2-22 2005 PDI: Touring Models
VEHICLE PDI CHECKLIST 2.10
PRIOR TO CUSTOMER DELIVERY
NOTE
Use this checklist for performing tasks related to this model
motorcycle setup.
❒ Uncrate:
Check for damaged or missing parts.
❒ Handlebars:
Verify proper position; tighten clamps to proper torque.
❒ Jiffy Stand:
Verify proper function.
❒ Note Any Additional Problems
(including cosmetic quality):
Perform Warranty repairs.
❒ Battery:
Perform required voltmeter test on Maxi Fuse (main fuse)
and battery.
❒ Install Maxi Fuse (main fuse).
❒ Install Fuel Pump Fuse (EFI vehicles only).
❒ Install Data Link Connector.
❒ Position Tour-Pak and Install Seat and Seat Strap:
If equipped
❒ Install Saddlebags and Side Covers:
Verify adequate saddlebag/side cover clearance.
❒ Install Antenna Mast(s):
If equipped
❒ Position Rear Speaker Harness.
❒ Install Windshield.
❒ Verify Proper Police Seat Air Bladder Pressure
(Police models).
❒ Install Instrument Bracket (FLHP models).
❒ Mirrors:
Inspect and adjust as necessary.
❒ Throttle Control Cables:
Inspect and adjust as necessary.
❒ Rear Air Suspension:
Inspect and adjust pressure as necessary.
❒ Engine Oil:
Verify oil is present (cold level).
❒ Lubrication System:
Inspect condition of oil lines and fittings.
❒ Transmission Lubricant:
Check and verify correct lubricant level.
❒ Primary Chaincase:
Check and verify lubricant is present.
❒ Clutch Operation:
Verify proper adjustment.
❒ Fuel System:
a. Inspect fuel system for leaks.
b. Fill, verify sender operation.
c. Verify low fuel light operation (if equipped).
❒ Fuel Outlet (valve or quick connect fitting)
and Hoses:
Verify operation and connections.
❒ Evaporative Control System:
Inspect hose routings, connections and fuel tank venting
to canister (if equipped).
❒ Lighting, Gauges, Electrical Systems:
a. Verify correct operation.
b. Verify adequate directional-to-fuel tank clearance
(FLHRS only).
❒ Tires:
Inspect condition and air pressure.
❒ Brake Systems (front and rear):
a. Correct fluid level (if necessary). Use DOT 4 fluid
only for 2005 FL models.
b. Verify proper ABS indicator function (Police models
only, if equipped).
❒ Road Test Vehicle: Low Speed.
a. Shift from first through third gear, checking clutch
operation, throttle control and transmission operation.
b. Verify low-speed braking for front and rear brakes.
c. Verify handling under braking conditions.
d. Verify low-speed handling. Verify that vehicle does
not pull to left or right.
e. Check for any abnormal vibrations.
f. Check electrical lamps, indicators.
❒ Road Test Vehicle: Highway Speed.
a. Shift from first through fifth gear, checking clutch
operation, throttle control and transmission operation.
b. Verify highway speed braking operation of front and
rear brakes.
c. Verify proper handling at highway speeds.
d. Check for any abnormal vibrations.
❒ Engine Oil:
Check and correct hot level.
❒ Create Vehicle Birth-Certificate Using
Digital Technician (optional).
❒ Clean Vehicle.
❒ Program Security System.
AT POINT OF CUSTOMER DELIVERY
❒ Suspension Adjustments.
❒ Shift Linkage Adjustment.
❒ Brake Hand Lever Adjustment.
❒ Review Vehicle Care and Maintenance Requirements.
NOTE
Be sure to submit a Dealer Product Quality Audit (DPQA) on
ANY adjustments and/or warranty work performed required to
deliver the vehicle to the customer.
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