Harley Davidson 2005 MOTORCYCLE. PREDELIVERY AND SETUP MANUAL — page 2

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WARNING LABEL PLACEMENT

All Sportster Models

(ALL VEHICLES SOLD OUTSIDE OF

See Figure 1-32. Peel appropriate label from sheet. Apply

label on top of air cleaner cover, centered on cover and lined

THE UNITED STATES)

up with edge of air cleaner back plate.

All dealers outside of the United States are required to apply

a warning label to the vehicle in the local language of the cus-

10685

tomer. A sheet of warning labels (Part No. 99942-05) is pro-

vided in the Owner’s Kit.

Apply the appropriate local language version of the warning

label as required to suit your local market. If your local lan-

guage is not represented on this label sheet, use the English

language label.

All EFI Big Twin Models

See Figure 1-30. Peel appropriate label from sheet. Apply

label on top of air cleaner cover, centered on cover and lined

up with edge of air cleaner back plate.

10683

Figure 1-32. Warning Label Placement-

All Sportster Models (Typical)

All VRSC Models

See Figure 1-33. Open seat. Peel appropriate label from

sheet. Apply label centered on rear end of air cleaner cover

with bottom edge of label 1.0 in. (25.4 mm) from rear edge of

air cleaner cover.

10686

Figure 1-30. Warning Label Placement-

All Big Twin EFI (Typical)

All Carbureted Big Twin Models

See Figure 1-31. Peel appropriate label from sheet. Apply

label on top of air cleaner cover, centered on cover and lined

up with edge of carburetor cutout in air cleaner back plate.

1.0 in

(25.4 mm)

10684

Figure 1-33. Warning Label Placement-

All VRSC Models (Typical)

Figure 1-31. Warning Label Placement-

All Big Twin Carbureted (Typical)

1-18

2005 PDI: All Models

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SPECIFICATIONS

2.1

TORQUE VALUES

The following torque values are included for fasteners that

may be loosened and tightened during Predelivery and

Setup. Any fasteners that are not loosened/removed do not

need to be checked during predelivery and setup.

Table 2-1. Torque Values

ITEM

TORQUE

NOTES

Handlebar clamp screws (front and rear)

12-16 ft-lbs

16.3-21.7 Nm

Must be checked at set-up.

Clutch inspection cover screws

84-108 in-lbs

9.5-12.2 Nm

FLHT windshield screws

25-30 in-lbs

2.8-3.4 Nm

FLTR windshield screws

6-13 in-lbs

0.7-1.5 Nm

Saddlebag mounting bracket bolts

60-96 in-lbs

6.8-10.8 Nm

Tour-Pak^® mounting bolts

96-120 in-lbs

10.8-13.5 Nm

FLHR/

Nacelle acorn nuts

72-108 in-lbs

8.1-12.2 Nm

FLHP

Handlebar clamp shroud screws

10-20 in-lbs

1.1-2.3 Nm

Handlebar clamp shroud nut

10-20 in-lbs

1.1-2.3 Nm

Nacelle trim nut

15-20 in-lbs

1.7-2.3 Nm

2005 TOURING MODELS

Idle Speed: 950 RPM at

Operating Temperature

SPECIFICATIONS

Use 950 RPM during Predelivery and Setup adjustments.

Engine idle speed may increase during engine break-in. Use

idle speed listed in the Touring Models Service Manual at Ini-

Table 2-2. Capacities

tial Maintenance check.

Component

ENGLISH

METRIC

NOTE

The idle speed on electronic fuel injected models can only be

Oil tank w/filter (Dry)

4 qt.

3.79 liter

set using a diagnostic tool such as DIGITAL TECHNICIAN

Transmission (Wet)

20-24 oz

591-710 ml

(Part No. HD-44750).

Primary Chaincase

32 oz

946 ml

All touring models except FLHTCSE² are shipped with

20W50 Harley Davidson 360 Motor oil. The FLHTCSE²

model ships with Syn-3^® lubricant in the engine, primary

and transmission.

2005 PDI: Touring Models

2-1

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INSTALLING DATA LINK

INSTALLING TOUR-PAK^®

CONNECTOR

NOTE

See Figure 2-1. The data link connector [91] (2) mounts in a

The seat screw is not factory installed on models with Tour-

clip on the electrical bracket (1) under the right side cover.

Paks. The seat screw is in the Parts Kit, Part No. 53318-99.

Cut the cable tie securing the data link connector harness to

On Ultra models, see Figure 2-2. Remove map pouch and

the frame and snap the connector into its clip on the electrical

molded Tour-Pak liner from Tour-Pak prior to performing the

bracket.

following procedures. Install both after work is completed.

pd0215

5029

1

2

Carbureted

Figure 2-2. Tour-Pak Liner and Map Pouch

pd0216

Five Bolt Mounting

Note that Tour-Pak has seven mounting holes which allow it

to be positioned forward on luggage rack for shipping

only. Mount Tour-Pak in the rearward position (front four

holes and rear center hole) so seat access screw can be

1

reached.

1. To avoid dropping or scratching the Tour-Pak, disconnect

the radio antenna cable and Tour-Pak lights connectors

and feed wiring out through hole at front of Tour-Pak

(after removing grommet). On Ultra models, repeat the

2

procedure to release the CB antenna cable and connec-

tor.

2. If not already removed, remove seat.

Fuel injected

3. Place a protective blanket across the frame tubes in the

1. Electrical bracket

seat area.

2. Data link connector [91]

4. From inside Tour-Pak, remove the nuts and oversized

Figure 2-1. Data Link Connector

shipping washers and then lift the Tour-Pak off the

mounting bolts setting it on the blanket. Retain nuts for

use later, discard large shipping washers.

2005 PDI: Touring Models

2-3

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5.

See Figure 2-3. Remove and discard the pushnuts (5)

SEATS AND PASSENGER STRAP

from the mounting bolts (1), and pull the bolts (1) and

washers (2) from the luggage rack (although the spacers

Refer to Touring Models Owner’s Manual for seat and pas-

(4) may be left in place between the top support tube (3)

senger strap removal and installation instructions. Road Glide

and the license plate bracket).

models must have the seat strap installed per the appropriate

6.

Locate Parts kit, Part no. 53318-99 in Tour-Pak or sad-

Service Manual.

dlebag. The plastic bag contains three spacers, bolts,

nuts and five washers used to mount Tour-Pak. Also in

parts kit is the seat retaining screw.

INSTALLING SIDECOVERS AND

7.

See Figure 2-4. Move Tour-Pak to rear so five mounting

SADDLEBAGS

holes align with five holes in top support tube.

NOTE

Check that each saddlebag is firmly seated on its saddlebag

Make certain bolts are installed with threaded end down. Bolt

bottom support rail. Check that adequate clearance exists

head and washer must be inside Tour-Pak.

between saddlebags and sidecovers. The front and rear

mounting brackets of each saddlebag have slotted mounting

8.

From inside Tour-Pak, install right rear bolt

(1) and

holes (on the bracket ends which attach to the motorcycle) to

washer (2) through bottom of Tour-Pak, hole in top sup-

allow for vertical adjustment of the saddlebag. If adjustment is

port tube

(3), luggage rack spacer

(4), and hole in

license plate bracket (5).

necessary, loosen the bolts which secure the saddlebag

mounting brackets to the motorcycle. Press down and to the

9.

Install washer (2) and locknut (6) on right rear bolt and

rear firmly on closed saddlebag, and then tighten the bolts to

tighten “finger-tight”. (This fastener will keep Tour-Pak in

60-96 in-lbs (6.8-10.8 Nm) torque.

position while remaining four bolts are installed.)

10. Install antenna ground lead ring terminal under washer

NOTE

of rear mounting bolt and install rear bolt as shown in

It is essential that the Tour-Pak be installed in the rearward

Figure 2-4.

position or seat removal/installation will not be possible due to

11. Install remaining bolts, washers, spacers and nuts as

interference with the forward-mounted Tour-Pak.

shown in Figure 2-4.

On Ultra models, see Figure 2-5. Check that AM/FM/WB

12. Tighten five nuts and bolts to 96-120 in-lbs (10.8-13.5

antenna (left side) cable is in its two clips on left side of Tour-

Nm).

Pak floor. Also check that CB antenna (right side) cable is in

two clips on right side of Tour-Pak floor. Verify that ground

strap of AM/FM/WB antenna is securely fastened to base

pd0188

plate in Tour-Pak with rear mounting screw.

1

5

3

4

2

1.

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

2.

Washer 1/4 in. inside dia. (2) (under bolt head)

3.

Top support tube

4.

Luggage rack spacer (2)

5.

Pushnuts (2)

Figure 2-3. Tour-Pak Shipping Fasteners

2-4

2005 PDI: Touring Models

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pd0187e

1

Bottom view showing

2

spacer (4) between license

plate bracket (5) and top

support tube (3).

4

4

3

3

5

6

5

2

2

6

1.

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

2.

Washer 1/4 in. inside dia. (7)

3.

Top support tube

4.

Luggage rack spacer (5)

5.

License plate bracket

6.

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

Figure 2-4. Tour-Pak Mounting

f1467b2x

Figure 2-5. Antenna Cable Clip

(CB Antenna Cable Shown)

2005 PDI: Touring Models

2-5

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RADIO ANTENNA MAST

REAR SPEAKER HARNESSES

INSTALLATION

1.

See Figure 2-6. Cut cable straps securing rear speaker

harnesses to passenger handrail (both right and left

Open the Tour-Pak lid.

sides). Locate plastic grommets packed in Tour-Pak.

FLHTC models are equipped with one antenna mast. Thread

2.

Press down on seat cushion, slide harness and connec-

the mast securely over the antenna mounting stud and

tor into speaker box.

tighten the set screw.

3.

Install split plastic grommet on harness and push grom-

FLHTCU models are equipped with two antenna masts —

met into hole in speaker box.

one with loading coil for CB radio for right side mounting, the

4.

Repeat steps 2 and 3 for left side.

other for AM/FM radio for left side.

On Ultra models only, use soapy water as a lubricant to install

a protective rubber boot (provided with vehicle) over tip of

6712

AM/FM antenna mast; slide boot down mast and over spring-

loaded base. Repeat for CB antenna, but, loosen upper set-

screw in base, slide mast from base and slide boot onto mast

below loading coil. Reassemble mast to base and adjust dis-

tance between bottom of loading coil to top of base to 1 in.

1

Thread each mast securely over its antenna mounting stud.

Tighten the two (3 on CB) set screws (one for antenna mast,

the other for antenna mounting stud) located in the spring-

loaded base of each antenna and one at top of loading coil.

NOTE

Standing Wave Ratio (SWR) will be checked later in these

procedures.

6711

2

1. Right speaker harness

2. Plastic grommet (shown partially installed)

Figure 2-6. Rear Speaker Harness Grommets

(Seat removed for clarity)

2-6

2005 PDI: Touring Models

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INSTALLING WINDSHIELD

Windshield Installation: FLTR

1. See Figure 2-8. Place black plastic washers (4) on the

five mounting screws (3). Position rubber trim along bot-

FLHTC, FLHTCU, FLHTCSE² (Wind Deflec-

tom of windshield. Insert screws through windshield

tor) and FLHTP (Fairing)

holes and thread loosely into five Wellnuts (5) with rubber

washers (6).

1. See Figure 2-7. Loosen the three fasteners along the top

of the outer fairing. It is not necessary to remove the fas-

2. Push Wellnuts with rubber washers into holes in fairing.

teners.

3. Beginning with the center screw and working outward

2. Slide windshield down between the inner and outer fair-

toward the rear edges of windshield, tighten all screws to

ing over the fasteners. Position on the raised boss on the

6-13 in-lbs (0.7-1.5 Nm). Make certain that the four outer

inner fairing.

screws are located at the upper end of the slots in the

windshield.

pd0173x

f2280x2x

5

1

6

4

3

2

1. Windshield

2. Outer fairing

3. Screw (5)

4. Flat washer (plastic) (5)

Figure 2-7. Windshield Installation-FLHT Models

5. Wellnut (5)

6. Flat washer (rubber) (5)

Figure 2-8. Windshield Installation-FLTR Models

CAUTION

Overtightening windshield fasteners may crack wind-

shield and/or fairing.

3. Tighten fasteners to 25-30 in-lbs (2.8-3.4 Nm).

2005 PDI: Touring Models

2-7

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Windshield Installation: FLHR/C and

pd0227

FLHP (Windshield)

16

15

6

CAUTION

Be sure you position the windshield bracket between the

7

rubber grommets. Incorrect mounting could result in

3

damage to the windshield.

See Figure 2-9. Insert your fingers into the wireform latch

9

14

springs at either side of the windshield and slide the BOT-

2

TOM windshield bracket notches onto the bottom grommets.

Slide the TOP bracket notches onto the top grommets.

8

NOTE

1

If windshield contacts clutch cable, reposition handlebars.

10

5

12

OMF53

4

11

13

1.

Nut

2.

Nacelle trim

3.

Screw

Figure 2-9. FLHR/C and FLHP Windshield Installation

4.

Nut

5.

Flat washer

Seat Adjustment: FLHTP

6.

Fork lock plate

7.

Screw (2)

Before applying load to the seat, refer to the Police Models

8.

Nacelle

Owner’s Manual for adjustment procedures of the FLHTP air-

9.

Handlebar clamp shroud

suspension seat. Confirm that air bladder is inflated to 10-psi

10.

Headlamp assembly

(69 kPa) minimum.

11.

Screw (8)

12.

Chrome headlamp ring

Instrument Mounting Bracket

13.

Screw

Installation: FLHP

14.

Stud plate

15.

Acorn nut (2)

The FLHP is provided with an instrument mounting bracket.

16.

Tachometer bracket

The bracket relocates the tachometer to allow the addition of

a radio speaker, and control panel.

Figure 2-10. FLHP Headlamp Nacelle

1. See Figure 2-10. Remove screw (13) securing chrome

ring (12) to headlamp nacelle (8). Remove chrome ring.

2. Remove eight fasteners (11) securing headlamp assem-

bly

(10). Squeeze two external tabs

(if present) to

remove wire connector at back of headlamp bulb.

Remove headlamp assembly from vehicle.

2-8

2005 PDI: Touring Models

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3.

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

p0044x5x

4.

Disconnect tachometer connector [108] inside headlamp

1

nacelle.

5.

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

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

(5).

2

6.

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

clamp shroud. Remove two screws (7) beneath lock

plate.

7.

Loosen four acorn nuts securing nacelle halves to fork

studs. Spread nacelle halves slightly and remove handle-

bar clamp shroud.

6

8.

Remove two acorn nuts (15) and flat washers securing

Tachometer and bracket (16) to handlebar clamp shroud.

9.

See Figure 2-11. A peel and stick foam tape holds the

stud plate (4) in place inside the handlebar clamp shroud

(3). Position instrument mounting bracket (2) on studs of

stud plate and secure in position using hardware pro-

vided by radio manufacturer (1).

10.

Using screw (5) and nut (6) provided, secure front tab of

5

3

instrument mounting bracket on handlebar clamp

shroud.

11.

Reinstall handlebar clamp shroud. Tighten acorn nuts

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

(8.1-12.2 Nm).

4

12.

See Figure 2-12. Mount tachometer on bracket with

acorn nuts and flat washers as shown.

1.

Nut (2)

13.

See Figure 2-10. Install two screws (7) to handlebar

2.

Instrument mounting bracket

clamp shroud and tighten to 10-20 in-lbs (1.1-2.3 Nm).

3.

Handlebar clamp shroud

Gently press fork lock plate (6) into place on handlebar

4.

Stud plate

clamp shroud.

5.

Screw

6.

Nut

14.

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

lbs (1.1-2.3 Nm).

Figure 2-11. FLHP Instrument Bracket

15.

Connect tachometer lead [108].

16.

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

ing nacelle trim. Tighten to 15-20 in-lbs (1.7-2.3 Nm).

5530

17.

Connect wire connector to socket on back of headlamp

bulb. Install and secure headlamp assembly to nacelle

with eight fasteners.

18.

Secure chrome ring (12) to headlamp nacelle with screw

(13).

NOTE

Check for adequate clearance between windshield and clutch

cable and handlebar position prior to completing assembly of

vehicle.

Figure 2-12. FLHP Tachometer Mount

2005 PDI: Touring Models

2-9

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MIRRORS

THROTTLE CONTROL CABLES

See Figure 2-13. Adjust mirrors for proper rear view. Verify

that mirror fasteners are properly tightened.

All Non-Ultra Models

Check throttle cable adjustment in accordance with proce-

dure given in Section 1 of Touring Models Service Manual.

pdoo72b

Ultra Models

Check throttle cable adjustment in accordance with proce-

dure given in Section 8 of Touring Models Service Manual.

Figure 2-13. Mirror Installation

2-10

2005 PDI: Touring Models

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REAR SUSPENSION

8472

AIR PRESSURE

CAUTION

Do not exceed maximum air pressure for rear suspen-

sion. Air components fill rapidly. Therefore, use low air

line pressure. Failure to do so may result in possible

damage to components. (00165a)

IMPORTANT NOTE

Maximum air pressure of rear suspension system is 50

psi (345 kPa).

Figure 2-14. Rear Suspension Air Pressure Valve

See Figure 2-14. Check rear suspension air pressure at air

valve located on the left side of the motorcycle below the

frame cover, above the left saddlebag. Refer to Table 2-3.

These are recommended starting points, adjust to suit load

conditions, riding style and comfort desired. Less initial pres-

sure does not necessarily result in a softer ride. Use a no-loss

gauge, add 3-5 psi (20.68-34.48 kPa) to clear line and adjust

for application.

Table 2-3. Rear Suspension Air Pressure (All Models Except FLHRS)

Pressure

Loading

psi

kPa

Solo rider -150 lbs (68.0 kg) maximum

0

0

Solo rider 150-200 lbs (68.0-90.7 kg)

0-10

0-69

Solo rider 200-250 lbs (90.7-113.4 kg)

5-15

35-103

Rider and 150 lbs (68.0 kg) passenger

10-15

69-103

Rider and 200 lbs (90.7 kg) passenger

20-25

138-172

Gross vehicle weight rating (GVWR)

20-35

138-241

Table 2-4. Rear Suspension Air Pressure (FLHRS and FLHTCSE² Only)

Pressure

Loading

psi

kPa

Solo rider -160 lbs (73.0 kg) maximum

0-5

0-35

Solo rider 160-200 lbs (73.0-90.7 kg)

0-10

0-69

Solo rider 200-250 lbs (90.7-113.4 kg)

5-10

35-69

Rider and 150 lbs (68.0 kg) passenger

20-30

138-207

Rider and Over 150 lbs (68 kg) passenger

25-35

172-241

Gross vehicle weight rating (GVWR)

40-50

276-345

2005 PDI: Touring Models

2-11

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LUBRICATION SYSTEM

2.3

3. Remove the dipstick and note the level of the oil. Add

ENGINE OIL LEVEL

only enough oil to bring the level to the FULL mark on the

dipstick. See Figure 2-15. Do not overfill.

CAUTION

4. Start engine and carefully check for oil leaks around

drain plug and oil filter.

The FLHTCSE² model is shipped from the factory with

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

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

ENGINE OIL LEVEL (SIDE CAR

NOT use standard lubricants in the FLHTCSE² model and

EQUIPPED VEHICLES)

do not mix lubricants as damage to the motorcycle can

result.

NOTE

IMPORTANT NOTE

Oil level cannot be accurately measured on a cold

Since a motorcycle equipped with a sidecar is fixed in an

upright position, the engine oil level reading must be adjusted

engine. For preride inspection with motorcycle leaning

on jiffy stand on level ground, oil should register on dip-

in this case; the actual FULL engine oil level will be about 1/2

inch above the original FULL mark on the oil tank dipstick.

stick between arrows when engine is cold. Do NOT add

oil to bring the level to the FULL mark on a COLD engine.

To insure the correct oil level with sidecar attached perform

Perform engine oil level COLD CHECK as follows:

the following:

1. With the vehicle resting on the jiffy stand on level ground,

1.

Without sidecar attached, check engine oil level with

remove the dipstick, wipe it off and insert it back into the

engine at normal operating temperature. See HOT

oil pan with the plug pushed completely into the fill spout.

CHECK procedure above.

2. Remove the dipstick and note the level of the oil. Oil level

2.

Verify oil level is at FULL mark on dipstick (add oil if

should register on the dipstick. See Figure 2-15. If oil

needed).

level is at or below the lower arrow, add only enough oil

3.

With sidecar attached, ride until engine is at normal

to bring the level to the add arrow on the dipstick.

operating temperature.

NOTE

4.

On a level surface, note engine oil level on dipstick.

Once the predelivery inspection procedure is complete and

5.

Scribe a line on dipstick at the oil level noted in step 4

the vehicle has been road-tested, the engine oil level should

above. The scribed line is the FULL mark for sidecar

be checked again as described in the following procedure.

operation.

Perform engine oil level HOT CHECK as follows:

1. With the vehicle resting on the jiffy stand on level ground,

allow engine to idle for 1-2 minutes. Turn engine off.

2. Remove the dipstick, wipe it off and insert it back into the

oil pan with the plug pushed completely into the fill spout.

COLD CHECK

HOT CHECK

f1254b3x

Figure 2-15. Engine Oil Dipstick

2-12

2005 PDI: Touring Models

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TRANSMISSION LUBRICANT

pd0206

NOTE

Allow vehicle to stand upright for a moment before checking

transmission lubricant level. This will allow lubricant level to

normalize.

Check the transmission lubricant level with the motorcycle

standing upright in accordance with the procedure given in

the Touring Models Service Manual.

CHAINCASE LUBRICANT LEVEL

AND CLUTCH OPERATION

NOTE

Do not remove the clutch cover on the FLHTCSE². It is not

necessary to check the primary chaincase lubricant level on

this vehicle. Also, the hydraulic clutch is not adjustable.

1. Remove five screws, clutch inspection cover and cover

gasket.

Figure 2-16. Chaincase Lubricant Level

2. See Figure 2-16. The primary chaincase lubricant level is

3. Check clutch action. Clutch lever should move freely and

acceptable when lubricant is visible in bottom of chain-

smoothly through its entire range of travel.

case with motorcycle standing upright (not resting on jiffy

4. Check clutch adjustment according to the procedures

stand).

given in the Touring Models Service Manual.

NOTE

The clutch inspection cover gasket may be reused ONLY

when checking chaincase lubricant level and reinstalling

clutch inspection cover at PDI.

5. Reinstall cover gasket and clutch inspection cover, and

secure with five screws. Tighten to 84-108 in-lbs (9.5-

12.2 Nm).

2005 PDI: Touring Models

2-13

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FUEL SYSTEM

2.4

GENERAL

CHECKING QUICK CONNECT FUEL

LINE FITTING-FUEL INJECTED

CAUTION

MODELS

Some fuel suppliers sell gasoline which has been

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

1WARNING

of alcohol or ether added to the fuel is important.

To avoid an uncontrolled discharge or spray of gasoline,

always be sure the quick-connect fitting (under left side

CAUTION

of fuel tank) is properly mated. A slight tug on the fuel

Do not use gasoline that contains methanol. Doing so

line will verify this condition. Gasoline is extremely flam-

can result in fuel system component failure, engine dam-

mable and highly explosive. Inadequate safety precau-

age and/or equipment malfunction. (00148a)

tions could result in death or serious injury.

● Gasolines containing ETHANOL (ethyl alcohol or grain

1. Tug on fuel supply line (under left side of fuel tank) to be

alcohol) can be used. Gasoline/ethanol blends are a mix-

sure quick connect fitting is properly mated.

ture of 10% ethanol and 90% unleaded gasoline. They

2. If fuel line comes free, push up on sleeve of quick-con-

are identified as “gasohol,” “ethanol enhanced,” or “con-

nect fitting and insert neck of fuel supply line fitting. While

tains ethanol.”

pushing up on bottom of fuel supply line fitting, pull down

● Gasolines containing METHYL TERTIARY BUTYL

on sleeve until it “clicks” into the locked position.

ETHER (MTBE) can also be used. Gasoline/MTBE

blends are a mixture of gasoline and as much as 15%

FUEL TANK

MTBE.

● REFORMULATED OR OXYGENATED GASOLINES

Make sure engine stop switch on the handlebar is switched to

(RFG):

“Reformulated gasoline” is a term used to

the OFF position. Turn the ignition/light switch to the IGNI-

describe gasoline blends that are specifically designed to

TION position. Fuel injected models: verify that Low Fuel

burn cleaner than other types of gasoline, leaving fewer

lamp is lit. Partially fill fuel tank with gasoline. Follow FUEL

“tailpipe” emissions. They are also formulated to evapo-

recommendations found in the Owner’s Manual. Use

rate less when you are filling your tank. Reformulated

unleaded gasoline, 91 octane or higher. Verify function of fuel

gasolines use additives to “oxygenate” the gas. Your

gauge as fuel tank is filling, then turn ignition/light switch OFF.

motorcycle will run normally using this type of gas and

Inspect fuel lines for leaks.

Harley Davidson recommends you use it when possible,

as an aid to cleaner air in our environment

Carbureted Models

Because of their different chemical properties (which affect

See Figure 2-17. After adding gasoline, check for smooth

fuel volatility and ignition characteristics), these blends may

operation of the fuel valve. Inspect fuel valve for leaks.

adversely affect the starting, drivability, and fuel efficiency of

the motorcycle. If you experience these problems, Harley-

Davidson recommends using straight, unleaded gasoline.

o0046box

CAUTION

Use only unleaded fuel in California model catalytic con-

verter-equipped motorcycles. Using leaded fuel will dam-

age the emission control system. (00150a).

Figure 2-17. Fuel Supply Valve

2-14

2005 PDI: Touring Models

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EVAPORATIVE EMISSIONS

CONTROL SYSTEM-CALIFORNIA

MODELS ONLY

See Figure 2-18. See Figure 2-19. Verify correct evaporative

emissions control system hose routing, connections, and fuel

tank venting to canister (if equipped).

1.

Carburetor (induction module on

2

fuel-injected models)

4

1

2.

Vacuum tube

5

3.

Fuel valve

4.

Filler neck fitting (Top of canopy on

3

FLHR/C/S)

5.

Fuel tank

6.

Fuel vapor vent tube

7.

Vapor valve

8.

Charcoal canister

9.

Purge tube

10. Clean air inlet tube (not used on

fuel-injected models)

7

11. Air cleaner backplate

9

6

10

8

11

f1706x4x

Figure 2-18. Evaporative Emissions Control System Hose Connections

f1884x4x

3

1

4

2

1.

Clean air inlet tube from air cleaner backplate (carbureted models only)

2.

Purge tube to carburetor or induction module

3.

Fuel vapor vent tube from fuel tank

4.

Fuel vapor vent tube from vapor valve

Figure 2-19. Evaporative Emissions Control System Hose Routing

2005 PDI: Touring Models

2-15

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ELECTRICAL SYSTEM

2.5

HEADLAMP

DIRECTIONAL LAMPS

Check headlamp beam for proper height and lateral align-

Adjust front directional lamps so lenses are aimed directly for-

ment in accordance with procedures given in Section 8 of the

ward. Verify that directional lamp fasteners are properly tight-

Touring Models Service Manual.

ened.

1WARNING

FRONT TURN SIGNALS

The automatic-on headlamp feature provides increased

(FLHRS ONLY)

visibility of the rider to other motorists. Be sure head-

lamp is on at all times. Poor visibility of rider to other

Adjust and tighten. Ensure that directionals do not contact

motorists can result in death or serious injury. (00030b)

fuel tank.

AUXILIARY LAMPS

INSTRUMENT PANEL

On models equipped with auxiliary lamps, check lamp beam

See Figure 2-20. The instrument panel has a Low Fuel,

for proper height and lateral alignment in accordance with

Check Engine, Security (if equipped) Battery, Cruise Control

procedures given in the Touring Models Service Manual.

(if equipped) and ABS (if equipped) warning lamps.

● The Low Fuel Warning lamp comes on when approxi-

mately 0.9 gallon (3.4 liter) of gasoline remains.

● The Check Engine lamp illuminates briefly (4 seconds) at

start-up and should then remain off unless an error code

is present.

f2185xax

d0715x8x

1

3

1

8

2

60

40

50

70

30

50

40

80

30

90

20

60

MPH

RPM x100

20

100

10

70

10

110

0

120

0

80

7

TI

7

-D

-D

6

6

2

4

5

4

8

5

FLHT and FLTR Models

FLHR Models

pd0221

40

30

50

1. Speedometer

20

60

2. Security system lamp

RPM x100

3. Tachometer

10

70

4. Cruise lamp

P

0

80

5. Odometer/trip-odometer

6. Low fuel warning lamp

7. Engine check lamp

-D

10

9

8. Battery discharge lamp

9. ABS lamp (optional police equipment)

FLHTP/FLHP Models Tachometer

10. Pursuit lamp indicator (police)

Figure 2-20. Instrument Panel Warning Lamps

2-16

2005 PDI: Touring Models

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8.

Check operation of all remaining lamps:

INDICATOR LAMPS/CONTROLS

● Headlamp-low and high beams

1. See Figure 2-21. Turn ignition/light switch to IGNITION

● Headlamp high beam indicator lamp

position, and check that Oil pressure indicator lamp turns

● Passing/pursuit lamps

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

and if TSSM EQUIPPED, THE SECURITY LAMP will illu-

● Pursuit lamp indicator lamp (FLHTP)

minate for approximately four seconds and then turn off.

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

NOTES

● Left directional (turn signal) indicator lamp

For any Systems problems, refer to the appropriate Electrical

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

Diagnostic manual for your model.

● Right directional (turn signal) indicator lamp

2.

Shift transmission to neutral position, and verify that neu-

tral indicator lamp turns on.

● Left front running lamp

3. Start engine; check operation of starter.

● Right front running lamp

● Tail lamp-running lamp and brake lamp filaments

NOTE

On Police models, the clutch lever must be depressed to

● Speedometer illumination lamp

operate the starter.

● Tachometer illumination lamp (if equipped)

4.

Check that oil pressure indicator lamp turns off when

● License plate lamp (HDI only)

engine is running above 1000 RPM.

● Sound System Operation (if equipped)

5.

Check operation of tachometer (if equipped).

9.

After engine has reached normal operating temperature,

6.

Disengage clutch (depress clutch lever), and verify that

turn engine off.

neutral indicator lamp turns off when transmission is

10.

Check engine oil level in manner previously specified.

shifted to any forward gear. Shift transmission to neutral

position, and verify that neutral indicator lamp turns on

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

again.

7. Check horn operation.

pd0192

3

1

2

1

2

1. Ignition switch unlocked

2. Ignition switch locked

3.

“Key ON” Ignition position

Figure 2-21. Ignition Switches

2005 PDI: Touring Models

2-17

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