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Harley Davidson Motor Softail (2005)

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DYNA III

TOURING II

GENERAL I

SOFTAIL IV

SPORTSTER V

VRSC VI

CVO VII

2005

HARLEY-DAVIDSON

MOTORCYCLE

PREDELIVERY

AND SETUP

MANUAL

The information in this Manual

applies to all 2005 motorcycle

models manufactured by

Harley-Davidson Motor Company.

Printed in the U.S.A.

VISIT THE HARLEY-DAVIDSON WEB SITE

http://www.harley-davidson.com

Binder 99946-88

Contents 99947-05

CMI-4.0M-06/04

iii

FOREWORD

INTRODUCTION

This PREDELIVERY AND SETUP MANUAL has been pre-

pared by Harley-Davidson Motor Company to provide the

Harley-Davidson dealer with the factory recommended steps

needed to prepare our motorcycles for delivery to the cus-

tomer.

NOTE

Harley-Davidson Motor Company considers the predelivery

inspections and procedures in this manual necessary to

assure customer safety and satisfaction. None of these

inspections or procedures should ever be left out, and only

qualiﬁed technicians should perform them.

HOW TO USE YOUR PREDELIVERY

AND SETUP MANUAL

Your Predelivery and Setup Manual is divided into seven sec-

tions:

●Section I–General Information: All Models

●Section ll–Predelivery Inspections: Touring Models

●Section lll–Predelivery Inspections: Dyna Models

●Section IV–Predelivery Inspections: Softail Models

●Section V–Predelivery Inspections: Sportster Models

●Section VI–Predelivery Inspections: VRSC Models

●Section VII–Predelivery Inspections: CVO Models

Refer to Section I ﬁrst for general setup instructions pertain-

ing to all current model motorcycles. Then, proceed to the

one Section (either II, III, IV, V, VI or VII) which covers the

inspection procedures for your speciﬁc model vehicle.

WARNINGS AND CAUTIONS

1WARNING1WARNING

WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious

injury. (00119a)

1CAUTION

CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate

injury. (00139a)

CAUTION

CAUTION used without the safety alert symbol indicates

a potentially hazardous situation which, if not avoided,

may result in property damage. (00140a)

NOTE

Refers to important information, and is placed in italic type.

It is recommended that you take special notice of these items.

PRODUCT REFERENCES

All tools mentioned in this manual with “HD” or “J” preceding

the part number must be ordered through Kent-Moore.

Direct all mail orders and general correspondence to the fol-

lowing address:

Kent-Moore

SPX Corporation

28635 Mound Road

Warren, Michigan USA 48092-3499

Telephone: 1-800-345-2233

Sealing and Threadlocking Products

LOCTITE PRODUCTS

Some procedures in this Service Manual call for the use of

Loctite® products. If you have any questions regarding Loctite

product usage or retailer/wholesaler locations, please call

Loctite Corp. at 1-800-323-5106.

CONTENTS

All photographs, illustrations and procedures may not neces-

sarily depict the most current model or component, but are

based on the latest production information available at the

time of publication.

Since product improvement is our continual goal, Harley-

Davidson reserves the right to change speciﬁcations, equip-

ment or designs at any time without notice and without incur-

ring obligation.

ORDERING INFORMATION

Additional binders or contents may be ordered from Parts &

Accessories. The binder and the contents must be ordered

separately.

●Binder: Part No. 99946-88

●Contents: Part No. 99947-05

TABLE OF CONTENTS

SECTION SUBJECT PAGE NUMBER

I General 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

V Predelivery Inspections: Sportster Models 5-1

VI Predelivery Inspections: VRSC Models 6-1

VII Predelivery Inspections: CVO* Models 7-1

*Custom Vehicle Operations

SUBJECT PAGE NO.

1.1 Uncrating and General Setup: All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Vehicle Crate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Uncrating Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Removing Cardboard Carton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Handlebar Installation–FLSTSC, FLSTN and FXDWG Models . . . . . . . . . . . 1-2

Adjusting Handlebars–All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Removing Vehicle From Pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Clutch Hand Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Front Brake Hand Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Front Brake Master Cylinder Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Vehicle Cleanup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Cosmetic Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Returning Steel Pallets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Maintenance-Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Date Of Manufacture Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Voltmeter Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Charging Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Warning Label Placement (All Vehicles Sold Outside of the United States) . 1-18

1.2 System Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

PREDELIVERY: ALL MODELS

2005 PDI: All Models 1-1

UNCRATING AND GENERAL SETUP: ALL MODELS 1.1

VEHICLE CRATE INSPECTION

Inspect each crate for external damage while it is still on

delivery truck. Open crate and inspect motorcycle for damage

before truck leaves your dealership. Refer to HARLEY-

DAVIDSON/BUELL WARRANTY MANUAL, “SHIPPING

DAMAGE PROCEDURE” for complete information on ﬁling

claims for damaged and over/short freight.

UNCRATING VEHICLE

CAUTION

Use caution when removing cardboard carton from pal-

let. DO NOT remove uprights before removing carton.

Failure to do so can cause damage to motorcycle.

NOTE

All Harley-Davidson motorcycles are shipped in crates using

returnable steel pallets. The steel pallets have fork openings

2x7 in. (5.1x17.8 cm) at the front and sides. Crates have

widths of 29 in. (73.7 cm) and 43 in. (109.2 cm) and all are 50

in. (127 cm) high. The VRSC, SPORTSTER, DYNA and some

SOFTAIL models are shipped with the front wheel turned to

the left or right in a “turn-wheel” crate. Removing the shipping

crate is similar on all models so the procedure given below is

typical for all models. Call your SPOC representative if you

have questions regarding steel pallet return.

REMOVING CARDBOARD CARTON

1. See Figure 1-1. Use a T-20 bit and an electric or air pow-

dered drill/driver to remove all fasteners from cardboard

carton. Open top carton ﬂaps.

2. See Figure 1-2. Using a box cutter, cut one end of the

cardboard carton. Slide carton away from pallet as

shown. Set carton aside for recycling.

3. See Figure 1-3. Remove both uprights (VRSC, FLST and

FLSTC crates have three uprights) by lifting upward. Set

uprights aside for recycling.

4. Open plastic bag enclosing motorcycle and push it down

off motorcycle. Remove protective tape and elastic pro-

tective netting, if present, from chrome and painted parts

of motorcycle.

Figure 1-1. Removing Screws

8796

Figure 1-2. Remove Cardboard Carton from Pallet.

Figure 1-3. Remove Uprights from Pallet

10426

8798

1-4 2005 PDI: All Models

FXDWG

After removing carton and protective plastic wrap:

1. See Figure 1-8. Remove and discard cloth tie (1) secur-

ing handlebar.

2. Remove the four bolts (2) from the riser. Retain the four

bolts.

3. Reroute the left hand switch wire conduit from between

the riser to a position in front of the riser.

4. Retrieve riser caps from passenger backrest.

5. Position the handlebar on top of the risers and fasten the

riser caps in place using the bolts removed in step 2.

6. See and ADJUSTING HANDLEBARS– ALL MODELS

Figure 1-10. Following the Dyna Glide, Softail, XL 883,

XL 883L and XL 1200R Models procedure, adjust the

handlebars and tighten the riser bolts to 12-18 ft-lbs

(16.3-24.4 Nm) in the sequence given.

7. See Figure 1-9. Attach brake line (2) and ground wire (3)

on upper triple clamp with clamp (1). Position brake line

inboard from fastener. Tighten fastener to 30-60 in-lbs

(3.4-6.8 Nm).

Figure 1-8. FXDWG

1. Cloth tie

2. Riser bolts (4)

3. Shipping clamps

4. Protective block

6052

6053

Figure 1-9. FXDWG Brake Line and Ground Wire

6062

1. Clamp

2. Brake line

3. Ground wire

4. Clamp

5. Screw

6059

2005 PDI: All Models 1-7

FLHR/C/S/I Road King, FLHP, FLHPE

1. See Figure 1-13. Remove screw (12) securing chrome

ring (11) to headlamp nacelle (7). Remove chrome ring.

2. Remove eight screws (10) securing headlamp assembly

(9). Squeeze two external tabs (if present) to remove

wire connector at back of headlamp bulb. Remove head-

lamp assembly from vehicle.

3. Remove nut (1) (inside nacelle) securing nacelle trim (2).

4. On Police models, disconnect tachometer lead.

5. Remove nacelle trim. Loosen (but do not remove) front

handlebar clamp shroud screw (3), nut and washer (4).

6. Gently pry off fork lock plate (5) at rear of handlebar

clamp shroud (8). Remove two screws (6) beneath lock

plate.

7. Loosen four acorn nuts securing nacelle halves to fork

studs. Spread nacelle halves slightly and remove handle-

bar clamp shroud.

8. Adjust handlebars following steps 2. 6. - of the FLHT,

FLHTC, FLHTCU and FLHTP procedure given on previ-

ous page.

9. Reinstall handlebar clamp shroud. Tighten acorn nuts

securing nacelle halves to fork studs to 72-108 in-lbs

(8.1-12.2 Nm).

10. Install two screws (6) to handlebar clamp shroud and

tighten to 10-20 in-lbs (1.1-2.3 Nm). Gently press fork

lock plate (5) into place on handlebar clamp shroud.

11. Tighten front handlebar clamp shroud nut (4) to 10-20

in-

lbs (1.1-2.3 Nm).

12. On police models, connect tachometer lead.

13. Install nacelle trim (2). Install nut (1) (inside nacelle) secur-

ing nacelle trim. Tighten to 15-20

in-lbs (1.7-2.3 Nm).

14. Connect wire connector to socket on back of headlamp

bulb. Install and secure headlamp assembly to nacelle

with eight fasteners.

15. Secure chrome ring (11) to headlamp nacelle with screw

(12).

NOTE

Check clearance between windshield and clutch cable and

handlebar position prior to completing assembly of vehicle.

Figure 1-13. FLHR/C, FLHP, FLHPE Models

pd0226 3

1. Nut

2. Nacelle trim

3. Front handlebar clamp shroud screw

4. Nut and washer

5. Fork lock plate

6. Screw (2)

7. Nacelle

8. Handlebar clamp shroud

9. Headlamp assembly

10. Screw (8)

11. Chrome headlamp ring

12. Screw

2005 PDI: All Models 1-9

VRSCB

NOTE

To gain access to the handlebar adjusting screws, the follow-

ing steps will be necessary:

1. Remove Maxi-Fuse.

2. See Figure 1-16. Remove instrument cluster screw from

location shown and pivot instrument cluster away from

handlebars.

3. Remove wiring harness connector and remove screw on

bottom side of instrument cluster.

4. Remove instrument cluster.

5. To be sure handlebars are properly centered, verify that

equal amounts of knurled areas on handlebar protrude

from outboard sides of upper handlebar clamp.

NOTE

On some models, knurled areas of handlebar will be com-

pletely hidden by upper handlebar clamp and will not be visi-

ble at all when handlebar is centered properly.

6. See Figure 1-17. Raise handlebars to normal riding posi-

tion; hold in position. Tighten two front screws (4) until

cast-in spacers (2) of upper clamp contact handlebar

lower clamp (1).

7. Tighten rear screws (3) to 16-20 Nm (12-15 ft-lbs).

8. Final tighten front screws (4) to 16-20 Nm (12-15 ft-lbs).

Slight gap between upper and lower clamps should exist

at rear.

9. Install instrument cluster.

10. Insert instrument cluster screw and tighten to 2.2-2.8 Nm

(20-24 in-lbs).

11. Install Maxi-Fuse.

Figure 1-16. Instrument Cluster Mounting Screw Location

Figure 1-17. VRSCB Models

10059

1. Lower clamp

2. Cast-in spacers (2)

3. Rear screw (2)

4. Front screw (2)

5. Upper clamp

pd0021b

Tighten

ﬁrst

FRONT

Produktspecifikationer

Varumärke:	Harley Davidson
Kategori:	Motor
Modell:	Softail (2005)
Färg på produkten:	Zwart
Vikt:	3700 g
Förpackningens vikt:	4000 g
Förpackningens bredd:	493 mm
Djuppackning:	105 mm
Förpackningshöjd:	109 mm
Snäll:	Rekrail
Husmaterial:	Staal
Monteringsverktyg:	Ja
Maximal viktkapacitet:	45.3 kg
Certifiering:	CE, UL, REACH, TAA
Hållbarhetscertifikat:	RoHS
Inklusive skruvar:	Ja
Antal skruvar:	16
(Ytter) huvudpaketets höjd:	109 mm
(Ytter) huvudförpackningens bredd:	493 mm
(Ytre) huvudpaketets längd:	105 mm
Kvantitet per (yttre) huvudkartong:	1 stuk(s)
Rackkapacitet:	2U
Harmoniserad systemkod (HS):	85389099
Installationsdjup (max):	1054 mm
Installationsdjup (min):	420 mm
Burmuttrar ingår:	Ja
Skruv-typ:	M5
Antal burmuttrar:	16