes.

sary).

Verify proper handling at highway speeds.

● Check controls to verify proper function.

Check for any abnormal vibrations.

● Check all electrical equipment and switches includ-

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

● Program Security System (if equipped)

ation.

● 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.

6-12

2005 PDI: VRSC Models

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CUSTOMER DELIVERY

6.9

IMPORTANT NOTES

NOTICE TO DEALER

●

The bright anodized finish on air box cover and fend-

ers requires special care. Also the wheels, rear fork

Before delivering motorcycle to owner, perform the following:

(swingarm) and all components painted with a spe-

Make sure vehicle owner receives, and is aware of

cial Silver paint require special care. The painted fin-

importance of reading Owner’s Manual, safety booklets

ish on frame, air box cover and fenders on the

and viewing Welcome To The Family video included with

VRSCSE model requires special care. An Instruction

owner’s kit.

Sheet covering care of this motorcycle has been

Review warranties with vehicle owner. Make sure owner

added to the Owner’s Kit. Review this Instruction

understands warranties. California dealers must give

Sheet with the Customer and answer any questions

customer a copy of Emissions Control System Warranty.

he or she may have.

Give IMPORTANT sheet and other printed material in lit-

●

If motorcycle is equipped with a TSSM, make sure

erature kit to vehicle owner.

key fob (remote control) and personal code have

Complete and sign warranty registration form. Have vehi-

been assigned to control the Harley Davidson Fac-

cle owner sign it.

tory Security System. If a personal code is not

assigned and key fob is lost or damaged while vehi-

Explain operation of vehicle controls to vehicle owner.

cle is armed, TSSM must be replaced. Make sure

Explain how turn signals and emergency flashers oper-

vehicle owner understands how to arm and disarm

ate.

security system. Explain how to disarm security sys-

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

tioning. Personal code should be written on the tear-

out card in VRSC Models Owner’s Manual and kept

on the owner’s person. Also, verify both key fobs

operate properly.

Whenever possible, introduce dealer Service Manager to

vehicle owner, and involve Service Manager in delivery

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

Parts Department personnel who should be contacted

regarding vehicle service/parts questions.

Inform vehicle owner about checking engine oil level,

checking tire pressure, and performing other basic 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.

2005 PDI: VRSC Models

6-13

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VEHICLE PDI CHECKLIST

6.10

❒ Throttle Cable Adjustment (if necessary).

PRIOR TO CUSTOMER DELIVERY

❒ Handlebars, Controls and Seat Strap:

NOTE

Adjust and tighten (if necessary).

Use this checklist for performing tasks related to this model

❒ Headlamps:

motorcycle setup.

Inspect and adjust as necessary.

❒ Uncrate:

❒ Mirrors:

Check for damaged or missing parts.

Inspect and adjust as necessary.

❒ Jiffy Stand:

❒ Road Test Vehicle: Low Speed

Verify proper function.

a. Shift from first through third gear, checking clutch

❒ Note Any Additional Problems

operation, throttle control, and transmission opera-

(including cosmetic quality):

tion.

Perform Warranty repairs.

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

❒ Battery:

c. Verify handling under braking conditions.

Perform required voltmeter test on

Maxi-Fuse

(main

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

fuse) and battery.

not pull to left or right.

❒ Install Maxi-Fuse (main fuse).

e. Check for any abnormal vibrations.

Check electrical lamps, indicators.

❒ Install Fuel Pump Fuse.

❒ Road Test Vehicle: Highway Speed

❒ Lubrication System:

a. Shift from first through fifth gear, checking clutch

Inspect condition of oil lines.

operation, throttle control, and transmission opera-

❒ Engine Oil:

tion.

Verify oil is present (cold level).

b. Verify highway speed braking operation of front and

❒ Primary Chaincase:

rear brakes.

c. Verify proper handling at highway speeds.

Check and verify lubricant is present.

d. Check for any abnormal vibrations.

❒ Fuel System:

❒ Engine Oil:

a. Inspect fuel system for leaks.

Check and correct hot level.

b. Fill, verify sender operation.

❒ Create Vehicle Birth-Certificate Using

c. Verify low fuel light operation.

Digital Technician (optional).

❒ Cooling System:

❒ Clean Vehicle.

a. Check and correct fluid level (if necessary).

b. Check radiator hose clamps for tightness.

AT POINT OF CUSTOMER DELIVERY

❒ Evaporative Control System:

Inspect hose routings, connections and fuel tank venting

❒ Suspension Adjustments.

to canister (if equipped).

❒ Brake Pedal Height Adjustment.

❒ Lighting, Gauges, Electrical Systems:

❒

Shift Linkage Adjustment.

Verify correct operation.

❒ Brake Hand Lever Adjustment.

❒ Tires:

❒ Review Vehicle Care and Maintenance Requirements.

Inspect condition and air pressure.

❒ Brake Systems (front and rear):

NOTE

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

Correct fluid level (if necessary).

ANY adjustments and/or warranty work performed required to

❒ Clutch Fluid:

deliver the vehicle to the customer.

Correct fluid level (if necessary).

6-14

2005 PDI: VRSC Models

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PREDELIVERY: CVO MODELS

SUBJECT

PAGE NO.

7.1 VRSCSE Model

7-1

General

7-1

Uncrating

7-1

Battery Testing And Charging

7-1

Indicator Lamps and Displays

7-2

Adjusting Handlebars

7-3

Adjusting Handlebar Controls

7-3

Checking Clutch Fluid

7-5

Mirrors And Turn Signals

7-6

Seats And Passenger Strap

7-6

Footrest Adjustment

7-7

Final Predelivery Inspections

7-7

7.2 FLHTCSE2 Model

7-8

General

7-8

Uncrating

7-8

Adjusting Handlebar Controls

7-8

Mirrors

7-9

Checking Clutch Fluid

7-9

Removable Rider Backrest

7-10

Wind Deflector

7-10

Removable Tour-Pak®

7-10

Radio Antenna

7-14

Removable Passenger Backrest

7-14

Delivering Vehicle With Removable Passenger Backrest Installed

7-15

Leather Dressing Application

7-16

Final Predelivery Inspections

7-16

7.3 FLSTFSE Model

7-17

General

7-17

Uncrating

7-17

Adjusting Handlebars

7-17

Adjusting Handlebar Controls

7-18

Checking Clutch Fluid

7-19

Mirrors And Turn Signals

7-19

Fuel Tank Console Extension

7-20

Seat

7-20

Final Predelivery Inspections

7-20

VII

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VRSCSE MODEL

7.1

GENERAL

BATTERY TESTING AND CHARGING

Follow the instructions in section I (All Models) and Section VI

(VRSC Models) and the following instructions to perform the

1WARNING

predelivery setup procedure on the VRSCSE model.

Batteries contain sulfuric acid, which could cause severe

This motorcycle is equipped with the Harley Davidson Fac-

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

tory Security System and siren.

rubberized gloves and protective clothing when working

with batteries. KEEP BATTERIES AWAY FROM CHIL-

DREN. (00063a)

UNCRATING

The VRSCSE is shipped in a “turn-wheel” crate which allows

1WARNING

the handlebar to be shipped in position on the handlebar ris-

ers.

Never remove warning label attached to top of battery.

Failure to read and understand all precautions in warning

Remove foam block from left handlebar grip. Remove plastic

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

end caps from both handlebar grips. Discard foam block and

plastic end caps.

WARNING

Check Contents of Crate

Battery posts, terminals and related accessories contain

Check that the following items are in a box in the crate:

lead and lead components, chemicals known in the State

of California to cause cancer and birth defects or other

● Motorcycle cover inside a storage bag

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

● Owner’s kit

● Two mirror kits

NOTES

● CVO ignition key

● The engine is equipped with a compression release, so a

NOTE

smaller (12 amp hour) battery provides adequate starting

If any parts are missing, call 1-800-695-2925 or Fax 1-717-

current.

852-6717. Provide your Dealer name, number, person to con-

● It will be necessary to remove the airbox cover to gain

tact, part number of missing item, and Motorcycle VIN.

access to the battery.

Removing Airbox Cover

1. Unlock and open seat.

2. See Figure 7-1. Unlatch and lift rear of airbox cover a few

inches.

3. Disconnect console connector.

4. Carefully slide airbox cover back to disengage locating

pins at front of cover from mounting tabs on frame.

Remove cover.

10769

Figure 7-1. Console Connector

2005 PDI: CVO Models

7-1

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Testing and Charging Battery

INDICATOR LAMPS AND DISPLAYS

1. Place test probes of voltmeter on battery terminals and

See Figure 7-2. View indicator lamps and displays and

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

turn ignition switch to “IGNITION” position. Check that

12.6 VDC.

the oil pressure indicator lamp

(12) turns on (before

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

engine is started). The Check Engine indicator lamp (2)

VDC or greater the battery is ready for use.

will illuminate for about four seconds and then go off. The

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

security lamp (5) will illuminate for about four seconds

by removing the applicable month and year. Month and

and then go off. The Battery icon (4) will illuminate to

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

indicate low voltage. Fuel gauge (7) should also indicate

driver without removing battery.

fuel tank level. Engine Coolant temperature lamp (1) will

4. If the open circuit

(disconnected) voltage reading is

illuminate to verify bulb filament and then go off.

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

NOTE

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

For any systems problems, please refer to the appropriate

fied.

Electrical Diagnostic manual for your model.

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

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

above.

10771

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

below

12.6 VDC, the battery must be replaced. To

remove battery, air cleaner and air cleaner bottom

must be removed. See appropriate Service Manual for

procedure.

IMPORTANT NOTE

Only remove air cleaner and air cleaner bottom if battery

could not be charged to 12.6 VDC and battery must be

removed and replaced.

Installing Airbox Cover

Carefully install airbox cover over airbox. Be careful not

to scratch or damage airbox cover, console or speedom-

eter. Engage locating pins on front of airbox cover with

tabs on frame.

See Figure

7-1. Connect console connector halves

together.

Lower rear of airbox cover onto frame and latch in place.

Close and lock seat.

1. Engine coolant temperature

2. Check engine

3. Low fuel

4. Alternator

5. Security system

6. Odometer/trip odometer

7. Fuel gauge

8. Left turn signal

9. High beam

10. Clock

11. Neutral

12. Oil

13. Right turn signal

Figure 7-2. VRSCSE Indicator Lamps and Displays

7-2

2005 PDI: CVO Models

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Shift transmission to neutral position, and verify that neu-

ADJUSTING HANDLEBAR

tral indicator lamp turns on.

CONTROLS

Start engine; check operation of starter.

Check that oil pressure indicator lamp (12) turns off

If handlebar controls and clutch and brake lever assemblies

when engine is running above 1200 RPM. Check that

are incorrectly positioned, they may be rotated slightly for

battery icon (4) turns off. Engine Coolant temperature

more comfortable riding position.

icon (1) must not illuminate.

Check that tachometer is functioning.

CAUTION

Disengage clutch (squeeze clutch lever), and verify that

neutral indicator lamp (11) turns off when transmission is

Do not rotate front brake lever assembly too far. Brake

shifted to any forward gear. Shift transmission to neutral

master cylinder fits into a machined relief in handlebar. If

position, and verify that neutral indicator lamp turns on

not properly located in the machined relief, master cylin-

again.

der can be damaged when clamp screws are tightened.

Handlebar surface contains range marks to properly

Check horn operation.

locate brake and clutch master cylinder and control

Check operation of all remaining lamps:

assemblies. These assemblies MUST be located within

● headlamp-low and high beams

that range.

● headlamp high beam indicator lamp (9)

To adjust handlebar controls, proceed as follows:

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

See Figure 7-3. Loosen (but do not remove) brake and

clutch lever assembly clamp screws (1) and handlebar

● Ieft directional (turn signal) indicator lamp (8)

switch housing screws (2).

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

● right directional (turn signal) indicator lamp (13)

d0419x1x

● Ieft front running lamp

● right front running lamp

● tail lamp-running lamp and brake lamp filaments

After engine has reached normal operating temperature,

turn engine off.

10.

Check engine oil level in manner previously specified.

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

CAUTION

Front brake lever assembly clamp screw (2)

Handlebar switch housing screw (2)

To avoid over-filling the oil sump, wait approximately

three minutes after adding oil before checking the oil

Figure 7-3. Handlebar Lever and Control

level with the dipstick. An over-filled sump can cause

Mounting Screws (Right Side Shown)

engine damage. (00188a)

See Figure 7-4. Range marks (4) are located on bottom

of handlebar adjacent to brake lever clamp assembly.

ADJUSTING HANDLEBARS

Rotate right control and brake master cylinder assembly

(2) slightly for most comfortable position. Make sure

The VRSCSE is shipped with the handlebars adjusted to a

control assembly is positioned so that clamp mating sur-

standard riding position. If handlebars need to be adjusted for

face (3) is located in area between range marks.

more comfortable rider position, proceed as follows:

1. Loosen, but do not remove, all four handlebar riser clamp

screws.

2. Raise or lower handlebars to desired position. Make cer-

tain handlebars are centered side-to-side in risers.

3. Tighten two front handlebar clamp screws until top and

bottom risers meet (no gap in front). DO NOT tighten

screws to more than 20.3 Nm (15 ft-lbs).

4. Tighten rear handlebar clamp screws to 16.3-20.3 Nm

(12-15 ft-lbs).

5. Final tighten front handlebar clamp screws to 16.3-20.3

Nm (12-15 ft-lbs).

2005 PDI: CVO Models

7-3

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Check Hose Clamps For Tightness

CAUTION

See Figure 7-5. If necessary, remove four screws (1) and

Control wiring is routed inside handlebar and may be

decorative cover (2) from water pump hose.

pinched or cut if controls are rotated too far.

Check the four hose clamps (two each on hoses) for

3. Beginning with top screw, tighten right lever assembly

tightness.

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

If removed, install decorative cover with four screws.

Beginning with lower screw, tighten right handlebar

Tighten screws to 1.1-1.4 Nm (10-12 in-lbs).

switch housing screws to 4.0-5.1 Nm (35-45 in-lbs).

With a long bladed screwdriver check two hose clamps

one at top left and one at top right of radiator.

NOTE

pd0214a

The engine ends of the radiator hoses are secured with a

plastic “shrink” clamp and do not require checking.

10770

1. Handlebar

2. Right control and brake lever assembly

3. Control assembly clamp mating surface

4. Range marks

Figure 7-4. Right Handlebar Control Assembly

(Bottom View)

Screw (4)

Decorative hose cover

Orient the left handlebar control assembly to match the

position of the right handlebar control assembly.

Figure 7-5. Coolant Hose Cover (Engine right side)

CAUTION

Control wiring is routed inside handlebar and may be

pinched or cut if controls are rotated too far.

6. Beginning with top screw, tighten left lever assembly

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

Beginning with lower screw, tighten left handlebar switch

housing screws to 4.0-5.1 Nm (35-45 in-lbs).

Test handlebar switches to make sure they are function-

ing properly and wiring has not become pinched or oth-

erwise damaged.

7-4

2005 PDI: CVO Models

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CHECKING CLUTCH FLUID

8834

CAUTION

D.O.T. 5 silicone hydraulic brake fluid is used in the

hydraulic clutch. Do not use other types of fluids as they

are not compatible and could cause equipment damage.

(00204a)

CAUTION

Do NOT allow foreign matter to enter the clutch master

cylinder reservoir. dirt or debris in the reservoir may

cause improper operation of the clutch and equipment

damage.

1CAUTION

Figure 7-6. Clutch Master Cylinder Reservoir

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

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

Stand the motorcycle upright (not leaning on the jiffy

In case of eye contact flush with large amounts of water

stand) on a level surface. Turn the handlebars to the right

and get medical attention. Swallowing large amounts of

if necessary, so the top of the clutch master cylinder res-

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

ervoir is level.

swallowed, obtain medical attention. Use in well venti-

View reservoir sightglass on reservoir cover and verify

lated area. KEEP OUT OF REACH OF CHILDREN.

fluid presence. Sightglass should appear dark if fluid is

(00144a)

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

The clutch is hydraulically actuated. See Figure 7-6. The

Service Manual. Use only D.O.T. 5 SILICONE HYDRAU-

clutch master cylinder fluid reservoir is located on the left

LIC BRAKE FLUID (Part No. 99902-77: 12 oz., 99901-

handlebar.

77: 1 gal.).

2005 PDI: CVO Models

7-5

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MIRRORS AND TURN SIGNALS

pd0208

The mirrors are enclosed in a box in the crate. Install mirrors

and adjust for proper rear view as follows:

1. See Figure 7-7. Place spacer (10) onto right side mirror

stem, slide mirror stem down through hole in front brake

master cylinder assembly and right turn signal bracket

(5). Install lockwasher (8) and screw on acorn nut (7) fin-

ger tight.

2. In the same fashion, install left side mirror assembly.

3. Adjust mirrors so a small portion of the rider’s shoulder is

visible in each mirror. This helps establish the relative

distance of vehicles to the rear of the motorcycle.

4. Tighten acorn nuts to 6.8-9.0 Nm (60-96 in-lbs).

5. To adjust turn signals:

a. Loosen set screws (9) approximately 1/8 turn.

NOTE

It is not necessary, nor desirable, to completely remove set

screw to re-adjust turn signal housing. It is only necessary to

loosen set screw 1/8 turn, adjust turn signal and re-tighten set

screw. Nylon lock pellet on set screw maintains locking ability

after many loosening/tightening cycles. If set screw is com-

pletely removed, it should be replaced.

b. Position front turn signal housings (1, 2) evenly with

lenses pointing straight ahead.

c. Tighten each set screw to 5.7-6.8 Nm (50-60 in-

Right turn signal housing

lbs).

Left turn signal housing

Jam nut (2)

Ball stud (2)

SEATS AND PASSENGER STRAP

Right turn signal bracket

Left turn signal bracket

Refer to VRSC Models Owner’s Manual for seat and passen-

Acorn nut (2)

ger strap removal and installation instructions.

Lockwasher (2)

Set screw (2)

10.

Spacer (2)

11.

Clutch control housing

12.

Brake control housing

13.

Mirror stem (2)

Figure 7-7. Turn Signals

7-6

2005 PDI: CVO Models

Harley Davidson 2005 MOTORCYCLE. PREDELIVERY AND SETUP MANUAL - page 5