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Harley Davidson 2005 MOTORCYCLE. PREDELIVERY AND SETUP MANUAL - page 6

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FOOTREST ADJUSTMENT

FINAL PREDELIVERY INSPECTIONS

If it is necessary to rotate rider or passenger footrests for cus-

CAUTION

tomer comfort, proceed as follows:

Do not use sharp objects to peel protective film from

1. See Figure 7-8. Remove screw (2) and footrest rubber

console insert and clutch release cover in the next two

insert (3) from footrest assembly (1).

steps. Sharp objects can scratch and damage finished

surfaces.

2. See Figure

7-9. Loosen footrest adjustment screw.

Rotate footrest assembly to desired angle. Tighten screw

1. The airbox console insert is protected during shipment

to 25.8 Nm (19 ft-lbs).

by a clear plastic film. Carefully peel the film away from

the console insert.

3. See Figure 7-8. Reinstall rubber insert (3) into footrest

2. The clutch release cover (righthand side of engine) is

assembly (1) and secure with screw (2). Tighten to 4.0-

protected during shipment by a clear plastic film. Care-

6.0 Nm (35-53 in-lbs).

fully peel the film away from the clutch release cover.

NOTE

Perform all the remaining Predelivery Inspections given in

10772

Section I (All Models) and Section VI (VRSC Models) that

3

apply to the VRSCA.

DO NOT REPEAT INSPECTIONS THAT WERE PER-

1

FORMED IN THIS SECTION.

2

1.

Footrest assembly

2.

Screw

3.

Rubber insert

Figure 7-8. Removing Footrest Rubber Insert

10773

Figure 7-9. Footrest Adjustment Screw

2005 PDI: CVO Models

7-7

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FLHTCSE² MODEL

7.2

GENERAL

ADJUSTING HANDLEBAR

CONTROLS

CAUTION

The FLHTCSE² model is shipped from the factory with

CAUTION

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

Control wiring is routed inside handlebar and may be

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

pinched or cut if controls are rotated too far.

NOT use standard lubricants and do not mix lubricants

as damage to the motorcycle can result.

CAUTION

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

(Touring Models) and the following instructions to perform the

Do not rotate front brake or clutch master cylinder

predelivery setup procedure on the FLHTCSE² model.

assemblies too far. If not properly located, master cylin-

der can be damaged when clamp screws are tightened.

This motorcycle is equipped with the Harley Davidson Fac-

Handlebar surface contains range marks to properly

tory Security System and siren.

locate brake and clutch master cylinder and control

NOTE

assemblies. These assemblies MUST be located within

FLHTCSE² models sold in the Australian market are not

that range.

equipped with a siren.

If necessary, adjust handlebar controls as follows:

1. See Figure 7-10. Loosen (but do not remove) front brake

UNCRATING

lever assembly clamp screws (1) and handlebar switch

housing screws (2).

CAUTION

f1993x8x

Roll motorcycle rearward off pallet slowly to avoid strik-

ing the oil cooler on the skid and causing damage to the

2

motorcycle.

Check Contents of Crate

Verify that the following items have been included:

NOTE

Keep garage door opener receiver with vehicle for delivery to

1

customer.

1. The following items are shipped in the Tour-Pak^® and

1.

Front brake lever assembly clamp screw (2)

saddlebags:

2.

Handlebar switch housing screw (2)

● Tour-Pak mounting hardware kit

Figure 7-10. Handlebar Lever and Control

● Tour-Pak support tube

Mounting Screws (Right Side Shown)

● Garage door opener receiver

● Wind deflector

● Tool pouch

● Maxi-Fuse and cover

● Data link plug

● Keys (including CVO key)

● Motorcycle cover

● Owner’s kit (including owner’s manual cover for vehi-

cles sold in domestic markets only).

● Antenna (shipped by right floorboard)

● Key fobs

● Leather care

● Saddlebag liners

● Tour-Pak liner

● Passenger backrest (detachable sissy bar)

2. A rider backrest is mounted on the vehicle.

NOTE

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

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

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

7-8

2005 PDI: CVO Models

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2. See Figure 7-11. Range marks (4) are located on bottom

CHECKING CLUTCH FLUID

of handlebar adjacent to front brake lever clamp assem-

bly. Rotate switch housing and front brake master cylin-

der assembly (2) slightly for most comfortable position.

CAUTION

Make sure control assembly is positioned so that clamp

mating surface (3) is located in area between range

D.O.T. 4 hydraulic brake fluid is the only type of fluid that

marks.

should be used in the hydraulic clutch. Do not use other

3. Beginning with top screw, tighten assembly clamp

types of fluid as they are not compatible and could cause

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

equipment damage.

4. Beginning with lower screw, tighten handlebar switch

housing screws to 35-45 in-lbs (4-5 Nm).

CAUTION

5. Repeat steps 1-4 above for clutch master cylinder and

Do NOT allow foreign matter to enter the clutch master

switch housing assemblies on left handlebar.

cylinder reservoir. dirt or debris in the reservoir may

6. Test handlebar switches to make sure they are function-

cause improper operation of the clutch and equipment

ing properly and wiring has not become pinched or oth-

damage.

erwise damaged.

CAUTION

pd0224

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

2

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

1

tion and protect surfaces from spills whenever brake

3

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

metic damage. (00239a)

1CAUTION

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

4

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)

The clutch is hydraulically actuated. See Figure 7-12. The

1. Handlebar

clutch master cylinder fluid reservoir is located on the left

2. Right control and brake lever assembly

handlebar.

3. Control assembly clamp mating surface

4. Range marks

Figure 7-11. Handlebar Control Assembly

8834

(Bottom View, Right Side Shown)

MIRRORS

Mirrors are installed on motorcycle and are rotated upside

down for shipping. Remove mirrors, re-install in correct orien-

tation and adjust for proper rear view. See Touring Models

Service Manual for mirror installation procedure.

Figure 7-12. Clutch Master Cylinder Reservoir

2005 PDI: CVO Models

7-9

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1. Stand the motorcycle upright (not leaning on the jiffy

3. See Figure 7-16. Place Tour-Pak on its front surface on a

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

clean, soft cloth or mat, being careful not to damage

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

painted surfaces.

ervoir is level.

4. See Figure 7-17. Locate five screws (1), ten washers (2),

2. View reservoir sightglass on reservoir cover and verify

five saddle spacers

(4), five locknuts

(6), removable

fluid presence. Sightglass should appear dark if fluid is

mounting bracket (5) and support tube (3).

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

Service Manual. Use only D.O.T. 4 HYDRAULIC BRAKE

FLUID (Part No. 99953-99A). Wash all residue of D.O.T.

10681

4 brake fluid spills off vehicle with water.

2

REMOVABLE RIDER BACKREST

Rider backrest is installed on seat at factory. Refer to

FLHTCSE² Owner’s Manual for backrest and seat removal/

installation instructions.

WIND DEFLECTOR

1

The wind deflector is shipped in the saddlebag. Unpack and

mount on vehicle following the INSTALLING WINDSHIELD

1.

Tour-Pak bracket mounts

Section of the Touring section.

2.

Passenger backrest mounts

Figure 7-13. Passenger Backrest and Tour-Pak

REMOVABLE TOUR-PAK

Docking Locations

See Figure 7-13. The Tour-Pak assembly mounts on the two

rear mounting points (1) on each side of the vehicle.

10692

NOTE

Assembly of the Tour-Pak to its mounting bracket is facilitated

with the help of an assistant.

1. See Figure 7-14. The FLHTCSE² is shipped with the

Tour-Pak (1) mounted forward of its normal mounting

position, on the removable mounting bracket (2) with a

cardboard shipping spacer (3) in between Tour-Pak and

1

mounting bracket. This temporary mounting allows

2

motorcycle to fit in shipping crate.

2. Open Tour-Pak lid and remove three long screws, wash-

ers and nuts that secure Tour-Pak to removable mount-

ing bracket. Remove and discard long screws, washers,

3

nuts and cardboard shipping spacer.

NOTE

1.

Tour-Pak

See Figure 7-15. Removable mounting bracket has two sets

2.

Removable mounting bracket

of holes for mounting Tour-Pak. The rear set of holes will be

3.

Cardboard shipping spacer

used to mount the Tour-Pak.

Figure 7-14. Tour-Pak Mounting Assembly as Shipped

CAUTION

When assembling Tour-Pak and mounting bracket, be

careful to avoid damaging painted surfaces.

7-10

2005 PDI: CVO Models

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10767

pd0222

Mount Tour-Pak

in rear holes

1

2

Figure 7-15. Removable Mounting Bracket

3

10704

4

5

6

Figure 7-16. Positioning Tour-Pak for Assembly

1.

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

2.

Washer 1/4 in. inside dia. (10)

3.

Support tube

4.

Saddle spacer (5)

5.

Removable mounting bracket

6.

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

Figure 7-17. Tour-Pak Mounting

2005 PDI: CVO Models

7-11

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5. See Figure 7-18. Insert one screw with washer through

10768

rear-most hole in Tour-Pak. Slide support tube onto

screw.

2

6. Install one saddle spacer onto screw with curved surface

of spacer facing support tube. Install washer and locknut.

Finger-tighten locknut only.

7. Install screws and washers in other four locations,

3

through Tour-Pak and support tube. Install saddle spac-

ers on screws with curved surface of each spacer facing

4

support tube.

8.

See Figure 7-19. Slide removable mounting bracket (1)

onto screws with bracket latches facing rear of Tour-Pak.

9. Install washers and locknuts

(2,

3). Tighten all five

screws and locknuts to 96-120 in-lbs (10.8-13.5 Nm).

10. See Figure 7-13. Install Tour-Pak on Tour-Pak bracket

mounts (1) and lock latches in place.

11. See Figure

7-20. Locate Tour-Pak power connector

1

between seat and fender strut cover on left side of motor-

cycle.

5

1.

Removable mounting bracket

10705

2.

Screw and locknut (4)

4

1

3.

Washer (4)

4.

Saddle spacer (4)

5.

Tour-Pak (front surface facing down)

Figure 7-19. Removable Mounting Bracket

10688

2

3

5

1. Support tube

2. Saddle spacer

Figure 7-20. Tour-Pak Power Connector

3. Screw and locknut

4. Washer

5. Tour-Pak (front surface facing down)

Figure 7-18. Mounting Support Tube

7-12

2005 PDI: CVO Models

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12. See Figure 7-21. Plug Tour-Pak harness into power con-

nector and tuck cable assembly between seat and fender

pd0220

strut cover.

10689

Figure 7-22. Coaxial Adapter

10690

10678

1

2

Figure 7-21. Connecting Tour-Pak Power Cable

3

NOTE

See Figure 7-22. With the radio antenna mast mounted on

the Tour-Pak antenna mount, the coaxial adapter shown in

10679

the figure allows connecting the antenna cable to the chassis

antenna mount. With Tour-Pak removed, the adapter may be

removed and antenna mast threaded directly onto the chas-

sis antenna mount.

13. See Figure 7-23. Make certain that coaxial adapter (2) is

securely finger-tightened into the antenna chassis mount

(3).

14. Pull enough coaxial cable from Tour-Pak to reach coaxial

adapter on antenna chassis mount, allowing for a small

amount of slack in cable.

15. Screw coaxial cable connector (1) into coaxial adapter

on antenna chassis mount. Finger-tighten securely.

1.

Coaxial connector

2.

Coaxial adapter

3.

Antenna chassis mount

Figure 7-23. Connecting Antenna Cable

(Tour-Pak Installed)

2005 PDI: CVO Models

7-13

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RADIO ANTENNA

10681

See Figure 7-24. Screw antenna (1) into antenna mount (2)

1

on Tour-Pak and tighten set screw with allen wrench (3).

10680

2

1

1.

Passenger backrest mounts

2.

Tour-Pak bracket mount

Figure 7-25. Passenger Backrest and Tour-Pak

Docking Locations

2

10707

3

1. Antenna

2. Antenna Tour-Pak mount

1

3. Allen wrench

Figure 7-24. Installing Antenna on Tour-Pak

REMOVABLE PASSENGER

2

BACKREST

See Figure 7-25. The passenger backrest assembly mounts

on the two forward mounting points (1) on each side of the

vehicle when the Tour-Pak is not installed.

Since the vehicle will ordinarily be delivered to the customer

with the Tour-Pak installed, store the removable passenger

1. Rear latch (2)

backrest inside the Tour-Pak and deliver to customer with

2.

“C” bracket guides (2)

vehicle.

Figure 7-26. Passenger Backrest

NOTE

Retain protective cardboard packaging for passenger back-

rest. Secure backrest in Tour-Pak to prevent damage to back-

rest assembly and interior of Tour-Pak.

7-14

2005 PDI: CVO Models

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DELIVERING VEHICLE WITH

10675

REMOVABLE PASSENGER

1

BACKREST INSTALLED

If the customer wishes the vehicle to be delivered with the

removable passenger backrest (see Figure 7-26.) installed on

the vehicle instead of the Tour-Pak, follow the instructions

below.

Passenger Backrest

NOTE

If the Tour-Pak is installed on the vehicle, it must be removed.

See Figure 7-25. Mount the passenger backrest assembly on

the two forward mounting points (1) on each side of the vehi-

10676

cle.

Radio Antenna

NOTE

See Figure 7-27. With the antenna mast mounted on the

2

Tour-Pak antenna mount, the coaxial adapter shown in the

figure allows connecting the antenna cable to the chassis

antenna mount. With Tour-Pak removed, the adapter may be

removed and antenna mast threaded directly onto the chas-

sis antenna mount.

pd0220

10677

Figure 7-27. Coaxial Adapter

3

4

1.

See Figure 7-28. Unscrew coaxial adapter

(1) from

antenna chassis mount. Place coaxial adapter in Tour-

Pak and deliver to customer with vehicle.

2.

Screw antenna (3) onto chassis mount and tighten set

screw with allen wrench (4).

1. Coaxial adapter

2. Antenna chassis mount

3. Antenna

4. Allen wrench

Figure 7-28. Installing Antenna (Tour-Pak Removed)

2005 PDI: CVO Models

7-15

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FLSTFSE MODEL

7.3

3. Tighten two front handlebar clamp screws until top and

GENERAL

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

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

CAUTION

4. Tighten rear handlebar clamp screws to 12-15 ft-lbs

(16.3-20.3 Nm).

The FLSTFSE model is shipped from the factory with

5. Final tighten front handlebar clamp screws to 12-15 ft-lbs

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

(16.3-20.3 Nm).

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

NOT use standard lubricants and do not mix lubricants

as damage to the motorcycle can result.

10762

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

(Softail Models) and the following instructions to perform the

predelivery setup procedure on the FLSTFSE model.

This motorcycle is equipped with the Harley Davidson Fac-

tory Security System and siren.

UNCRATING

See Figure 7-29. The FLSTFSE is shipped in a “turn-wheel”

crate which allows the handlebar to be shipped in position on

the handlebar risers.

Check Contents of Crate

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

● Seat

● Motorcycle cover

● Owner’s kit

Figure 7-29. FLSTFSE Shipped in Turn-Wheel Crate

● Right mirror

NOTES

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

717-852-6717. Provide your Dealer name, number, per-

10763

son to contact, part number of missing item, and Motor-

cycle VIN.

● See Figure

7-30. After crating straps have been

removed, make sure to remove the plastic crating strap

bracket from the vehicle.

ADJUSTING HANDLEBARS

The FLSTFSE is shipped with the handlebars adjusted to a

standard riding position. If handlebars need to be adjusted for

more comfortable rider position, proceed as follows:

Figure 7-30. Plastic Crating Strap Bracket

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.

2005 PDI: CVO Models

7-17

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ADJUSTING HANDLEBAR

d0419x1x

CONTROLS

2

If handlebar controls and clutch and brake lever assemblies

are incorrectly positioned, they may be rotated slightly for

more comfortable riding position.

CAUTION

1

Do not rotate front brake lever assembly too far. Brake

master cylinder fits into a machined relief in handlebar. If

1. Front brake lever assembly clamp screw (2)

not properly located in the machined relief, master cylin-

2. Handlebar switch housing screw (2)

der can be damaged when clamp screws are tightened.

Handlebar surface contains range marks to properly

Figure 7-31. Handlebar Lever and Control

locate brake and clutch master cylinders and control

Mounting Screws (Right Side Shown)

assemblies. These assemblies MUST be located within

that range.

To adjust handlebar controls, proceed as follows:

pd0214a

2

1.

See Figure 7-31. Loosen (but do not remove) brake and

1

clutch lever assembly clamp screws (1) and handlebar

3

switch housing screws (2).

2.

See Figure 7-32. Range marks (4) are located on bottom

of handlebar adjacent to brake lever clamp assembly.

Rotate right control and brake master cylinder assembly

(2) slightly for most comfortable position. Make sure

control assembly is positioned so that clamp mating sur-

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

4

CAUTION

Control wiring is routed inside handlebar and may be

pinched or cut if controls are rotated too far.

3. Beginning with top screw, tighten right lever assembly

1.

Handlebar

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

2.

Right control and brake lever assembly

4. Beginning with lower screw, tighten right handlebar

3.

Control assembly clamp mating surface

switch housing screws to 35-45 in-lbs (4-5 Nm).

4.

Range marks

5.

Orient the left handlebar control assembly to match the

position of the right handlebar control assembly.

Figure 7-32. Right Handlebar Control Assembly

(Bottom View)

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

7. Beginning with lower screw, tighten left handlebar switch

housing screws to 35-45 in-lbs (4-5 Nm).

8.

Test handlebar switches to make sure they are function-

ing properly and wiring has not become pinched or oth-

erwise damaged.

7-18

2005 PDI: CVO Models

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CHECKING CLUTCH FLUID

MIRRORS AND TURN SIGNALS

The right mirror is enclosed in a box in the crate. Install mirror

CAUTION

and adjust for proper rear view as follows:

1. See Figure 7-34. Place spacer (10) onto right side mirror

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

stem, slide mirror stem down through hole in front brake

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

master cylinder assembly and right turn signal bracket

are not compatible and could cause equipment damage.

(00204a)

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

ger tight.

2. Adjust both mirrors so a small portion of the rider’s shoul-

CAUTION

der is visible in each mirror. This helps establish the rela-

Do NOT allow foreign matter to enter the clutch master

tive distance of vehicles to the rear of the motorcycle.

cylinder reservoir. dirt or debris in the reservoir may

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

cause improper operation of the clutch and equipment

4. To adjust turn signals:

damage.

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

1CAUTION

pd0213

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

10

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

In case of eye contact flush with large amounts of water

11

2

and get medical attention. Swallowing large amounts of

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

swallowed, obtain medical attention. Use in well venti-

4

6

lated area. KEEP OUT OF REACH OF CHILDREN.

10

(00144a)

9

The clutch is hydraulically actuated. See Figure 7-33. The

12

clutch master cylinder fluid reservoir (1) is located on the left

handlebar.

3

5

8

8834

7

1

9

4

8

3

7

1.

Right turn signal housing

2.

Left turn signal housing

3.

Jam nut (2)

4.

Ball stud (2)

5.

Right turn signal bracket

6.

Left turn signal bracket

7.

Acorn nut (2) @ 60-96 in-lbs (6.8-9.0 Nm)

8.

Lockwasher (2)

9.

Set screw (2) @ 50-60 in-lbs (5.7-6.8 Nm)

Figure 7-33. Clutch Master Cylinder Reservoir

10.

Spacer (2)

11.

Clutch control housing

1.

Stand the motorcycle upright (not leaning on the jiffy

12.

Brake control housing

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

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

Figure 7-34. Turn Signals

ervoir is level.

2.

View reservoir sightglass on reservoir cover and verify

fluid presence. Sightglass should appear dark if fluid is

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

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

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

77: 1 gal.).

2005 PDI: CVO Models

7-19

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NOTE

10766

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

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

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

setscrew. Nylon lock pellet on setscrew maintains locking

ability after many loosening/tightening cycles. If setscrew is

1

completely 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

50-60 in-lbs (5.7-6.8

2

Nm).

FUEL TANK CONSOLE EXTENSION

3

See Figure 7-35. Remove screw (2) from fuel tank mounting

tab. Insert screw through hole in rear end of fuel tank console

extension (1) and screw into fuel tank mounting tab. Tighten

1.

Fuel tank console extension

securely.

2.

Mounting screw

3.

Seat mounting channel

SEAT

Figure 7-35. Fuel Tank Console Extension

Remove seat and mounting screw from carton. See Figure 7-

FINAL PREDELIVERY INSPECTIONS

35. Place tang on front underside of seat into channel in

frame (3). Slide seat forward into place. Secure with mounting

Perform all the remaining Predelivery Inspections given in

screw into rear fender.

Section I (All Models) and Section IV (Softail Models) that

apply to the FLSTF model.

NOTE

Do not remove the clutch cover. It is not necessary to check

the primary chaincase lubricant level on the FLSTFSE. Also,

the hydraulic clutch is not adjustable.

DO NOT REPEAT INSPECTIONS THAT WERE PER-

FORMED IN THIS SECTION.

7-20

2005 PDI: CVO Models

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