1-14 2005 PDI: All Models
VEHICLE CLEANUP
1WARNING1WARNING
Do not let the brakes, engine, mufflers or air cleaner get
wet when washing your motorcycle. Allowing these com-
ponents to get too wet can adversely affect their perfor-
mance, which could result in death or serious injury.
Start engine immediately after washing, and make sure
brakes and engine are operating properly before riding in
traffic. (00078b)
CAUTION
Avoid spraying water directly on handlebar switches. Wet
handlebar switches may be inoperative.
Remove protective shipping tape from motorcycle. Wash
entire motorcycle before beginning actual predelivery inspec-
tion. If vehicle is equipped with frame downtube reflectors,
remove any plastic cable straps wrapped around reflectors
(cable straps are used during assembly at factory for retain-
ing reflectors to downtubes while reflector adhesive cures).
COSMETIC QUALITY
Paint Finish Inspection and Repair
Under good lighting conditions, examine all painted parts for
any damage or irregularities in the paint finish. To aid the
dealer network in addressing quality concerns, Harley-David-
son Motor Company has developed a zoning and criteria pro-
tocol, which enables us to exceed customer’s expectations. If
you discover any condition requiring repair, use Paint Repair
Kit (Part No. HD-39994); available through Kent-Moore, at the
following address, to correct the condition.
Kent-Moore
28635 Mound Rd
Warren, Michigan 48092-3499
(phone) 1-800-345-2233
Instructions covering painted part repair are included with the
Paint repair Kit. Additional paint repair information is available
from Harley-Davidson on the PHD training videotape No. 136.
Additional cosmetic quality information is available in the Har-
ley-Davidson Cosmetic Booklet (Part No. HD-99514-05) and
on-line Cosmetic Training located on HDU On-line.
RETURNING STEEL PALLETS
NOTE
International Dealers/Distributors should check with their H-D
office to determine whether or not to return pallets.
1. See Figure 1-26. Remove and discard plastic motor shim
(1).
2. Turn eye-bolts (2) so they are parallel with sides of pallet.
This will allow stacking pallets for shipment.
NOTE
On VRSC pallets place eye-bolt from rear in enclosed area
(3) of pallet.
3. Place hold-down straps you are returning to factory in
enclosed area (3) of pallets.
CAUTION
Do not mix 29 in. (736.6 mm) width pallets with 43 in.
(1.09 m) width pallets on the same 7-pallet stack. Mixing
pallets of different width could result in an unstable bun-
dle and pallet damage.
4. Stack seven pallets keeping all eye-bolts on same end.
5. Band pallets by threading hold-down straps through both
end cross members of top and bottom pallets. (If neces-
sary connect two straps together.)
6. Tighten straps to secure pallet bundles.
7. Call, Fax, E-mail or use www.h-dnet.com to arrange
pallet return to Harley-Davidson.
Figure 1-26. Vehicle Pallet
1. Plastic motor shim
2. Eye-bolts
3. Enclosed area
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