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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LEATHER DRESSING APPLICATION
FINAL PREDELIVERY INSPECTIONS
Apply Harley Davidson Leather Dressing, Part No. 98261-
Perform all the remaining Predelivery Inspections given in
91V to the following:
Section I (All Models) and Section II (Touring Models) that
apply to the ELECTRA GLIDE (FLHT).
Seat.
NOTE
Rider backrest pad.
Do not remove the clutch cover. It is not necessary to check
Passenger backrest pad (mounted on Tour-Pak).
the primary chaincase lubricant level on the FLHTCSE2. Also,
Detachable passenger backrest pad.
the hydraulic clutch is not adjustable.
DO NOT REPEAT INSPECTIONS THAT WERE PER-
FORMED IN THIS SECTION.
7-16
2005 PDI: CVO Models

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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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