Harley Davidson 2008 Touring Models. Service Manual — page 15

13. Cut cable strap in hole of crossbrace to free clutch cable

from right frame downtube. See

Figure 2-87

. Continue as

follows:

a.

FLHR/C: Remove acorn nut to release P-clamp from
stud in upper fork bracket. Remove clutch cable from
P-clamp. See

Figure 2-88

.

b.

FLHX, FLHT/C/U: Remove outer fairing. See

2.35 UPPER FAIRING AND WINDSHIELD: FLHX,
FLHT/C/U

. Cut cable strap to release clutch cable

from left fairing bracket. See

Figure 2-89

.

c.

FLTR: Release clutch cable from cable clip anchored
in hole on left side of instrument nacelle.

14. Remove clutch cable from motorcycle.

1

2

6

3

4

5

sm04744

1.

Clutch release cover

2.

Retaining ring

3.

Outer ramp

4.

Ball and socket

5.

Inner ramp

6.

Coupling

Figure 2-86. Disassemble Clutch Release Cover

INSTALLATION

1.

See

Figure 2-85

. Insert clutch cable eyelet into groove of

clutch hand lever aligning eyelet with hole without bushing.
Insert anchor pin through lever and eyelet.

2.

Insert lever into groove of clutch lever bracket fitting sleeve
at end of cable housing into bore on inboard side of
bracket.

3.

Align hole in hand lever with hole in bracket and install
pivot pin. Install retaining ring in pivot pin groove.

4.

If removed, install two T27 TORX screws (with flat
washers) to secure handlebar clamp to clutch lever
bracket. See

Figure 2-85

. Starting with the top screw,

tighten screws to 60-80 in-lbs (6.8-9.0 Nm).

5.

Start clutch cable routing as follows:

a.

FLHR/C: Capture clutch cable in P-clamp. Slide P-
clamp on stud in upper fork bracket and install acorn
nut. Orient P-clamp as shown in

Figure 2-88

. On left

side of steering head, run cable downward between
engine guard and front of left frame downtube.

b.

FLHX, FLHT/C/U: Feed clutch cable through grommet
on left side of inner fairing. Route cable on inboard
side of left fairing bracket between upper and lower
wings of radio (or storage box) support bracket. Cable
strap clutch cable to left fairing bracket using oblong
hole at this location. See

Figure 2-89

. Run the cable

downward along left side of steering head, and then
between engine guard and front of left frame down-
tube. Install the outer fairing. See

2.35 UPPER

FAIRING AND WINDSHIELD: FLHX, FLHT/C/U

.

c.

FLTR: Capture clutch cable in cable clip and anchor
clip in hole on left side of instrument nacelle. Run
cable forward and then rearward beneath instrument
nacelle following left side of steering head. Run cable
downward between engine guard and front of left
frame downtube.

1

2

sm04745

1.

Cable strap

2.

Right frame downtube

Figure 2-87. Clutch Cable Routing (Right Side View)

2008 Touring Service: Chassis 2-73

1

2

sm04985

1.

P-clamp

2.

Acorn nut

Figure 2-88. FLHR/C Clutch Cable Routing (Left Side View)

sm04746

Figure 2-89. Secure Clutch Cable to Fairing Bracket

6.

All Models, Continue downward progression while
crossing to right side of motorcycle and then run cable
between outboard side of voltage regulator and inboard
side of right frame downtube. Threading cable strap
through hole in crossbrace, secure clutch cable to down-
tube as shown in

Figure 2-87

. Following inboard side of

frame downtube, route cable between bottom of cam cover
and top of lower frame tube to area of clutch release cover.

7.

Inspect cable fitting O-ring and replace if damaged or
deformed. Install clutch cable fitting into clutch release
cover. Do not tighten cable fitting at this time.

8.

Place outer ramp (ball socket side up) in clutch release
cover with tab in cover slot. See

Figure 2-90

.

9.

Apply a multi-purpose grease to the balls and outer ramp
sockets. Place a ball in each of three outer ramp sockets.

10. Hold coupling with button facing outboard. Install clutch

cable barrel in recess of coupling. With ball sockets facing
outboard, place hook of inner ramp on button of coupling.

Holding inner ramp and coupling together, turn the
assembly over.

11. Place inner ramp (ball socket side down) over balls in

outer ramp sockets.

Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

12. Install retaining ring, so that the gap is centered above the

break in the ribbing at bottom of clutch release cover. See

Figure 2-90

.

13. Verify that two dowel pins are in place on transmission

side door flange. Hang a new gasket on the dowel pins.

14. Holding the clutch release cover in position, install six

socket head screws (with captive washers).Tighten screws
to 84-108 in-lbs (9.5-12.2 Nm) in the sequence shown in

Figure 2-91

.

15. Tighten clutch cable fitting to 90-120 in-lbs (10.2-13.6

Nm).

16. Check the O-ring on the transmission drain plug for tears,

cuts or general deterioration. Replace as necessary.

17. Install transmission drain plug. Tighten the plug to 14-21

ft-lbs (19-28 Nm).

18. Remove the transmission lubricant filler plug from the right

side of the transmission case. Inspect the O-ring for cuts,
tears or general deterioration. Replace the O-ring if
necessary.

19. Pour 32 oz. (946 ml) of transmission lubricant through

the fill hole. Use only Harley-Davidson FORMULA+
TRANSMISSION AND PRIMARY CHAINCASE LUB-
RICANT, Part No. 99851-05 (quart).

20. With the motorcycle resting on the jiffy stand on level

ground, insert the filler plug into the fill hole so that it is
resting on the threads. Do not screw the filler plug into the
fill hole. Remove the filler plug and note the level of the
lubricant on the dipstick. Lubricant level should be between
the A(dd) and F(ull) marks.

2-74 2008 Touring Service: Chassis

1

2

sm04747

1.

Outer ramp tab and slot

2.

Retaining ring gap

Figure 2-90. Assemble Clutch Release Cover

1

6

4

3

2

5

sm03668

Figure 2-91. Clutch Release Cover Torque Sequence (Short

Screws at Locations 1 and 6)

21. Install the filler plug in the transmission case and tighten

to 25-75 in-lbs (2.8-8.5 Nm).

22. Adjust the clutch cable. See

1.11 CLUTCH

.

23. Install right side exhaust system. See

4.18 EXHAUST

SYSTEM

.

24. Install maxi-fuse. See

8.5 SYSTEM FUSES AND RELAYS

.

2008 Touring Service: Chassis 2-75

2.24

HANDLEBARS

ADJUSTMENT

1.

Remove maxi-fuse. See

8.5 SYSTEM FUSES AND

RELAYS

.

2.

Gain access to upper handlebar clamp:

a.

FLHR/C: Remove decorative plate from handlebar
clamp shroud. See

Figure 2-92

and

Figure 2-93

.

b.

FLHX, FLHT/C/U:

Remove fairing cap. See

2.36 FAIRING CAP: FLHX, FLHT/C/U

.

c.

FLTR:

Remove instrument bezel. See

2.40 INSTRUMENT BEZEL: FLTR

.

3.

Loosen rear screws on the upper handlebar clamp. On
FLTR models, loosen the front screws instead.

4.

Position handlebars for rider posture and comfort.

5.

To be sure that the handlebars are centered, verify that
the knurled area on the outboard side of the left side
handlebar clamp is equal to that on the right side.

6.

Snug upper handlebar clamp screws.

7.

Slowly turn handlebars to the full right fork stop and then
the full left fork stop to be sure there is no contact with the
fuel tank. If contact occurs and handlebars are properly
aligned, raise handlebars as necessary until the proper
clearance is obtained.

8.

Tighten the upper handlebar clamp screws to 16-20 ft-
lbs (21.7-27.1 Nm).

9.

Reassemble:

a.

FLHR/C: Install decorative plate onto handlebar clamp
shroud. See

Figure 2-92

.

b.

FLHX, FLHT/C/U:

Install fairing cap. See

2.36 FAIRING CAP: FLHX, FLHT/C/U

.

c.

FLTR: Install instrument bezel. See

2.40 INSTRU-

MENT BEZEL: FLTR

.

10. If necessary, adjust left and right handlebar switch controls

as follows:

a.

Loosen two screws securing handlebar clamp to
clutch lever bracket (left) or master cylinder reservoir
(right).

b.

Position switch controls for rider posture and comfort.

c.

Beginning with top screw, tighten screws securing
handlebar clamp to clutch lever bracket to 72-108 in-
lbs (8-12 Nm).

d.

Beginning with top screw, tighten screws securing
handlebar clamp to master cylinder reservoir to 72-80
in-lbs (8-9 Nm).

11. Install maxi-fuse. See

8.5 SYSTEM FUSES AND RELAYS

.

sm03840

Figure 2-92. Remove Decorative Plate (FLHR/C)

sm03838

Figure 2-93. Loosen Upper Handlebar Clamp Screws

(FLHR/C)

REMOVAL

1.

Remove maxi-fuse. See

8.5 SYSTEM FUSES AND

RELAYS

.

2.

Remove or disconnect twist grip sensor jumper harness
depending upon whether the handlebar is being replaced
or just removed. See

4.9 TWIST GRIP SENSOR

.

3.

Place blanket or protective cover over front of fuel tank to
protect against scratches or other damage.

2-76 2008 Touring Service: Chassis

4.

Gain access to upper handlebar clamp:

a.

FLHR/C: Remove handlebar clamp shroud. See

2.45 HEADLAMP NACELLE: FLHR/C

.

b.

FLHX, FLHT/C/U:

Remove fairing cap. See

2.36 FAIRING CAP: FLHX, FLHT/C/U

. Remove radio

(or storage box). See

8.32 ADVANCED AUDIO

SYSTEM

.

c.

FLTR:

Remove instrument nacelle. See

2.41 INSTRUMENT NACELLE: FLTR

.

5.

Remove right and left handlebar switch controls. See

8.39 HANDLEBAR SWITCH ASSEMBLIES

and

8.39 HANDLEBAR SWITCH ASSEMBLIES

, respectively.

6.

Remove upper handlebar clamp screws. Remove upper
handlebar clamp and handlebar.

INSTALLATION

1.

Place new handlebars on lower handlebar clamps. Install
upper handlebar clamp and loosely install clamp screws.

2.

To be sure that the handlebars are centered, verify that
the knurled area on the outboard side of the left side
handlebar clamp is equal to that on the right side.

3.

Snug upper handlebar clamp screws.

4.

Slowly turn handlebars to the full right fork stop and then
the full left fork stop to be sure there is no contact with the
fuel tank. If contact occurs and handlebars are properly
aligned, raise handlebars as necessary until the proper
clearance is obtained.

5.

Tighten upper handlebar clamp screws as follows:

a.

Tighten front screws until upper and lower handlebar
clamps make contact.

b.

Tighten rear screws to 16-20 ft-lbs (21.7-27.1 Nm).

c.

Tighten front screws to 16-20 ft-lbs (21.7-27.1 Nm).

NOTE

A slight gap will exist between the upper and lower clamps at
the rear of the handlebars after tightening.

6.

Install left hand grip, if removed. See

2.24 HANDLEBARS,

Left Hand Grip

.

7.

Install right and left handlebar switch controls. See

8.39 HANDLEBAR SWITCH ASSEMBLIES

and

8.39 HANDLEBAR SWITCH ASSEMBLIES

, respectively.

8.

Reassemble:

a.

FLHR/C: Install handlebar clamp shroud. See

2.45 HEADLAMP NACELLE: FLHR/C

.

b.

FLHX, FLHT/C/U:

Install fairing cap. See

2.36 FAIRING CAP: FLHX, FLHT/C/U

. Install radio

(or storage box). See

8.32 ADVANCED AUDIO

SYSTEM

.

c.

FLTR: Install instrument nacelle. See

2.41 INSTRU-

MENT NACELLE: FLTR

.

9.

Install or connect twist grip sensor jumper harness
depending upon whether the handlebar was replaced or
just removed. See

4.9 TWIST GRIP SENSOR

.

10. Install maxi-fuse. See

8.5 SYSTEM FUSES AND RELAYS

.

11. Turn Ignition/Light Key Switch to IGNITION and test each

handlebar switch for proper operation.

12. Apply front brake hand lever to test operation of brake

lamp.

8

10

9

1

4

5

4

7

3

6

2

sm02933

1.

Screw

2.

Upper clamp

3.

Lower clamp

4.

Cup washer

5.

Spacer

6.

Rubber bushing

7.

Bolt

8.

Ground cable (left clamp only)

9.

Flat washer (right clamp only)

10. Large flat washer (right clamp only)

Figure 2-94. Handlebar Clamp Assemblies

LEFT HAND GRIP

Removal

1.

Remove left handlebar switch controls. See

8.39 HANDLEBAR SWITCH ASSEMBLIES

.

2.

Use a sharp blade to carefully cut rubber and then peel
off handlebar.

3.

Thoroughly clean handlebar to remove all residual
adhesive.

2008 Touring Service: Chassis 2-77

Installation

1.

Obtain a new left hand grip and Harley-Davidson Adhesive
(Part No. 99839-95). Apply a coat of the adhesive to the
inside surface of the grip 1.0 in. (25.4 mm) from the open
end. Apply a coat to the end of the handlebar.

2.

Immediately push grip completely onto end of handlebar
using a twisting motion. Do not hesitate when installing
grip or adhesive may dry before installation is complete.

NOTE

If the left hand grip is patterned, align it with the pattern on the
right grip with the throttle in the fully closed position.

3.

Let 6-8 hours elapse at 70°F. (21°C.) to allow adhesive
to fully cure.

4.

Install left handlebar switch controls. See

8.39 HANDLEBAR SWITCH ASSEMBLIES

.

RUBBER MOUNTS

NOTE

For complete disassembly of the handlebar clamp assemblies
and/or to replace the rubber mounts, proceed as follows.

Removal: General

1.

Turn fork to left fork stop and loosen right side bolt at
bottom of upper fork bracket. Turn fork to right fork stop
and loosen left side bolt at bottom of upper fork bracket.

2.

Remove handlebars. See

2.24 HANDLEBARS, Removal

.

Removal: Right Side

1.

Holding lower handlebar clamp to prevent rotation, turn
bolt at bottom of upper fork bracket until free.

2.

Remove lower handlebar clamp, flat washer and cup
washer at top of upper fork bracket. See

Figure 2-95

.

3.

Pull bushing from fork bracket bore and discard. See

Figure 2-96

.

4.

Moving to bottom of upper fork bracket, remove bolt, large
flat washer and cup washer. See

Figure 2-97

.

5.

Pull bushing and spacer from fork bracket bore. Remove
spacer from bushing. See

Figure 2-98

. Discard bushing.

Removal: Left Side

1.

Holding lower handlebar clamp to prevent rotation, turn
bolt at bottom of upper fork bracket until free.

2.

Remove lower handlebar clamp, ground wire ring terminal
and cup washer at top of upper fork bracket.

3.

Pull bushing from fork bracket bore and discard. See

Figure 2-96

.

4.

Moving to bottom of upper fork bracket, remove bolt and
cup washer.

5.

Pull bushing and spacer from fork bracket bore. Remove
spacer from bushing. See

Figure 2-98

. Discard bushing.

sm02935

Figure 2-95. Remove Flat Washer and Upper Cup Washer

(Right Side)

sm02936

Figure 2-96. Remove Upper Bushing (Right Side)

sm02937

Figure 2-97. Remove Bolt, Large Washer, and Lower Cup

Washer (Right Side)

2-78 2008 Touring Service: Chassis

sm02938

Figure 2-98. Remove Spacer from Lower Bushing

Installation: Right Side

1.

Insert spacer into new bushing until flush with outboard
side of collar. See

Figure 2-98

.

2.

Insert bushing into bore at bottom of upper fork bracket
fitting collar of bushing over lip of boss.

3.

Install large flat washer and cup washer on bolt. See

Figure 2-97

. Insert bolt into bushing fitting concave side

of cup washer over collar of bushing.

4.

Moving to top of upper fork bracket, insert bushing into
bore fitting collar of bushing over lip of boss. See

Figure 2-96

.

5.

Install cup washer over threaded end of bolt fitting concave
side over collar of bushing. Install flat washer. See

Figure 2-95

.

6.

Apply two or three drops of Loctite Medium Strength
Threadlocker 243 (blue) to threads of bolt and start lower

handlebar clamp. Holding clamp to prevent rotation, turn
bolt at bottom of upper fork bracket until snug.

Installation: Left Side

1.

Insert spacer into new bushing until flush with outboard
side of collar. See

Figure 2-98

.

2.

Insert bushing into bore at bottom of upper fork bracket
fitting collar of bushing over lip of boss.

3.

Install cup washer on bolt. Insert bolt into bushing fitting
concave side of cup washer over collar of bushing.

4.

Moving to top of upper fork bracket, insert bushing into
bore fitting collar of bushing over lip of boss. See

Figure 2-96

.

5.

Install cup washer over threaded end of bolt fitting concave
side over collar of bushing. Install ground wire ring ter-
minal.

6.

Apply two or three drops of Loctite Medium Strength
Threadlocker 243 (blue) to threads of bolt and start lower
handlebar clamp. Holding clamp to prevent rotation, turn
bolt at bottom of upper fork bracket until snug.

Installation: General

1.

Install handlebars and upper handlebar clamp. See

2.24 HANDLEBARS, Installation

.

2.

Turn fork to left fork stop and tighten right side bolt at
bottom of upper fork bracket to 30-40 ft-lbs (40.7-54.2
Nm). Turn fork to right fork stop and tighten left side bolt
to the same torque value.

3.

Complete assembly of motorcycle. See

2.24 HANDLE-

BARS, Installation

.

2008 Touring Service: Chassis 2-79

2.25

MIRRORS

ALL MODELS EXCEPT FLHX

Removal

1.

Remove acorn nut and lock washer.

2.

Remove threaded stem of mirror from hole in clutch or
brake lever bracket. See

Figure 2-99

.

Installation

1.

Insert threaded stem of mirror into hole in clutch or brake
lever bracket.

2.

Install lock washer and acorn nut.

3.

Adjust mirror as necessary and tighten acorn nut to 60-96
in-lbs (6.8-10.8 Nm).

3

2

1

sm04981

1.

Acorn nut

2.

Lock washer

3.

Mirror

Figure 2-99. Mirror Assembly (All Models Except FLHX)

FLHX

Removal

1.

Remove outer fairing. See

2.35 UPPER FAIRING AND

WINDSHIELD: FLHX, FLHT/C/U

.

2.

Remove flange nut and plastic washer. Remove mirror.
See

Figure 2-100

.

Installation

1.

With the rounded side of the mirror on the outboard side
(and the bar and shield logo right side up), insert threaded
stud and index pin on swivel block through holes in inner
fairing. See

Figure 2-101

.

sm04982

Figure 2-100. Remove Outer Fairing (FLHX)

1

5

2

3

6

4

sm04983

1.

Threaded stud

2.

Index pin

3.

Swivel block stamp

4.

Plastic washer

5.

Stamped post

6.

Flange nut

Figure 2-101. Left Side Mirror Assembly (FLHX)

NOTE

The letters "L" or "R" are stamped on the swivel blocks to dif-
ferentiate between left and right side mirrors.

2.

With the post on the outboard side, place the plastic
washer against the inner fairing engaging two holes in
washer with threaded stud and index pin.

NOTE

The letters "L" or "R" are stamped on the posts to differentiate
between left and right side washers.

2-80 2008 Touring Service: Chassis

3.

Install flange nut on threaded stud and tighten to 30-40
in-lbs (3.4-4.5 Nm). See

Figure 2-100

.

4.

Adjust mirror as necessary.

5.

Install outer fairing. See

2.35 UPPER FAIRING AND

WINDSHIELD: FLHX, FLHT/C/U

.

2008 Touring Service: Chassis 2-81

2.26

SEAT

SEAT: FLHT

Removal

Detach passenger seat strap before removing seat. Failure
to do so can result in damage to rear fender paint. (00225a)

1.

Open left side saddlebag.

2.

Remove screw to release passenger seat strap from seat
strap bracket. A firm tug may be necessary to free end of
strap from slot of seat strap bracket. See

Figure 2-102

.

3.

Draw free end of passenger seat strap to right side of
motorcycle.

4.

Remove screw to detach seat mounting bracket from top
of rear fender.

5.

Push seat rearward to free slot from tongue on rear fuel
tank bracket. See

Figure 2-103

.

Installation

1.

Place seat on frame.

2.

Firmly push front of seat downward and then forward until
slot engages tongue on rear fuel tank bracket. See

Figure 2-103

.

3.

Align hole in seat mounting bracket with seat retention nut
in rear fender. Install screw and tighten to 20-40 in-
lbs (2.3-4.5 Nm).

NOTE

If seat retention nut is damaged or lost, see

2.26 SEAT, Seat

Retention Nut Replacement

for instructions.

4.

Draw free end of passenger seat strap to left side of
motorcycle.

5.

Start screw to fasten passenger seat strap to seat strap
bracket. Feed end of strap into slot of seat strap bracket
and tighten screw to 48-72 in-lbs (5.4-8.1 Nm). See

Figure 2-102

.

6.

Close left side saddlebag

After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)

om01012

Figure 2-102. Seat Strap Bracket Screw (FLHT/C/U)

2

1

sm04968

1.

Seat bottom slot

2.

Fuel tank rear bracket tongue

Figure 2-103. Seat Mounting

2-82 2008 Touring Service: Chassis

SEAT: FLHTC/U

Removal

1.

Open left side saddlebag.

2.

Remove screw to release passenger seat strap from seat
strap bracket. A firm tug may be necessary to free end of
strap from slot of seat strap bracket. See

Figure 2-102

.

3.

Draw free end of passenger seat strap to right side of
motorcycle.

4.

Open Tour-Pak to move passenger seat backrest out of
the way.

NOTE

The Tour-Pak must be moved to the rearward position to
access the seat mounting bracket screw. If installed in the for-
ward position, remove Tour-Pak and install in the rearward
position. See

2.29 TOUR-PAK

for more information.

5.

Remove screw to detach seat mounting bracket from top
of rear fender. To protect finish of Tour-Pak, cover rear
seat mounting bracket with palm of hand.

6.

While pushing seat forward, raise rear of seat until bracket
clears Tour-Pak. Push seat rearward to free slot from
tongue on rear fuel tank bracket. See

Figure 2-103

.

7.

Remove seat from frame.

Installation

1.

See

Figure 2-103

. Place seat on frame.

2.

To protect finish of Tour-Pak, cover rear seat mounting
bracket with palm of hand.

3.

While raising rear of seat approximately 3 in. (76.2 mm),
use other hand to firmly push front of seat downward and
then forward until slot engages tongue on rear fuel tank
bracket.

4.

Align hole in seat mounting bracket with seat retention nut
in rear fender. Install screw and tighten to 20-40 in-
lbs (2.3-4.5 Nm).

NOTE

If seat retention nut is damaged or lost, see SEAT RETENTION
NUT REPLACEMENT for instructions.

5.

Draw free end of passenger seat strap to left side of
motorcycle.

6.

Start screw to fasten passenger seat strap to seat strap
bracket. Feed end of strap into slot of seat strap bracket
and tighten screw to 48-72 in-lbs (5.4-8.1 Nm). See

Figure 2-102

.

7.

Close left side saddlebag

After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)

SEAT: FLHR/C, FLHX, FLTR

Removal

1.

Remove left side saddlebag.

2.

Remove screw (with flat washer) to remove passenger
seat strap and saddlebag front mounting bracket from
chrome frame tube cover.

3.

Draw free end of passenger seat strap to right side of
motorcycle (passing through slots in seat on FLHRC
models). See

Figure 2-104

.

4.

Remove screw to detach seat mounting bracket from top
of rear fender.

5.

Push seat rearward to free slot from tongue on rear fuel
tank bracket. See

Figure 2-103

.

6.

Remove seat from frame.

Installation

1.

Place seat on frame.

2.

Firmly push front of seat downward and then forward until
slot engages tongue on rear fuel tank bracket. See

Figure 2-103

.

3.

Align hole in seat mounting bracket with seat retention nut
in rear fender. Install screw and tighten to 20-40 in-
lbs (2.3-4.5 Nm).

NOTE

If seat retention nut is damaged or lost, see

2.26 SEAT, Seat

Retention Nut Replacement

for instructions.

4.

Draw free end of passenger seat strap to left side of
motorcycle (passing through slots in seat on FLHRC
models). See

Figure 2-104

.

sm04967

Figure 2-104. Route Passenger Seat Strap Through Slots

(FLHRC)

5.

Insert screw with flat washer through passenger seat strap
and slotted hole of saddlebag front mounting bracket.
Insert screw into forward hole in chrome frame tube cover.
Snug screw, but do not tighten.

6.

Install left side saddlebag.

7.

Tighten saddlebag front mounting bracket screw to 60-96
in-lbs (6.8-10.8 Nm).

2008 Touring Service: Chassis 2-83

After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)

SEAT RETENTION NUT REPLACEMENT

1.

Slide retention nut over tapered end of cable strap, so that
larger OD of nut rests on cable strap eyelet. From bottom
of rear fender, feed cable strap up through fender hole.
See inset of

Figure 2-105

.

2.

With tab on retention nut seated in notch of fender hole,
pull up on cable strap to hold nut snug against underside
of rear fender. From the side opposite the tab, slide on
the retention washer to lock the position of the retention
nut. Remove cable strap.

1

2

4

3

sm04964

1.

Rear fender

2.

Retention nut

3.

Tab

4.

Retention washer

Figure 2-105. Install Seat Retention Nut

2-84 2008 Touring Service: Chassis

2.27

SADDLEBAGS

OPENING

NOTE

Maximum recommended load for each saddlebag is 15 lbs (6.8
kg).

FLHRC

1.

Raise the decorative buckle and press tabs on both sides
of catch to release from receptacle. Repeat step to release
second catch. See

Figure 2-106

.

2.

Rotate hinge on outboard side of saddlebag to open lid.

1

2

sm03580

1.

Catch

2.

Receptacle

Figure 2-106. Open Saddlebag (FLHRC)

FLHR, FLHX, FLHT/C/U, FLTR

1.

Use key to unlock lid latch if locked.

2.

Pull bottom of latch outward and then lift upward raising
outboard corners of saddlebag lid. See upper frame of

Figure 2-107

.

3.

With top of lid tilted toward motorcycle, carefully lift inboard
side of lid upward disengaging front and rear anchor tabs
from anchor brackets.

4.

Pivot lid on latch hinge to open. A nylon check strap sus-
pends the lid in the open position. See lower frame of

Figure 2-107

.

5

2

1

3

4

sm02939

1.

Latch

2.

Hinge

3.

Anchor tabs

4.

Anchor brackets

5.

Check strap

Figure 2-107. Open Saddlebag (FLHR, FLHX, FLHT/C/U,

FLTR)

CLOSING

FLHRC

1.

Rotate hinge on outboard side of saddlebag to close lid.

2.

Insert catch into receptacle until tabs fully engage. Repeat
step to secure second catch. See upper frame of

Figure 2-106

.

FLHR, FLHX, FLHT/C/U, FLTR

1.

Rotate lid to closed position engaging both anchor tabs
with bottom of anchor brackets. Press bottom of latch
inward until it snaps closed. See lower frame of

Figure 2-107

.

2.

Use key to lock lid latch.

2008 Touring Service: Chassis 2-85

REMOVAL

1.

Open saddlebag. See

2.27 SADDLEBAGS, Opening

.

2.

Grasp bail wire inside saddlebag and rotate each stud a
full 1/4 turn in a counterclockwise direction. Remove bail
head studs with flat washers from grommets. See

Figure 2-108

.

NOTE

On some HDI motorcycles, the bail wire has been removed
from the quick release stud. In these cases, turn the stud by
engaging the slotted end with a large screwdriver.

3.

Remove saddlebag.

1

3

5

6

7

8

4

2

sm03538

1.

Bail wire

2.

Stud

3.

Flat washer

4.

Grommet

5.

Spring plate

6.

Wire form

7.

Front bracket

8.

Rear bracket

Figure 2-108. Saddlebag Quick-Release Fasteners

INSTALLATION

1.

Position saddlebag on motorcycle aligning holes in grom-
mets with those in front and rear mounting brackets.

NOTE

Replace grommets if torn or deteriorated. Moisten new
grommet with glass cleaner or soapy water and work smaller
OD through hole into saddlebag. See

Figure 2-108

.

2.

Place flat washers on bail head studs, if removed.

3.

With groove at end of stud held in a horizontal position,
insert stud through holes in grommet and front mounting

bracket. When groove engages wire form of spring plate
on inboard side of bracket, turn stud clockwise a full 1/4
turn until it locks in place. Install rear bail head stud in the
same manner.

NOTE

On some HDI motorcycles, the bail wire has been removed
from the quick release stud. In these cases, turn the stud by
engaging the slotted end with a large screwdriver.

NOTE

Molded rubber insert at bottom of saddlebag must fit snugly
on lower saddlebag support rail. If saddlebag is not fully seated,
use an open end/box wrench to loosen bolts securing mounting
brackets to saddlebag support and frame. See

Figure 2-109

.

Alternately tighten bolts to 60-96 in-lbs (7-11 Nm) after seating
saddlebag.

4.

Close saddlebag. See

2.27 SADDLEBAGS, Closing

.

1

2

sm03576

1.

Front mounting bracket

2.

Rear mounting bracket

Figure 2-109. Saddlebag Mounting Brackets (Right Side

View)

2-86 2008 Touring Service: Chassis

2.28

SADDLEBAG SERVICE

SADDLEBAG HARDWARE

Removal

1.

Lay clean pad or blanket on work bench to protect painted
surfaces of saddlebag.

2.

Remove saddlebag from motorcycle leaving lid open. See

2.27 SADDLEBAGS

.

3.

Lay saddlebag flat on pad with the inboard side facing up
and the lid closest to you.

4.

Remove two T20 TORX screws to release check strap
from lid.

5.

Remove two T15 TORX screws to release check strap
from saddlebag.

6.

Remove two remaining T15 TORX screws to remove latch
from saddlebag. Move saddlebag back and out of the way.

NOTE

This procedure assumes that the latch is NOT removed from
the saddlebag lid. If there is doubt as to whether the procedure
can be accomplished without scratching painted surfaces of
the lid, then remove the five remaining T15 TORX screws to
completely remove latch.

7.

Position lid right side up with latch closest to you.

8.

Raise latch slightly and rotate hinge on inboard side so
that it is topside with the two plastic rub bars pointed
upward. See upper frame of

Figure 2-110

.

9.

Rotate rub bar section of hinge to expose hinge pin and
spring. Using a flat tip screwdriver, carefully bend crimped
end link outward. See lower frame of

Figure 2-110

.

NOTE

The end link on opposite side of hinge has a weld spot that
prevents pin removal.

10. Reposition lid so that it is upside down with the latch

farthest from you. Rotate hinge so that plastic rub bars
are positioned beneath latch and spring is topside.

11. Using a needle nose pliers, grasp pin through opening just

outboard of the spring and push toward the crimped link
side. Work pin in this manner until end can be seen exiting
crimped link. See upper frame of

Figure 2-111

. If neces-

sary, pry crimped link outward a little more to achieve the
desired result.

12. Grasping end with needle nose pliers, slowly pull pin from

links until spring can be slid off opposite end. Only pull pin
as far as necessary to remove spring. See lower frame of

Figure 2-111

.

sm03539

Figure 2-110. Lid Right Side Up With Latch on Near Side

sm03540

Figure 2-111. Lid Up Side Down With Latch on Far Side

2008 Touring Service: Chassis 2-87

Installation

1.

Slide new spring onto end of pin. Orient spring as shown
in lower frame of

Figure 2-111

.

2.

Slide pin back through links. Using tapered end of needle
nose pliers, push end of pin into crimped link.

3.

Reposition lid so that it is right side up with latch closest
to you. As before, raise latch slightly and rotate hinge on
inboard side so that it is topside with plastic rub bars
pointing upward. Now rotate rub bar section of hinge to
expose hinge pin and spring. See

Figure 2-110

.

4.

Holding lid down with elbow, if necessary, use a pliers to
bend crimped link back into its original position, so that
pin is captured and will not back out of hinge.

5.

Reposition lid so that it is upside down with the latch
farthest from you. Move saddlebag forward for reinstalla-
tion of lid. Align four holes in saddlebag with those in latch.

6.

Install two inboard T15 TORX screws to fasten latch to
saddlebag. Alternately tighten screws to 20-25 in-lbs (2.3-
2.8 Nm).

7.

Align holes in check strap with those in lid and saddlebag.
Orient check strap so that logo is topside with the bottom
of the bar and shield on the lid side.

8.

Install two T15 TORX screws to fasten check strap and
latch to saddlebag. Alternately tighten screws to 20-25 in-
lbs (2.3-2.8 Nm).

9.

Install two T20 TORX screws to fasten check strap to lid.
Alternately tighten screws to 18-20 in-lbs (2.0-2.3 Nm).

10. Close saddlebag and install on motorcycle. See

2.27 SADDLEBAGS

.

SADDLEBAG GUARD/SUPPORT RAIL

Removal

1.

Remove saddlebag. See

2.27 SADDLEBAGS

.

2.

Disassemble saddlebag guard, support and/or rails as
necessary. See

Figure 2-112

,

Figure 2-113

or

Figure 2-114

.

Installation

1.

Assemble saddlebag guard, support and/or rails as
necessary. Replace any damaged parts. See

Figure 2-112

,

Figure 2-113

or

Figure 2-114

. Refer to the table associated

with each figure for the correct fastener torque specifica-
tions.

2.

Install saddlebag. See

2.27 SADDLEBAGS

.

2-88 2008 Touring Service: Chassis