Harley Davidson Touring 2005 Repair Service Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Touring Year: 2005 Codes Chassis Code: V-Twin (specific designation varies by sub-model) 👋 Introduction Market Position Target Audience: Professional Harley-Davidson technicians, dealership service...

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Art.-Nr: 561337

Stichworte: 2005 Harley Davidson Misc Motorcycle Motorcycles Touring

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Beschreibung

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Touring

Year:

Codes

Chassis Code:

V-Twin (specific designation varies by sub-model)

👋 Introduction

Market Position

Target Audience:

Professional Harley-Davidson technicians, dealership service departments, experienced independent mechanics, and dedicated DIY enthusiasts

Competitive Analysis

Value Proposition:

Provides essential technical data and procedures for maintaining and repairing complex Harley-Davidson touring motorcycles, ensuring longevity and optimal performance.

Key Features

Features:

Instant download access, comprehensive system coverage, detailed diagrams and schematics, troubleshooting guides.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete repair and service for 2005 Harley-Davidson Touring models

Secondary Coverage:

Maintenance, diagnostics, troubleshooting, and component overhaul

Page Count

Estimated Page Count:

800-1200 (typical for comprehensive service manuals of this era, exact count not provided in description)

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Twin Cam 88 (EFI and Carbureted variants), Twin Cam 95 (optional/screamin eagle), internal engine components (pistons, rings, valves, cams, lubrication, cooling)

Fuel System:

Electronic Fuel Injection (EFI) systems (e.g., Delphi Electronic Control Module - ECM), Carbureted systems (e.g., Keihin CV carburetor), fuel pumps, filters, lines

Ignition System:

Electronic ignition, spark plugs, ignition coils, crank position sensor, troubleshooting ignition faults

Transmission:

5-speed Cruise Drive Transmission, clutch operation and service, gearbox internals, primary drive, final drive

Electrical System:

Wiring diagrams, battery maintenance, charging system (alternator, regulator), starter motor, lighting systems (headlamp, taillamp, turn signals), gauges, horn, accessory circuits

Brakes:

Hydraulic brake systems (front and rear), brake calipers, master cylinders, brake pads, rotors, brake fluid specifications and bleeding procedures

Suspension:

Front fork (e.g., 49mm Tele-Guide), rear shock absorbers, wheel bearings, swingarm service

Frame And Body:

Frame inspection and repair, body panel removal and installation, fairings, saddlebags, mounting hardware

Wheels And Tires:

Wheel specifications, tire types and sizes, balancing, spoke tension (if applicable)

Exhaust System:

Exhaust pipe routing, mufflers, heat shields, exhaust gasket replacement

Diagnostics:

Troubleshooting common issues, diagnostic trouble codes (DTCs) for EFI models, diagnostic connectors and procedures

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, spark plug replacement, drive belt inspection, chain adjustment (if applicable), brake service, fluid changes

Engine Repair:

Top-end overhaul (cylinder head, valves, pistons), bottom-end overhaul (crankshaft, connecting rods), cam replacement, timing procedures

Transmission Repair:

Clutch adjustment and replacement, gearbox disassembly and reassembly, bearing replacement

Electrical Troubleshooting:

Wiring diagram interpretation, fault finding for lighting, charging, starting, and ignition systems

Brake System Service:

Brake pad replacement, caliper service, master cylinder overhaul, bleeding procedures, fluid flush

Suspension Service:

Fork seal replacement, fork oil changes, shock absorber replacement, swingarm bushing replacement

Efi Tuning And Diagnostics:

ECM diagnostics, sensor testing, fuel injector service, throttle body cleaning

Bodywork Repair:

Fairing repair and mounting, saddlebag installation and removal, cosmetic component replacement

Torque Specifications:

Detailed torque values for all critical fasteners

Technical Depth

Depth:

Comprehensive (suitable for professional technicians and experienced DIYers)

Diagnostic Capability:

Advanced diagnostic procedures for EFI systems, including component testing and troubleshooting logic

Rebuild Procedures:

Detailed step-by-step instructions for complete engine and transmission rebuilds

Special Tools:

Identification and usage of specialized Harley-Davidson tools required for specific procedures

📊 Manual Specifications

File Format

Format:

Searchability:

Likely text-searchable PDF for efficient information retrieval

Print Quality

Quality:

Digital reproduction quality (dependent on source scan/creation, typically clear diagrams and text)

Binding Type

Binding:

N/A (Digital format)

Paper Type

Paper:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Harley-Davidson Twin Cam

Displacement Options:

88 cubic inches (1450cc), 95 cubic inches (1550cc - Screamin' Eagle/optional)

Configuration:

45-degree V-twin, pushrod actuated overhead valves

Performance

Horsepower Approximate:

60-70 HP (varies by specific model and tuning, for Twin Cam 88)

Torque Approximate:

80-90 lb-ft (varies by specific model and tuning, for Twin Cam 88)

Fuel System

Carbureted Models:

Keihin CV (Constant Velocity) carburetor, 40mm

Efi Models:

Multi-point Fuel Injection with Delphi Electronic Control Module (ECM)

Fuel Type Required:

Unleaded gasoline, minimum 91 octane (octane rating may vary by region/recommendation)

Lubrication

Oil Type:

Harley-Davidson SYN3 Full Synthetic Motorcycle Oil or equivalent SAE 20W-50 API CI-4 (or compatible specification)

Oil Capacity Engine:

Approx. 3.5 US quarts (3.3 liters) with filter change

Cooling

Cooling Method:

Air-cooled

🔧 Transmission

Standard

Type:

5-speed constant mesh, helical gears

Gear Ratios:

Specific ratios are detailed within the manual for each gear (e.g., 1st: 9.315, 2nd: 6.654, 3rd: 4.948, 4th: 3.879, 5th: 3.150 - illustrative, actual ratios may vary)

Features

Clutch Type:

Wet, multi-plate, diaphragm spring

Transmission Oil Type:

Harley-Davidson Formula + Transmission Oil or equivalent SAE 85W-140 API GL-5

Primary Drive Type:

Enclosed, wet clutch, primary chain drive to transmission

📐 Dimensions

Exterior

Wheelbase:

Approximately 63.5 inches (1613 mm) (varies slightly by model)

Length:

Approximately 94.0 inches (2388 mm) (varies slightly by model)

Weights

Dry Weight:

Approximately 700-800 lbs (318-363 kg) (varies by model)

Gross Vehicle Weight Rating Gvwr:

Typically around 1300-1400 lbs (590-635 kg)

Cargo

Saddlebag Capacity:

Approx. 2.25 cubic feet (63.7 liters) combined (varies by model)

🛡️ Safety Features

Ratings

Crash Test Ratings:

Not applicable to motorcycles in the same manner as automobiles; focus is on engineering integrity and rider protection systems.

Active Features

Braking System:

Dual-disc front brake, single-disc rear brake, hydraulic actuation

Lighting:

Halogen headlamp, LED taillamp, clear lens front and rear turn signals

Passive Features

Chassis Design:

Robust steel frame designed for stability and rider control

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM/CB radio with cassette or CD player (model dependent), handlebar-mounted controls

Cruise Control:

Electronic cruise control on many Touring models

Driver Assistance

Anti-lock Braking System (ABS) available as an option on certain models

Connectivity

Diagnostic Port:

4-pin diagnostic connector for EFI models to interface with diagnostic tools

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000 miles (8,000 km) or annually, whichever comes first

Primary Chain Tensioner Inspection:

Inspect every 10,000 miles (16,000 km)

Spark Plug Replacement:

Every 10,000 miles (16,000 km) or as needed

Brake Fluid Flush:

Every 2 years (refer to manual for specific DOT rating and interval)

Transmission Oil Change:

Every 10,000 miles (16,000 km) or annually

Fluid Specifications

Engine Oil Spec:

SAE 20W-50 API CI-4 (Harley-Davidson SYN3 recommended)

Transmission Oil Spec:

SAE 85W-140 API GL-5 (Harley-Davidson Formula + recommended)

Brake Fluid Spec:

DOT 4 (refer to specific model variant in manual)

Known Issues

Primary Chain Tensioner:

Early Twin Cam models (pre-2007) had hydraulic tensioners that could wear and fail, leading to noise and potential damage. Manual provides inspection and replacement procedures.

Cam Chain Tensioner Wear:

Similar to primary tensioner, internal cam chain tensioners can wear. Manual details inspection and replacement.

Crank Position Sensor Failure:

Can lead to no-start or intermittent stalling conditions. Manual covers testing and replacement.

Rear Main Seal Leaks:

Occasional leaks can develop. Manual covers replacement procedures, which can be involved.

📚 Vehicle History

Brand Heritage

Heritage:

Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer with a rich history in performance, touring, and customization.

Model Evolution

Touring Lineage:

The Touring line has evolved significantly, with the 2005 models featuring the established Twin Cam engine and advanced chassis designs for comfort and handling.

Production

Manufacturing Location:

Primarily York, Pennsylvania, USA; Milwaukee, Wisconsin, USA

🏆 Awards & Recognition

Recognitions

Brand Recognition:

Harley-Davidson is a globally recognized brand synonymous with the American motorcycle lifestyle and a leader in the touring segment.