Harley-Davidson Sportster (2005) manual

D YNA III T OURING II GENERAL I SOFT AIL IV SPOR TSTER V VRSC VI CV O VII 2005 HARLEY-D A VIDSON MO T ORCYCLE PREDELIVER Y AND SETUP MANU AL The information in this Manual applies to all 2005 motorcycle models manufactured by Harley-Davidson Motor Company . © 2004 H-D All RIGHTS RESER VED Printed in the U.S.A. VISIT THE HARLEY-D A VIDSON WEB SITE [...]

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iii FOREW ORD INTR ODUCTION This PREDELIVER Y AND SETUP MANUAL has been pre- pared by Harley-Da vidson Motor Company to provide the Harley-Davidson dealer with the f actor y recommended steps needed to prepare our motorcycles f or delivery to the cus- tomer . NO TE Harley-Davidson Motor Compan y considers the predeliv er y inspections and procedure[...]

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v T ABLE OF CONTENTS SECTION SUBJECT P AGE NUMBER IG eneral Information: All Models 1-1 II Predelivery Inspections: Touring Models 2-1 III Predelivery Inspections: Dyna Models 3-1 IV Predelivery Inspections: Softail Models 4-1 VP redelivery Inspections: Sportster Models 5-1 VI Predelivery Inspections: VRSC Models 6-1 VII Predelivery Inspections: CV[...]

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SUBJECT P AGE NO . 1.1 Uncrating and General Setup: All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Vehicle Crate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Uncrating Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Remo[...]

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2005 PDI: All Models 1-1 UNCRA TING AND GENERAL SETUP: ALL MODELS 1.1 VEHICLE CRA TE INSPECTION Inspect each crate f or e xternal damage while it is still on delivery truck. Open crate and inspect motorcycle f or damage bef ore truck leav es your dealership. Ref er to HARLEY - DA VIDSON/BUELL W ARRANTY MANUAL, “SHIPPING D AMA GE PROCEDURE” for [...]

1-2 2005 PDI: All Models NO TE Alwa ys install/adjust handlebars before removing motorcycle from pallet. See HANDLEBAR INST ALLA TION–FLSTSC, FLSTN AND FXD WG MODELS a nd ADJUSTING HANDLE- BARS– ALL MODELS . 5. If uninstalled par ts are in crate , verify your receipt of all separate items b y comparing with par ts list in shipping crate. 6. If [...]

2005 PDI: All Models 1-3 FLSTN After removing carton and protective plastic wrap: 1. See Figure 1-6. Remove and discard cloth tie (3) secur- ing handlebar . 2. Remov e the riser bolts (2) and shipping clamp (1) from handlebar risers. Retain the bolts. Remov e and discard protective b lock (4) from right handlebar grip. 3. Route handlebar s witch co[...]

1-4 2005 PDI: All Models FXD WG After removing carton and protective plastic wrap: 1. See Figure 1-8. Remove and discard cloth tie (1) secur- ing handlebar . 2. Remov e the f our bolts (2) from the riser . Retain the four bolts. 3. Reroute the left hand s witch wire conduit from between the riser to a position in front of the r iser . 4. Retriev e [...]

2005 PDI: All Models 1-5 CA UTION See Figure 1-9. Attach brake line as shown bef ore remov- ing motorc ycle fr om pallet. If brake line is not secured, it could be pinched and damaged in fr ont fork stop. 8. Attach brak e line to bottom of steering stem with clamp (4) and screw (5). Tighten to 96-120 in-lbs ( 10.9-13.6 Nm). 9. See Figure 1-8. Remov[...]

1-6 2005 PDI: All Models XL 883C and XL 1200C Models 1. See Figure 1-11. Loosen four scre ws (1, 2) of handlebar upper clamp (3). ). 2. T o be sure handlebars are properly centered, verify that equal amounts of knurled areas on handlebar protrude from outboard sides of upper handlebar clamp . NO TE On some models, knurled areas of handlebar will be[...]

2005 PDI: All Models 1-7 FLHR/C/S/I Road King, FLHP , FLHPE 1. See Figure 1-13. Remove scre w (12) securing chrome ri ng (11) to headlamp nacelle (7). Remov e chrome r ing. 2. Remov e eight screws (10) securing headlamp assemb ly (9). Squeeze two e xter nal tabs (if present) to remov e wire connector at back of headlamp b ulb . Remov e head- lamp a[...]

1-8 2005 PDI: All Models FL TR Road Glide 1. See Figure 1-14. Remov e two T25 TORX scre ws at sides of instrument bezel. 2. Carefully push tab at rear of instrument bezel from slot abov e ignition s witch. Gently raise free side of bezel until tabs at front of instrument nacelle disengage from slot at front of bezel (concealed behind decorativ e ad[...]

2005 PDI: All Models 1-9 VRSCB NO TE To gain access to the handlebar adjusting screws, the f ollow- ing steps will be necessar y: 1. Remov e Maxi-Fuse. 2. See Figure 1-16. Remov e instr ument cluster screw from location shown and piv ot instrument cluster awa y from handlebars. 3. Remov e wiring har ness connector and remov e screw on bottom side o[...]

1-10 2005 PDI: All Models REMO VING VEHICLE FROM P ALLET All Models 1 W ARNING 1 W ARNING Alwa ys have someone stead y motorcyc le while each strap is being removed to pre vent tipping. Motorc ycle front suspension is secured in a compressed state b y two n ylon straps. Releasing strap tension on one side of motorc ycle could result in the fr ont o[...]

2005 PDI: All Models 1-11 2. See Figure 1-20. Place a 2x4 in. (50.8x101.6 mm) board between steel cross braces (see arro w) behind front tire to aid rolling motorcycle rearward off pallet. 3. Carefully roll vehicle off pallet. 1 W ARNING 1 W ARNING Alwa ys park motorc ycle on a level, firm surface. An unbalanced motorc ycle can fall o ver which co[...]

1-12 2005 PDI: All Models CLUTCH HAND LEVER NO TE ● See Figure 1-21. A ll Dyna models hav e Maxi-Fuse wrapped in plastic wrapping around clutch hand le ver and left handlebar grip . ● See Figure 1-22. See Figure 1-23. All Sportster models hav e Maxi-Fuse and headlamp snap cap fitted into pro- tective f oam on clutch hand lev er and left handle[...]

2005 PDI: All Models 1-13 FR ONT BRAKE HAND LEVER If handlebar controls need to be adjusted, perf or m the f ollow- ing procedure. 1. See Figure 1-25. Loosen, but do not remo ve , front brak e master cylinder clamp screws (1) and handlebar s witch housing clamp screws (2). 2. Rotate master cylinder housing and handlebar s witch housing as necessar [...]

1-14 2005 PDI: All Models VEHICLE CLEANUP 1 W ARNING 1 W ARNING Do not let the brakes, engine, muffler s or air cleaner get wet when washing your motor cycle. Allo wing these com- ponents to get too wet can adversel y affect their perf or- mance, which could result in death or serious injury . Start engine immediately after washing, and make sure [...]

2005 PDI: All Models 1-15 MAINTENANCE-FREE B A TTERIES All models are equipped with maintenance-free batteries that are permanently sealed, valve-regulated, lead/calcium and sulfuric acid electrolyte batter ies . The electrolyte is immobi- lized in a glass fibre separator . Therefore, the batteries are identified as “T ype AGM” which is the a[...]

1-16 2005 PDI: All Models DA TE OF MANUF A CTURE CODE See Figure 1-29. The battery date code stick er has a number and two letters. The number signifies the year the battery was manuf actured. 9 – 1999 0 – 2000 1 – 2001 2 – 2002 3 – 2003 4 – 2004 5 – 2005 The letters signify the month the batter y w as activated. J A–J anuary MY–[...]

2005 PDI: All Models 1-17 NO TE The figures listed abov e assume that the battery is charging at room temperature. If wa r mer than room temperature , use a slightly shor ter charging time. If colder , use a slightly longer charging time. NO TE The use of constant current chargers to charge sealed main- tenance-free batteries is not recommended. A[...]

1-18 2005 PDI: All Models W ARNING LABEL PLA CEMENT (ALL VEHICLES SOLD OUTSIDE OF THE UNITED ST A TES) All dealers outside of the United States are required to apply a warning label to the vehicle in the local language of the cus- tomer . A sheet of warning labels (P ar t No . 99942-05) is pro- vided in the Owner’ s Kit. Apply the appropriate loc[...]

2005 PDI: All Models 1-19 SYSTEM PR OBLEMS 1.2 GENERAL All system problems f all into at least one of three general cat- egories. No Start The engine cranks ov er freely , but will not start. This does not include situations where the engine will not crank, such as a security disabled star ter , dead batter y , etc. This condition assumes that all [...]

1-20 2005 PDI: All Models NO TES[...]

SUBJECT P AGE NO . 2.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2005 Touring Models Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

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2005 PDI: T ouring Models 2-1 SPECIFICA TIONS 2.1 T ORQUE V ALUES The f ollowing torque v alues are included f or fasteners that ma y be loosened and tightened during Predelivery and Setup . Any f asteners that are not loosened/remov ed do not need to be check ed during predelivery and setup. 2005 T OURING MODELS SPECIFICA TIONS Idle Speed: 950 RPM[...]

2-2 2005 PDI: T ouring Models INITIAL ASSEMBL Y 2.2 BA TTER Y TESTING AND CHARGING 1 W ARNING 1 W ARNING Batteries contain sulfuric acid, which could cause se vere bu rns to eyes and skin. Wear a pr otective face shield, rubberized gloves and pr otective clothing when w orking with batteries. KEEP B A TTERIES A W A Y FROM CHIL- DREN. (00063a) 1 W A[...]

2005 PDI: T ouring Models 2-3 INST ALLING D A T A LINK CONNECT OR See Figure 2-1. The data link connector [91] (2) mounts in a clip on the electrical brack et (1) under the right side cover . Cut the cable tie securing the data link connector harness to the frame and snap the connector into its clip on the electrical brac ket. INST ALLING T OUR-P A[...]

2-4 2005 PDI: T ouring Models 5. See Figure 2-3. Remov e and discard the pushnuts (5) from the mounting bolts (1), and pull the bolts (1) and w ashers (2) from the luggage rac k (although the spacers (4) ma y be left in place between the top suppor t tube (3) and the license plate brac ket). 6. Locate P ar ts kit, P ar t no. 53318-99 in T our-Pak o[...]

2005 PDI: T ouring Models 2-5 Figure 2-4. T our -Pak Mounting Bottom view showing spacer (4) between license plate bracket (5) and top support tube (3). 1. Bolt, 1/4-20 x 2-1/4 in. (5) 2. W asher 1/4 in. inside dia. (7) 3. T op support tube 4. Luggage rac k spacer (5) 5. License plate bracket 6. Lockn ut, Nylon cap, 1/4-20 (5) pd0187e 5 3 4 2 1 6 4[...]

2-6 2005 PDI: T ouring Models RADIO ANTENNA MAST INST ALLA TION Open the T our-Pak lid. FLHTC models are equipped with one antenna mast. Thread the mast securely ov er the antenna mounting stud and tighten the set screw . FLHTCU models are equipped with two antenna masts — one with loading coil f or CB radio f or right side mounting, the other f [...]

2005 PDI: T ouring Models 2-7 INST ALLING WINDSHIELD FLHTC, FLHTCU, FLHTCSE 2 (Wind Deflec- tor) and FLHTP (Fairing) 1. See Figure 2-7. Loosen the three f asteners along the top of the outer f airing. It is not necessary to remove the f as- teners. 2. Slide windshield down between the inner and outer f air- ing ov er the f asteners. P osition on t[...]

2-8 2005 PDI: T ouring Models Windshield Installation: FLHR/C and FLHP (Windshield) CA UTION Be sure you position the windshield brac ket between the rubber grommets. Incorrect mounting could result in damage to the windshield. See Figure 2-9. Insert your fingers into the wireform latch springs at either side of the windshield and slide the BOT - [...]

2005 PDI: T ouring Models 2-9 3. Remov e nut (1) (inside nacelle) securing nacelle trim (2). 4. Disconnect tachometer connector [108] inside headlamp nacelle. 5. Remov e nacelle trim. Loosen (but do not remov e) front handlebar clamp shroud screw (3), n ut (4) and washer (5). 6. Gently pr y off f or k lock plate (6) at rear of handlebar clamp shrou[...]

2-10 2005 PDI: T ouring Models MIRR ORS See Figure 2-13. Adjust mirrors for proper rear vie w . V erify that mirror f asteners are properly tightened. THRO TTLE CONTROL CABLES All Non-Ultra Models Check throttle cab le adjustment in accordance with proce- dure given in Section 1 of T ouring Models Ser vice Manual. Ultra Models Check throttle cab le[...]

2005 PDI: T ouring Models 2-11 REAR SUSPENSION AIR PRESSURE CA UTION Do not exceed maxim um air pressure for rear suspen- sion. Air components fill rapidly . Therefore, use low air line pressure. F ailure to do so may result in possib le damage to components. (00165a) IMPORT ANT NOTE Maximum air pressure of rear suspension system is 50 psi (345 kP[...]

2-12 2005 PDI: T ouring Models LUBRICA TION SYSTEM 2.3 ENGINE OIL LEVEL CA UTION The FLHTCSE 2 model is shipped from the factory with SYN-3 ® lubricant exclusivel y in the engine, primary and transmission. If there is a need to top off lubricants, DO NO T use standard lubricants in the FLHTCSE 2 model and do not mix lubricants as damage to the mot[...]

2005 PDI: T ouring Models 2-13 TRANSMISSION LUBRICANT NO TE Allow v ehicle to stand upright for a moment bef ore checking transmission lubricant lev el. This will allow lubricant lev el to normalize. Check the tr ansmission lubricant lev el with the motorcycle standing upright in accordance with the procedure given in the T our ing Models Service M[...]

2-14 2005 PDI: T ouring Models FUEL SYSTEM 2.4 GENERAL CA UTION Some fuel suppliers sell gasoline which has been bl ended with an alcohol or an ether . The type and amount of alcohol or ether added to the fuel is important. CA UTION Do not use gasoline that contains methanol. Doing so can result in fuel system component failure, engine dam- ag e an[...]

2005 PDI: T ouring Models 2-15 EV APORA TIVE EMISSIONS CONTR OL SYSTEM–CALIFORNIA MODELS ONL Y See Figure 2-18. See Figure 2-19. Ve r ify correct e vapor ative emissions control system hose routing, connections, and fuel tank venting to canister (if equipped). Figure 2-18. Evaporative Emissions Contr ol System Hose Connections 1. Carburetor (indu[...]

2-16 2005 PDI: T ouring Models ELECTRICAL SYSTEM 2.5 HEADLAMP Check headlamp beam f or proper height and lateral align- ment in accordance with procedures given in Section 8 of the T ouring Models Ser vice Manual. 1 W ARNING 1 W ARNING The automatic-on headlamp feature pr ovides increased visibility of the rider to other motorists. Be sure head- la[...]

2005 PDI: T ouring Models 2-17 INDICA T OR LAMPS/CONTR OLS 1. See Figure 2-21. Tu rn ignition/light switch to IGNITION position, and check that Oil pressure indicator lamp turns on (bef ore engine is star ted). The Check Engine lamp and if TSSM EQUIPPED , THE SECURITY LAMP will illu- minate f or approximately f our seconds and then tur n off . NO T[...]

2-18 2005 PDI: T ouring Models TIRES 2.6 FR ONT AND REAR TIRES 1 W ARNING 1 W ARNING Do not inflate tire bey ond maximum pressures specified on sidewall. Over inflated tires can blow out, which could result in death or serious injury . (00027a). 1 W ARNING 1 W ARNING Harley-Da vidson front and rear tires are not the same. Interc hanging front an[...]

2005 PDI: T ouring Models 2-19 BRAKE SYSTEM 2.7 BRAKES 1 CA UTION Direct contact of D .O .T . 4 brake fluid with eyes can cause irritation. A void eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing lar ge amounts of D.O .T . 4 brake fluid can cause digestive discomfort. If swallowed, obtai[...]

2-20 2005 PDI: T ouring Models DEALER R O AD TEST 2.8 RO AD TEST After you complete motorcycle inspection, tak e motorcycle f or a road test. Check all systems and ov erall operation of motor- cycle: engine, transmission, clutch, brak es, handling, etc. On Ultra models, chec k Cr uise Control, rear speakers and rider/ passenger sound system control[...]

2005 PDI: T ouring Models 2-21 CUST OMER DELIVER Y 2.9 NO TICE T O DEALER Bef ore delivering motorcycle to owner , perform the f ollowing: 1. Make sure v ehicle owner receives, and is a ware of impor tance of reading Owner’ s Manual, safety booklets and viewing We lcome T o The Famil y video included with owner’ s kit. 2. Re view w arranties wi[...]

2-22 2005 PDI: T ouring Models VEHICLE PDI CHECKLIST 2.10 PRIOR T O CUST OMER DELIVER Y NO TE Use this checklist f or performing tasks related to this model motorcycle setup . ❒ Uncrate: Check f or damaged or missing par ts. ❒ Handlebars: Ve r ify proper position; tighten clamps to proper torque. ❒ Jiffy Stand: Ve r ify proper function. ❒ N[...]

SUBJECT P AGE NO . 3.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 2005 Dyna Models Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

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2005 PDI: Dyna Models 3-1 SPECIFICA TIONS 3.1 T ORQUE V ALUES The f ollowing torque v alues are included f or fasteners that ma y be loosened and tightened during Predelivery and Setup . Any f asteners that are not loosened/remov ed do not need to be check ed during predelivery and setup. 2005 DYNA MODELS SPECIFICA TIONS Idle Speed: 950 RPM at Oper[...]

3-2 2005 PDI: Dyna Models INITIAL ASSEMBL Y 3.2 BA TTER Y TESTING AND CHARGING 1 W ARNING 1 W ARNING Batteries contain sulfuric acid, which could cause se vere bu rns to eyes and skin. Wear a pr otective face shield, rubberized gloves and pr otective clothing when w orking with batteries. KEEP B A TTERIES A W A Y FROM CHIL- DREN. (00063a) 1 W ARNIN[...]

2005 PDI: Dyna Models 3-3 THRO TTLE CABLES Tw ist and release throttle control gr ip a f ew times to verify proper operation of throttle control system. With throttle fric- tion screw loosened, carb uretor throttle must return to idle position each time throttle control grip is released. 1 W ARNING 1 W ARNING Throttle cab les must not pull tight wh[...]

3-4 2005 PDI: Dyna Models SUSPENSION ADJUSTMENT FOR FXDX MODEL Ref er to the Dyna Models Owner’ s Manual for suspension adjustment instructions for FXDX model. SHIFT LEVER Inspect shift linkage f or free mov ement. Check shift le ver adjustment; r ider’ s foot must be ab le to fit easily under shift le ver . Adjust shift lev er if required. SE[...]

2005 PDI: Dyna Models 3-5 LUBRICA TION SYSTEM 3.3 ENGINE OIL LEVEL Check engine oil le vel with engine turned off and motorcycle resting on jiffy stand on le vel surf ace. 1. Remov e filler cap with attached dipstick. Wipe dipstick clean. 2. Install filler cap . Make sure cap is fully seated in oil pan filler neck. 3. See Figure 3-3. Remove fil[...]

3-6 2005 PDI: Dyna Models FUEL SYSTEM 3.4 GENERAL CA UTION Some fuel suppliers sell gasoline which has been bl ended with an alcohol or an ether . The type and amount of alcohol or ether added to the fuel is important. CA UTION Do not use gasoline that contains methanol. Doing so can result in fuel system component failure, engine dam- ag e and/or [...]

2005 PDI: Dyna Models 3-7 ELECTRICAL SYSTEM 3.5 HEADLAMP Check headlamp beam f or proper height and lateral align- ment in accordance with procedures given in the Dyna Mod- els Ser vice Manual 1 W ARNING 1 W ARNING The automatic-on headlamp feature pr ovides increased visibility of the rider to other motorists. Be sure head- lamp is on at all times[...]

3-8 2005 PDI: Dyna Models MIRR ORS AND DIRECTIONAL LAMPS See Figure 3-7. Adjust mirrors f or proper rear view . Adjust front directional lamps so lenses are aimed directly f orward; adjust rear directional lamps so lenses are aimed directly rearward. V erify that mirror and directional lamp fasteners are properly tightened. Tighten mirror f astener[...]

2005 PDI: Dyna Models 3-9 TIRES 3.6 FR ONT AND REAR TIRES 1 W ARNING 1 W ARNING Do not inflate tire bey ond maximum pressure as speci- fied on sidewall. Over inflated tires can blow out, which could result in death or serious injury . (00027a) 1 W ARNING 1 W ARNING Harley-Da vidson front and rear tires are not the same. Interc hanging front and [...]

3-10 2005 PDI: Dyna Models BRAKE SYSTEM 3.7 BRAKES 1 CA UTION Direct contact with D .O .T . 5 brake fluid can cause eye irri- tation, swelling, and redness. A vid eye contact. In case of ey e contact flush with large amounts of water and get medical attention. Swallowing lar ge amounts of D.O .T . 5 brake fluid can cause digestive discomfort. If[...]

2005 PDI: Dyna Models 3-11 DEALER R O AD TEST 3.8 RO AD TEST After you complete motorcycle inspection, tak e motorcycle f or a road test. Check all systems and ov erall operation of motor- cycle: engine, transmission, clutch, brak es, handling, etc. After road test, return motorcycle to shop, and thoroughly clean off any road dirt. Check and correc[...]

3-12 2005 PDI: Dyna Models CUST OMER DELIVER Y 3.9 NO TICE T O DEALER Bef ore delivering motorcycle to owner , perform the f ollowing: 1. Make sure v ehicle owner receives , and is aw are of impor tance of reading Owner’ s Manual, safety booklets and viewing We lcome T o The Famil y video included with owner’ s kit. 2. Re view w arranties with [...]

2005 PDI: Dyna Models 3-13 VEHICLE PDI CHECKLIST 3.10 PRIOR T O CUST OMER DELIVER Y NO TE Use this checklist f or performing tasks related to this model motorcycle setup . ❒ Uncrate: Check f or damaged or missing par ts. ❒ Jiffy Stand: Ve r ify proper function. ❒ Note Any Additional Pr oblems (including cosmetic quality): Pe r fo r m Warr ant[...]

3-14 2005 PDI: Dyna Models NO TES[...]

SUBJECT P AGE NO . 4.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 2005 Softail Models Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

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2005 PDI: Softail Models 4-1 SPECIFICA TIONS 4.1 T ORQUE V ALUES The f ollowing torque v alues are included f or fasteners that ma y be loosened and tightened during Predelivery and Setup . Any f asteners that are not loosened/remov ed do not need to be check ed during predelivery and setup. 2005 SOFT AIL MODELS SPECIFICA TIONS Idle Speed: 950 RPM [...]

4-2 2005 PDI: Softail Models INITIAL ASSEMBL Y 4.2 BA TTER Y TESTING AND CHARGING 1 W ARNING 1 W ARNING Batteries contain sulfuric acid, which could cause se vere bu rns to eyes and skin. Wear a pr otective face shield, rubberized gloves and pr otective clothing when w orking with batteries. KEEP B A TTERIES A W A Y FROM CHIL- DREN. (00063a) 1 W AR[...]

2005 PDI: Softail Models 4-3 7. Check oper ation 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 ● ri ght directional (turn signal) lamps–front and rear ● ri ght directional (turn signal) [...]

4-4 2005 PDI: Softail Models Windshield Installation: FLSTC CA UTION Be sure you position the windshield brac ket notches in the groo ves 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 inser ting the side brac kets betw een the headlamp and t[...]

2005 PDI: Softail Models 4-5 LUBRICA TION SYSTEM 4.3 ENGINE OIL LEVEL CA UTION The FLSTFSE model is shipped from the factory with SYN-3 ® lubricant exclusivel y in the engine, primary and transmission. If there is a need to top off lubricants, DO NO T use standard lubricants in the FLSTFSE model and do not mix lubricants as damage to the motorc yc[...]

4-6 2005 PDI: Softail Models FUEL SYSTEM 4.4 GENERAL CA UTION Some fuel suppliers sell gasoline which has been bl ended with an alcohol or an ether . The type and amount of alcohol or ether added to the fuel is important. CA UTION Do not use gasoline that contains methanol. Doing so can result in fuel system component failure, engine dam- ag e and/[...]

2005 PDI: Softail Models 4-7 ELECTRICAL SYSTEM 4.5 HEADLAMP Check headlamp beam f or proper height and lateral align- ment in accordance with procedures given in the Softail Mod- els Ser vice Manual. 1 W ARNING 1 W ARNING The automatic-on headlamp feature pr ovides increased visibility of the rider to other motorists. Be sure head- lamp is on at al[...]

4-8 2005 PDI: Softail Models TIRES 4.6 FR ONT AND REAR TIRES 1 W ARNING 1 W ARNING Do not alter or modify front suspension/f ender/tire type on FXSTS models. The motorcyc le handling characteris- tics and front end structural integrity might be ad versel y affected. This may cause loss of contr ol, which could result in death or serious injury . 1 [...]

2005 PDI: Softail Models 4-9 BRAKE SYSTEM 4.7 BRAKES 1 CA UTION Direct contact with D .O .T . 5 brake fluid can cause eye irri- tation, swelling, and redness. A vid eye contact. In case of ey e contact flush with large amounts of water and get medical attention. Swallowing lar ge amounts of D.O .T . 5 brake fluid can cause digestive discomfort. [...]

4-10 2005 PDI: Softail Models DEALER R O AD TEST 4.8 RO AD TEST After you complete motorcycle inspection, tak e motorcycle f or a road test. Check all systems and ov erall operation of motor- cycle: engine, transmission, clutch, brak es, handling, etc. After road test, return motorcycle to shop, and thoroughly clean off any road dirt. Check and cor[...]

2005 PDI: Softail Models 4-11 CUST OMER DELIVER Y 4.9 NO TICE T O DEALER Bef ore delivering motorcycle to owner , perform the f ollowing: 1. Make sure v ehicle owner receives, and is a ware of impor tance of reading Owner’ s Manual, safety booklets and viewing We lcome T o The Famil y video included with owner’ s kit. 2. Re view w arranties wit[...]

4-12 2005 PDI: Softail Models VEHICLE PDI CHECKLIST 4.10 PRIOR T O CUST OMER DELIVER Y NO TE Use this checklist f or performing tasks related to this model motorcycle setup . ❒ Uncrate: Check f or damaged or missing par ts. ❒ Jiffy Stand: Ve r ify proper function. ❒ Note Any Additional Pr oblems (including cosmetic quality): Pe r f or m W arr[...]

SUBJECT P AGE NO . 5.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 2005 Sportster Models Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

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2005 PDI: Sportster Models 5-1 SPECIFICA TIONS 5.1 T ORQUE V ALUES The f ollowing torque v alues are included f or fasteners that ma y be loosened and tightened during Predelivery and Setup . Any f asteners that are not loosened/remov ed do not need to be check ed during predelivery and setup. 2005 SPOR TSTER MODELS SPECIFICA TIONS Idle Speed: 950 [...]

5-2 2005 PDI: Sportster Models INITIAL ASSEMBL Y 5.2 BA TTER Y TESTING AND CHARGING 1 W ARNING 1 W ARNING Batteries contain sulfuric acid, which could cause se vere bu rns to eyes and skin. Wear a pr otective face shield, rubberized gloves and pr otective clothing when w orking with batteries. KEEP B A TTERIES A W A Y FROM CHIL- DREN. (00063a) 1 W [...]

2005 PDI: Sportster Models 5-3 INST ALLING MAXI-FUSE The 30 amp Maxi-Fuse provides battery power to the ignition sw itch and ICM. The Maxi-Fuse is not installed at the factory . It is mounted in protective f oam attached to the left handlebar gr ip of the motorcycle in the crate. See Figure 5-2. The Maxi-Fuse holder is located under the left side c[...]

5-4 2005 PDI: Sportster Models MIRR ORS NO TE XL 883L model: r ighthand mirror is shipped in protectiv e foam on left hand grip and must be installed. 1. XL 883L models: a. See Figure 5-4. Inser t mirror (1) stem into hole in master cylinder assembly (2). b. Install lock w asher (3) and lock n ut (4). Tighten to 96-144 in-lbs (10.9-16.3 Nm). 2. Adj[...]

2005 PDI: Sportster Models 5-5 LUBRICA TION SYSTEM 5.3 ENGINE OIL LEVEL Check engine oil le vel in oil tank at least once e very 500 miles (800 km). Check le vel more frequently if engine uses more oil than normal or if vehicle is operated under harsh conditions. Oil tank capacity is 3.6 quar ts (U .S.) (3.4 liters). Refer to Owner’ s Manual fo r[...]

5-6 2005 PDI: Sportster Models FUEL SYSTEM 5.4 GENERAL CA UTION Some fuel suppliers sell gasoline which has been bl ended with an alcohol or an ether . The type and amount of alcohol or ether added to the fuel is important. CA UTION Do not use gasoline that contains methanol. Doing so can result in fuel system component failure, engine dam- ag e an[...]

2005 PDI: Sportster Models 5-7 ELECTRICAL SYSTEM 5.5 HEADLAMP ALIGNMENT Check headlamp beam f or proper height and lateral align- ment in accordance with procedures given in Section 1 of the Spor tster Models Service Manual. 1 W ARNING 1 W ARNING The automatic-on headlamp feature pr ovides increased visibility of the rider to other motorists. Be su[...]

5-8 2005 PDI: Sportster Models TIRES 5.6 FR ONT AND REAR TIRES 1 W ARNING 1 W ARNING Do not inflate tire bey ond maximum pressure as speci- fied on sidewall. Over inflated tires can blow out, which could result in death or serious injury . (00027a) 1 W ARNING 1 W ARNING Harley-Da vidson front and rear tires are not the same. Interc hanging front[...]

2005 PDI: Sportster Models 5-9 BRAKE SYSTEM 5.7 REAR BRAKE 1 CA UTION Direct contact with D .O .T . 5 brake fluid can cause eye irri- tation, swelling, and redness. A vid eye contact. In case of ey e contact flush with large amounts of water and get medical attention. Swallowing lar ge amounts of D.O .T . 5 brake fluid can cause digestive discom[...]

5-10 2005 PDI: Sportster Models DEALER R O AD TEST 5.8 RO AD TEST After you complete motorcycle inspection, tak e motorcycle f or a road test. Check all systems and ov erall operation of motor- cycle: engine, transmission, clutch, brak es, handling, etc. After road test, return motorcycle to shop, and thoroughly clean off any road dirt. Check and c[...]

2005 PDI: Sportster Models 5-11 CUST OMER DELIVER Y 5.9 NO TICE T O DEALER Bef ore delivering motorcycle to owner , perform the f ollowing: 1. Make sure v ehicle owner receives, and is a ware of impor tance of reading Owner’ s Manual, safety booklets and viewing We lcome T o The Famil y video included with owner’ s kit. 2. Re view w arranties w[...]

5-12 2005 PDI: Sportster Models VEHICLE PDI CHECKLIST 5.10 PRIOR T O CUST OMER DELIVER Y NO TE Use this checklist f or performing tasks related to this model motorcycle setup . ❒ Uncrate: Check f or damaged or missing par ts. ❒ Jiffy Stand: Ve r ify proper function. ❒ Note Any Additional Pr oblems (including cosmetic quality): Pe r f or m W a[...]

SUBJECT P AGE NO . 6.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 2005 VRSC Models Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

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2005 PDI: VRSC Models 6-1 SPECIFICA TIONS 6.1 T ORQUE V ALUES The f ollowing torque v alues are included f or fasteners that ma y be loosened and tightened during Predelivery and Setup . Any f asteners that are not loosened/remov ed do not need to be check ed during Predelivery and Setup. 2005 VRSC MODELS SPECIFICA TIONS ITEM T ORQUE NO TES Fr ont [...]

6-2 2005 PDI: VRSC Models INITIAL ASSEMBL Y 6.2 BA TTER Y TESTING AND CHARGING 1 W ARNING 1 W ARNING Batteries contain sulfuric acid, which could cause se vere bu rns to eyes and skin. Wear a pr otective face shield, rubberized gloves and pr otective clothing when w orking with batteries. KEEP B A TTERIES A W A Y FROM CHIL- DREN. (00063a) 1 W ARNIN[...]

2005 PDI: VRSC Models 6-3 INST ALLING MAXI-FUSE NO TES ● The 40 amp Maxi-Fuse provides battery power to the ignition s witch and ECM. The Maxi-Fuse is not installed at the f actor y . It is shipped in the fuse holder boot next to the sock et. ● It will also be necessar y to install the fuel pump fuse that is located in a spare fuse location. Se[...]

6-4 2005 PDI: VRSC Models LUBRICA TION SYSTEM 6.3 ENGINE OIL LEVEL CA UTION Do NO T operate the engine when the oil level is belo w the add mark on the dipstic k at operating temperature. Engine damage will result. (00187a) CA UTION To av oid over-filling the oil sump, wait appro ximately three minutes after adding oil bef ore chec king the oil le[...]

2005 PDI: VRSC Models 6-5 Pressure Cap Location NO TES ● See Figure 6-5. The pressure cap is located beneath seat behind the air bo x. Nor mally the pressure cap does not need to be remov ed. Coolant lev el can be checked at the e xpansion tank located on right side behind steer ing head. Coolant can be added at the expansion tank if le vel is lo[...]

6-6 2005 PDI: VRSC Models Checking Coolant Le vel In Expansion T ank 1. See Figure 6-8. Remove f astener at upper cor ner of lou- ve red cover and remo ve co ver . 2. See Figure 6-9. Check coolant le vel in expansion tank with coolant cold and vehicle resting on jiffy stand. If le vel is below “COLD FULL ” line on tank, remo ve cap from tank an[...]

2005 PDI: VRSC Models 6-7 FUEL SYSTEM 6.4 GENERAL CA UTION Some fuel suppliers sell gasoline which has been bl ended with an alcohol or an ether . The type and amount of alcohol or ether added to the fuel is important. CA UTION Do not use gasoline that contains methanol. Doing so can result in fuel system component failure, engine dam- ag e and/or [...]

6-8 2005 PDI: VRSC Models ELECTRICAL SYSTEM 6.5 HEADLAMP 1 W ARNING 1 W ARNING The automatic-on headlamp feature pr ovides increased visibility of the rider to other motorists. Be sure head- lamp is on at all times. P oor visibility of rider to other motorists can result in death or serious injury . (00030b) Inspection See Figure 6-10. Chec k headl[...]

2005 PDI: VRSC Models 6-9 VRSCB models: 1. See Figure 6-12. Loosen headlamp clamp nut (1). 2. Tilt headlamp (6) up or down to properly aim it in relation to the horizontal line, and, at the same time , tur n it right or left to direct light beam straight ahead. 3. Tighten headlamp clamp nut to 13.6-20.3 Nm (120-180 in-lbs ) after headlamp is proper[...]

6-10 2005 PDI: VRSC Models TIRES 6.6 FR ONT AND REAR TIRES 1 W ARNING 1 W ARNING Do not inflate tire bey ond maximum pressure as speci- fied on sidewall. Over inflated tires can blow out, which could result in death or serious injury . (00027a) 1 W ARNING 1 W ARNING Harley-Da vidson front and rear tires are not the same. Interc hanging front and[...]

2005 PDI: VRSC Models 6-11 BRAKE SYSTEM 6.7 REAR BRAKE MASTER CYLINDER 1 CA UTION Direct contact of D .O .T . 5 brake fluid with eyes can cause ey e irritation, swelling, and redness. A void e ye contact. In case of eye contact flush with lar ge amounts of water and get medical attention. Swallowing large amounts of D. O. T. 5 brake fluid can ca[...]

6-12 2005 PDI: VRSC Models DEALER R O AD TEST 6.8 RO AD TEST After you complete motorcycle inspection, tak e motorcycle f or a road test. Check all systems and ov erall operation of motor- cycle: engine, transmission, clutch, brak es, handling, etc. After road test, return motorcycle to shop, and thoroughly clean off any road dirt. Check and correc[...]

2005 PDI: VRSC Models 6-13 CUST OMER DELIVER Y 6.9 NO TICE T O DEALER Bef ore delivering motorcycle to owner , perform the f ollowing: 1. Make sure v ehicle owner receives, and is a ware of impor tance of reading Owner’ s Manual, safety booklets and viewing We lcome T o The Famil y video included with owner’ s kit. 2. Re view w arranties with v[...]

6-14 2005 PDI: VRSC Models VEHICLE PDI CHECKLIST 6.10 PRIOR T O CUST OMER DELIVER Y NO TE Use this checklist f or performing tasks related to this model motorcycle setup . ❒ Uncrate: Check f or damaged or missing par ts. ❒ Jiffy Stand: Ve r ify proper function. ❒ Note Any Additional Pr oblems (including cosmetic quality): Pe r f or m W arrant[...]

SUBJECT P AGE NO . 7.1 VRSCSE Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Uncrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

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2005 PDI: CV O Models 7-1 VRSCSE MODEL 7.1 GENERAL Fo llo w the instructions in section I (All Models) and Section VI (VRSC Models) and the f ollowing instructions to perform the predelivery setup procedure on the VRSCSE model. This motorcycle is equipped with the Harley-Davidson F ac- tor y Security System and siren. UNCRA TING The VRSCSE is shipp[...]

7-2 2005 PDI: CV O Models T esting and Charging Battery 1. Place test probes of voltmeter on battery terminals and check the v oltage of the batter y 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. 3. See Section 1. Mark the date on the batter y warran[...]

2005 PDI: CV O Models 7-3 2. Shift transmission to neutral position, and v er ify that neu- tral indicator lamp turns on. 3. Star t engine; check operation of starter. 4. Check that oil pressure indicator lamp (12) turns off when engine is running above 1200 RPM. Chec k that batter y icon (4) turns off. Engine Coolant temperature icon (1) must not [...]

7-4 2005 PDI: CV O Models CA UTION Control wiring is r outed inside handlebar and may be pinched or cut if contr ols are rotated too far . 3. Beginning with top screw , tighten right lev er assembly clamp screws to 6.8-9.0 Nm (60-80 in-lbs ). 4. Beginning with lower scre w , tighten right handlebar sw itch housing scre ws to 4.0-5.1 Nm (35-45 in-lb[...]

2005 PDI: CV O Models 7-5 CHECKING CLUTCH FLUID CA UTION D. O. T. 5 silicone hydraulic brake fluid is used in the h ydraulic c lutch. Do not use other types of fluids as they are not compatible and could cause equipment damage. (00204a) CA UTION Do NO T allow f oreign matter to enter the clutc h master cy linder reservoir . dirt or debris in the [...]

7-6 2005 PDI: CV O Models MIRR ORS AND TURN SIGNALS The mirrors are enclosed in a bo x in the crate. Install mirrors and adjust f or proper rear view as f ollows: 1. See Figure 7-7. Place spacer (10) onto right side mirror stem, slide mirror stem down through hole in front brak e master cylinder assembly and right turn signal brack et (5). Install [...]

2005 PDI: CV O Models 7-7 FOO TREST ADJUSTMENT If it is necessar y to rotate rider or passenger f ootrests for cus- tomer comf or t, proceed as f ollows: 1. See Figure 7-8. Remov e screw (2) and f ootrest r ubber inser t (3) from f ootrest assembly (1). 2. See Figure 7-9. Loosen footrest adjustment scre w . Rotate f ootrest assembly to desired angl[...]

7-8 2005 PDI: CV O Models FLHTCSE 2 MODEL 7.2 GENERAL CA UTION The FLHTCSE 2 model is shipped from the factory with SYN-3 ® lubricant exclusivel y in the engine, primary and transmission. If there is a need to top off lubricants, DO NO T use standard lubricants and do not mix lubricants as damage to the motorc ycle can result. F ollow the instruct[...]

2005 PDI: CV O Models 7-9 2. See Figure 7-11. Range marks (4) are located on bottom of handlebar adjacent to front brak e lev er clamp assem- bl y. Rotate switch housing and front brak e master cylin- der assembly (2) slightly f or most comf or table position. Make sure control assemb ly is positioned so that clamp mating surf ace (3) is located in[...]

7-10 2005 PDI: CV O Models 1. Stand the motorcycle upright (not leaning on the jiffy stand) on a le vel surf ace. T ur n the handlebars to the right if necessar y , so the top of the clutch master cylinder res- er v oir is le vel. 2. View reservoir sightglass on reservoir cov er and verify fluid presence. Sightglass should appear dark if fluid is[...]

2005 PDI: CV O Models 7-11 Figure 7-15. Remov able Mounting Bracket Figure 7-16. P ositioning T our -Pak f or Assembly Mount T our-P ak in rear holes 10767 10704 Figure 7-17. T our -Pak Mounting 4 2 1 6 3 5 1. Screw , 1/4-20 x 2-1/4 in. (5) 2. W asher 1/4 in. inside dia. (10) 3. Support tube 4. Saddle spacer (5) 5. Remov able mounting brac ket 6. L[...]

7-12 2005 PDI: CV O Models 5. See Figure 7-18. Inser t one screw with w asher through rear-most hole in T our-Pak. Slide suppor t tube onto screw . 6. Install one saddle spacer onto screw with curved surf ace of spacer f acing suppor t tube. Install washer and loc knut. Finger-tighten lockn ut only . 7. Install screws and w ashers in other f our lo[...]

2005 PDI: CV O Models 7-13 12. See Figure 7-21. Plug T our-P ak har ness into pow er con- nector and tuck cab le assembly betw een seat and fender strut cover . NO TE See Figure 7-22. With the radio antenna mast mounted on the T our-Pak antenna mount, the coaxial adapter sho wn in the figure allows connecting the antenna cab le to the chassis ante[...]

7-14 2005 PDI: CV O Models RADIO ANTENNA See Figure 7-24. S cre w antenna (1) into antenna mount (2) on T our-Pak and tighten set scre w with allen wrench (3). REMO V ABLE P ASSENGER BA CKREST See Figure 7-25. The passenger backrest assemb ly mounts on the two f orward mounting points (1) on each side of the v ehicle when the T our-P ak is not inst[...]

2005 PDI: CV O Models 7-15 DELIVERING VEHIC LE WITH REMO VAB LE PASSENG ER BAC KREST INSTALLED If the customer wishes the vehicle to be deliv ered with the remov able passenger bac krest (see Figure 7-26. ) installed on the vehicle instead of the T our-P ak, f ollow the instructions below . P assenger Backrest NO TE If the T our-Pak is installed on[...]

7-16 2005 PDI: CV O Models LEATHER DRESSING APPLICA TION Apply Harley-Davidson Leather Dressing, P art No. 98261- 91V to the f ollowing: ● Seat. ● Rider backrest pad. ● Pa ssenger backrest pad (mounted on T our-P ak). ● Detachable passenger bac krest pad. FINAL PREDELIVER Y INSPECTIONS Pe rform all the remaining Predelivery Inspections give[...]

2005 PDI: CV O Models 7-17 FLSTFSE MODEL 7.3 GENERAL CA UTION The FLSTFSE model is shipped from the factory with SYN-3 ® lubricant exclusivel y in the engine, primary and transmission. If there is a need to top off lubricants, DO NO T use standard lubricants and do not mix lubricants as damage to the motorc ycle can result. Fo llo w the instructio[...]

7-18 2005 PDI: CV O Models ADJUSTING HANDLEB AR CONTR OLS If handlebar controls and clutch and brak e lev er assemblies are incorrectly positioned, they ma y be rotated slightly for more comf or table riding position. CA UTION Do not rotate fr ont brake lever assemb ly too far . Brake master cylinder fits into a machined relief in handlebar . If n[...]

2005 PDI: CV O Models 7-19 CHECKING CLUTCH FLUID CA UTION D. O. T. 5 silicone hydraulic brake fluid is used in the h ydraulic c lutch. Do not use other types of fluids as they are not compatible and could cause equipment damage. (00204a) CA UTION Do NO T allow f oreign matter to enter the clutc h master cy linder reservoir . dirt or debris in the[...]

7-20 2005 PDI: CV O Models NO TE It is not necessar y , nor desirable , to completely remov e set- screw to re-adjust turn signal housing. It is only necessar y to loosen setscrew 1/8 turn, adjust tur n signal and re-tighten setscrew . Nylon lock pellet on setscre w maintains locking ability after many loosening/tightening cycles . If setscrew is c[...]