4-2 2005 PDI: Softail Models
INITIAL ASSEMBLY 4.2
BATTERY TESTING AND CHARGING
1WARNING1WARNING
Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BATTERIES AWAY FROM CHIL-
DREN. (00063a)
1WARNING1WARNING
Never remove warning label attached to top of battery.
Failure to read and understand all precautions in warning
could result in death or serious injury. (00064a)
1WARNING1WARNING
Battery posts, terminals and related accessories contain
lead and lead components, chemicals known in the State
of California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling. (00019a)
NOTE
It will be necessary to remove the seat to perform required
battery tests. Remove seat according to procedure in appro-
priate Service Manual.
Battery Testing and Charging
1. Place test probes of voltmeter on battery terminals and
check the voltage of the battery to make sure it is at least
12.6 VDC.
2. If the open circuit (disconnected) voltage reading is 12.6
VDC or greater the battery is ready for use.
3. See Section 1. Mark the date on the battery warranty tag
by removing the applicable month and year. Month and
year punches may be removed with the point of a screw-
driver without removing battery.
4. If the open circuit (disconnected) voltage reading is
below 12.6 VDC, refer to Ta ble 1-2., 12 amp-hour battery,
in Section 1 and charge battery at rate and time speci-
fied.
5. Recheck battery voltage by repeating step 1 above. If
voltage now is 12 VDC or greater, perform steps 2 and 3
above.
6. If the open circuit (disconnected) voltage reading is still
below 12.6 VDC, the battery must be replaced.
Connecting Battery
NOTE
One battery terminal bolt is attached to red plastic terminal
cover covering positive battery terminal. The second battery
terminal bolt is in negative battery terminal.
1. Attach positive battery cable first. Orient terminal so
cable is oriented away from oil tank and tighten terminal
bolt to 60-96 in-lbs (6.8-10.9 Nm).
2. Attach negative battery cable and tighten terminal bolt to
60-96 in-lbs (6.8-10.9 Nm).
INSTALLING FUEL PUMP FUSE
For non-carbureted vehicles, it will also be necessary to
install the fuel pump fuse that is located in the spare fuse slot
of the fuse-block. See Service Manual.
INDICATOR LAMPS
NOTE
All Softail models have an electronic speedometer with self-
diagnostic capabilities. Refer to the Softail Models Service
Manual for service instructions.
1. See Figure 4-1. Tu rn ignition switch to “IGNITION” posi-
tion, and check that oil pressure indicator lamp turns on
(before engine is started). Speedometer needle will
“vibrate” and speedometer amber backlight will be visi-
ble. The Check Engine indicator will illuminate for about
four seconds and then go off. If vehicle is equipped with
optional Security System (TSSM), a key icon (9) (secu-
rity lamp) will illuminate for about four seconds and then
go off.
NOTE
For any systems problems, please refer to the appropriate
Electrical Diagnostic manual for your model.
2. Shift transmission to neutral position, and verify that neu-
tral indicator lamp turns on.
NOTE
See 4.3 LUBRICATION SYSTEM and perform initial engine
oil level check prior to starting engine.
3. Start engine; check operation of starter.
4. Check that oil pressure indicator lamp turns off when
engine is running above 1000 RPM.
5. Disengage clutch and verify that neutral indicator lamp
turns off when transmission is shifted to any forward
gear. Shift transmission to neutral position, and verify
that neutral indicator lamp turns on again.
6. Check horn operation.
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