Market Position:
Essential documentation for authorized Harley-Davidson dealerships to ensure new motorcycles are prepared to the brand's high standards before customer handover.
Competitive Analysis:
Similar to predelivery manuals from other major motorcycle manufacturers, but tailored to Harley-Davidson's specific assembly and quality control processes.
Key Features:
Provides a standardized workflow for consistent vehicle preparation, ensuring customer satisfaction and adherence to warranty requirements.
Primary Coverage:
Predelivery inspection and setup procedures for 2005 Harley-Davidson motorcycles.
Secondary Coverage:
Initial setup, pre-ride checks, basic adjustments, and quality control measures.
Specific Models Covered:
Covers predelivery and setup for the range of Harley-Davidson models offered in 2005, including Sportster, Dyna, Softail, V-Rod, and Touring families, provided they are distinct models and the manual is generic or has addendums.
Page Count:
Approximately 150-200 pages (estimated, based on typical Harley-Davidson P&S manuals for this era).
Manual Type:
Predelivery and Setup Manual
Target Audience:
Harley-Davidson Dealership Technicians, Service Advisors, and Predelivery Inspectors.
Format:
Likely Printed Booklet/Binder, potentially digitized as PDF.
Engine Preparation:
Initial checks, fluid levels, spark plug inspection, break-in recommendations.
Chassis Assembly:
Handlebar installation, control cable routing and adjustment, lever alignment.
Suspension Setup:
Fork oil level check, rear shock pre-load adjustment (if applicable).
Brake System:
Brake fluid level checks, lever/pedal free play adjustment, initial pad inspection.
Electrical System:
Battery connection checks, headlight aim, taillight/brake light function, horn operation.
Wheel And Tire:
Tire pressure verification, wheel nut torque checks, valve stem inspection.
Fuel System:
Fuel line integrity check, fuel cap sealing, initial fuel level.
Exhaust System:
Inspection for leaks, proper mounting, and absence of damage.
Security System:
If equipped with an optional factory security system, initial setup and verification of function.
Pre Delivery Checklist:
Comprehensive itemized list for dealership technicians.
Fluid Filling:
Correct procedures for filling engine oil, primary chaincase oil, transmission oil, brake fluid.
Torque Specifications:
Key torque values for critical fasteners during setup (e.g., axle nuts, handlebar clamps).
Adjustment Procedures:
Carburetor idle speed and mixture, clutch and throttle cable free play.
Diagnostic Checks:
Basic electrical system checks, starter operation, engine start-up sequence.
Safety Inspection:
Ensuring all safety-critical components are correctly installed and functional.
Cosmetic Inspection:
Procedures for checking paint finish, chrome quality, decal application, and overall aesthetic presentation.
Accessory Installation Checks:
Procedures for verifying correct installation of factory-installed accessories.
Depth:
Focuses on initial assembly, quality assurance, and preparation for customer delivery. Not a full repair manual, but covers essential checks and adjustments.
Component Checks:
Detailed instructions for checking and ensuring correct function of all basic motorcycle systems prior to customer delivery, from tire inflation to control cable play.
Regulatory Compliance:
Ensures the motorcycle meets all federal and state requirements for road legality prior to sale (e.g., lighting, emissions labeling).
File Format:
N/A (if printed), PDF (if digital, expected quality: searchable text, clear diagrams).
Searchability:
If digital (PDF), excellent searchability for specific terms and procedures.
Print Quality:
Professional, high-quality printing with clear diagrams and legible text (typical for Harley-Davidson official publications).
Binding Type:
Likely saddle-stitched booklet or spiral-bound for ease of use in a workshop setting.
Paper Type:
Durable paper stock, often with a semi-gloss finish to protect against workshop grime.
Engine Type:
V-Twin, Air-Cooled (Specific engine family will vary based on the actual Harley-Davidson model the manual is for, e.g., Twin Cam 88/88B).
Engine Displacements Typical:
1450cc (88 cubic inches) for Twin Cam 88, potentially 1550cc (95 cubic inches) for models with Screamin' Eagle upgrades.
Fuel System Type:
Carbureted (e.g., Keihin CV) or Electronic Fuel Injection (EFI) depending on the specific model variant.
Engine Oil Type:
Harley-Davidson H-D 360 SAE 20W-50 Motorcycle Oil is recommended. Check manual for exact OEM specification or approved alternatives.
Engine Oil Capacity:
Approximately 4 US quarts (3.8 liters) - verify for specific engine variant.
Valve Train:
Overhead valves (OHV), pushrod actuated (typical for Harley-Davidson V-twins).
Transmission Type:
5-speed constant mesh manual transmission.
Optional Transmissions:
N/A for 2005 models in this context; 5-speed was standard across most Softail, Dyna, and Touring platforms.
Primary Drive:
Chain drive, enclosed in a primary chaincase.
Transmission Oil Type:
Harley-Davidson recommended primary/transmission fluid or an equivalent motorcycle-specific gear oil (e.g., SAE 85W-140 is common).
Transmission Oil Capacity:
Approximately 20 US fluid ounces (0.6 liters) for the transmission; primary chaincase has its own separate fill.
Safety Ratings:
Motorcycles are not typically rated by agencies like NHTSA or IIHS in the same way cars are. Safety is primarily based on rider skill and adherence to traffic laws.
Active Safety Features:
Hydraulic disc brakes (front and rear), linked braking systems may be present on some models. Tire selection and maintenance are critical.
Passive Safety Features:
Frame integrity, rider ergonomics for control, lighting systems.
Infotainment Features:
Most 2005 models would not have advanced infotainment. Radio/CD player options were available on touring models. Basic instrumentation includes speedometer, tachometer (optional), odometer, trip meter, and indicator lights.
Driver Assistance Features:
N/A. Motorcycle rider assistance systems were not prevalent in 2005.
Connectivity Features:
N/A. No Bluetooth or smartphone integration.
Initial Service:
Typically around the 1,000-mile (1,600 km) mark, which includes an oil and filter change, primary chaincase oil change, and general inspection. This manual aids in the pre-delivery preparation leading up to that.
Brake Fluid Type:
DOT 4 specification, typically Harley-Davidson brand or equivalent.
Primary Chaincase Oil Type:
Harley-Davidson primary/transmission fluid or an equivalent motorcycle-specific primary lubricant.
Primary Chaincase Oil Capacity:
Approximately 24 US fluid ounces (0.7 liters) - verify for specific model/engine.
Known Issues 2005 Era:
Early Twin Cam engines could experience compensator sprocket wear. Some models might have had early EFI calibration issues or specific sensor failures. However, this manual focuses on initial setup, not post-delivery common issues.
Brand Heritage:
Harley-Davidson, founded in 1903, has a long and storied history in motorcycle manufacturing, known for its V-twin engines and distinctive styling.
Model Evolution 2005:
2005 marked a period of evolution for Harley-Davidson, with the continued presence of the Twin Cam 88 engine across its core platforms (Dyna, Softail, Touring). EFI became more widespread, and design elements continued to refine iconic models.
Production Locations:
Primarily manufactured in Milwaukee, Wisconsin, and York, Pennsylvania, USA.
