Harley Davidson 2008 Touring Models. Service Manual — page 7

A.15

PACKARD METRI-PACK TERMINALS

METRI-PACK TERMINAL CRIMPS

TOOL NAME

PART NUMBER

PACKARD TERMINAL CRIMP TOOL

HD-38125-6

PACKARD TERMINAL CRIMPER

HD-38125-7

PACKARD CRIMPING TOOL

HD-38125-8

Matching Terminal To Crimper

Metri-Pack connectors embossed with the initials P.E.D. require
Packard crimp tools to crimp terminals to wire leads.

Terminals are crimped twice to a wire lead, once over the wire
core and a second time over the insulation/seal.

See

Figure A-44

. A completed crimp may require two different

crimping dies found on PACKARD TERMINAL CRIMP
TOOL (Part No. HD-38125-6) and/or PACKARD TERMINAL
CRIMPER (Part No. HD-38125-7). The terminal (pin or socket)
and the wire lead gauge will determine the core crimp die and
the insulator/seal die.

NOTE

The PACKARD CRIMPING TOOL (Part No. HD-38125-8) will
also crimp sealed splice connectors in wire gauge sizes 18-20,
14-16 and 10-12.

Preparing Wire Lead

Use a wire striper to strip off the insulation and expose 5/32
in. (4.0 mm) of wire core.

Crimping Wire Core

NOTE

Metri-Pack terminal crimps require two steps. Always perform
Crimping Wire Core before Crimping Insulation/Seal.

1.

Squeeze and release handles until ratchet automatically
opens.

2.

Identify the corresponding sized nest for the core crimp.

3.

Position the core crimp in the die. Be Sure the core crimp
tails are facing the forming jaws.

4.

Gently squeeze the handles until crimpers just secure the
core crimp tails.

5.

Insert stripped wire between crimp tails. Verify that wire
is positioned so that short pair of crimp tails squeeze core
wire strands, while long pair is positioned over the insula-
tion or seal material.

6.

Squeeze handles tightly closed. Release grip and the tool
will automatically open.

1

2

3

sm00035

1.

HD-38125-6 sealed terminals

2.

HD-38125-7 non-sealed terminals

3.

HD-38125-8 non-sealed terminals

Figure A-44. Metri-Pack Terminal Crimp Tools

Crimping Insulation/Seal

NOTE

Always perform Crimping Wire Core before Crimping Insu-
lation/Seal.

1.

See

Figure A-45

. Identify the correct die for the insula-

tion/seal crimp (2).

2008 Touring Service: Appendix A Connector Repair A-29

2.

Position the insulation/seal crimp in the nest. Be sure the
insulation/seal crimp tails are facing the forming jaws.

3.

Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimp is complete.

Inspecting Crimps

1.

See

Figure A-45

. Inspect the wire core crimp (1). The tails

should be folded in on the wire core without any distortion
or excess wire strands.

2.

Inspect the insulation (2) or seal (3) crimp. The tails of the
terminal should be wrapped around the insulation without
distortion.

3

2

1

sm00036

1.

Wire core crimp

2.

Insulation crimp

3.

Seal crimp

Figure A-45. Metri-Pack Connector: Inspect Core and

Insulation/Seal Crimps

A-30 2008 Touring Service: Appendix A Connector Repair

A.16

PACKARD ECM CONNECTOR

PACKARD 100W CONNECTOR REPAIR

General

A Packard 100W connector connects the the electronic control
module (ECM) to the main harness.

NOTE

For vehicles with 73-pin connectors, see

A.17 PACKARD

MICRO-64 CONNECTORS

and

A.15 PACKARD METRI-PACK

TERMINALS

.

Separating Socket Housing From ECM

See

Figure A-46

. While pressing the connector into the ECM,

press the thumb lever (1) against the connector until the latch
(2) pops out of the catch (3) on the ECM.

Mating Socket Housing To ECM

Push the connector into the ECM until the latch is captured by
the catch on the ECM.

Removing Socket Terminal

1.

See

Figure A-47

. Gently depress latch (1) on each side

of the clear plastic secondary lock (2) and remove. For
best results, release one side at a time.

2.

Carefully cut cable strap (3) to free strain relief collar (4)
from conduit (5).

3.

See

Figure A-48

. Using a thin blade, gently pry at seam

at back of socket housing to release three plastic pins (1)
from slots in housing. Separate and spread halves of
socket housing.

4.

Push on wire lead to free terminal from chamber.

Installing Socket Terminal

1.

From inside socket housing, gently pull on wire to draw
terminal into chamber.

2.

Exercising caution to avoid pinching wires, press halves
of socket housing together until three plastic pins fully
engage slots in housing.

3.

Install new cable strap in groove of strain relief collar
capturing cable conduit.

4.

With the two ribs on the secondary lock on the same side
as the external latch, install over terminals until latches
lock in place.

Crimping Terminals

If necessary, crimp new terminals on wire leads. See

A.15 PACKARD METRI-PACK TERMINALS

.

2

3

1

sm00037

1.

Thumb lever

2.

Latch

3.

Catch (ECM)

Figure A-46. Packard 100W to ECM (Typical)

2008 Touring Service: Appendix A Connector Repair A-31

7

4

6

3

4

5

1

2

sm04531

5.

1.

Adjuster cam

Increase belt deflection

2.

6.

Reduce belt deflection

Cone nut

7.

3.

E-clip

Weld nut

4.

Weld nub

Figure 1-23. Rear Wheel Adjuster Cams

3.

Use BELT TENSION GAUGE (Part No. HD-35381A) to
check belt deflection. See

1.13 REAR BELT DEFLEC-

TION, Checking Belt Deflection

.

a.

Repeat steps if belt is still too tight.

b.

If belt is now too loose, see Belt Too Loose.

c.

If belt deflection is within specification, see Reas-
sembly.

Reassembly

NOTE

The compensator sprocket bearing has a split inner race that
requires proper compression. Deviation from the following
procedure may lead to premature bearing failure.

1.

Holding weld nut on left side of axle, proceed as follows:

a.

Tighten cone nut to 95-105 ft-lbs (128.8-142.4 Nm).

b.

Loosen cone nut one full turn.

c.

Retighten cone nut to above specification.

NOTE

If the axle moves during tightening of the cone nut, then the
belt deflection procedure must be restarted.

2.

Recheck belt deflection to verify that it is still within spe-
cification. If the belt deflection is not within specification,
loosen cone nut and then snug to 15-20 ft-lbs (20-27 Nm)
before returning to Belt Too Loose or Belt Too Tight.

3.

With the flat side out, install new E-clip in groove on right
side of axle.

4.

Install saddlebags.

2008 Touring Service: Maintenance 1-29

1.14

BLEEDING BRAKES

GENERAL

Use denatured alcohol to clean brake system components.
Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even
after assembly. Deterioration of these components can
cause brake failure, which could result in death or serious
injury. (00291a)

Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

Do not allow dirt or debris to enter the master cylinder
reservoir. Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)

Front brake hand lever and rear brake foot pedal must have a
firm feel when brakes are applied. If not, bleed system as
described.

PROCEDURE

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN II

HD-48650

BASIC VACUUM BRAKE BLEEDER

SNAP-ON BB200A

NOTES

•

For best results, use the BASIC VACUUM BRAKE
BLEEDER (Part No. Snap-On BB200A) or equivalent tool,
particularly if the brake system was completely drained.
Refer to the instructions provided with the tool. If a vacuum
brake bleeder is not available, use the procedure which
follows.

•

When removing or replacing a bleeder valve in the rear
brake caliper or front banjo bleeder bolts, remove the o-
ring from the bleeder valve groove or bore and discard.
The o-ring is required only for brake bleeding at the factory.
Although not sold separately, it may be present in certain
assemblies as currently sold. If care is not taken to remove
and discard the o-ring, it may become lodged in the cal-

iper/banjo bleeder bolt bore during bleeder valve installa-
tion and prevent proper torquing or sealing.

•

After bleeding the brake system on ABS equipped motor-
cycles, confirm that the brake lines are properly connected
if either the ABS module or more than one brake line was
removed. To accomplish this, install master cylinder
reservoir cover, connect motorcycle to DIGITAL TECHNI-
CIAN II (Part No. HD-48650) and perform "ABS Service"
procedure in the "Toolbox" menu.

1.

Remove bleeder valve cap. Install end of a length of clear
plastic tubing over caliper bleeder valve. Place free end
of tube in a clean container.

2.

If bleeding rear brake system, stand motorcycle upright,
so that rear master cylinder reservoir is level. If bleeding
front brake system, rest motorcycle on jiffy stand and turn
front wheel toward left fork stop until front master cylinder
reservoir is level.

NOTE

Wrap a clean shop cloth around the outside of the master cyl-
inder reservoir to protect paint from brake fluid spills.

3.

Remove two screws to release cover from master cylinder
reservoir.

4.

See

Figure 1-24

. Add D.O.T. 4 BRAKE FLUID to master

cylinder reservoir as follows:

a.

Front master cylinder reservoir: flush with step
(marked MAX) cast at rear of reservoir or 0.20 in. (5.0
mm) from the top.

b.

Rear master cylinder reservoir: flush with ledge cast
at front of reservoir or 0.26 in. (6.5 mm) from the top.

5.

Pump the brake lever/pedal to build up hydraulic pressure.

6.

While holding the brake lever/pedal, open brake caliper
bleeder valve about 3/4 turn. Close bleeder valve as soon
as a loss of hydraulic pressure is detected (or when brake
lever/pedal has moved 1/2 to 3/4 of its full range of travel).
Allow brake lever/pedal to return slowly to its released
position.

7.

Repeat steps 4-6 until all air bubbles are purged and a
solid column of fluid is observed in the bleeder tube. Pay
careful attention to the level of the fluid in the master cyl-
inder reservoir. To avoid drawing air into the brake lines,
always add fluid to the master cylinder reservoir before it
empties.

8.

Tighten bleeder valve to 80-100 in-lbs (9.0-11.3 Nm).
Install bleeder valve cap.

NOTE

If bleeding the front brake system, repeat applicable steps to
bleed the line to the second brake caliper.

9.

Add brake fluid to the master cylinder reservoir as
described in step 4.

1-30 2008 Touring Service: Maintenance

A plugged or covered relief port can cause brake drag or
lock-up, which could lead to loss of control, resulting in
death or serious injury. (00288a)

10. Verify proper operation of the master cylinder relief port.

Actuate the brake hand lever. A slight spurt of fluid will
break the fluid surface in the reservoir if all internal com-
ponents are working properly.

11. Install master cylinder reservoir cover, but first verify that

the cover gasket bellows is not extended or brake fluid
will be ejected from the reservoir. Install two cover screws
and alternately tighten as follows:

a.

Front master cylinder reservoir: 7-10 in-lbs (0.8-1.1
Nm).

b.

Rear master cylinder reservoir: 12-15 in-lbs (1.4-1.7
Nm).

12. If motorcycle is ABS equipped, and either the ABS module

or more than one brake line was removed, confirm that
brake system is properly connected. To accomplish this,
connect motorcycle to DIGITAL TECHNICIAN II (Part
No. HD-48650) and perform "ABS Service" procedure in
the "Toolbox" menu.

13. With the Ignition/Light Key Switch turned to IGNITION,

alternately apply front and rear brakes to verify operation
of the brake lamp.

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

14. Test ride motorcycle. Repeat the bleeding procedure if

brakes feel spongy.

1

2

sm04727

1.

Front master cylinder reservoir

2.

Rear master cylinder reservoir

Figure 1-24. Brake Fluid Level

2008 Touring Service: Maintenance 1-31

1.15

BRAKE PADS AND DISCS

INSPECTION

Check brake pads and discs:

•

At every scheduled service interval.

•

Whenever the components are removed during service
procedures.

Brake Pads

Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

Replace both rear brake pads (inner and outer) if the friction
material of either pad is worn to 0.016 in. (0.4 mm) or less
above the backing plate.

Replace all front brake pads (inner and outer pads of both the
left and right side calipers) if the friction material of any single
pad is worn to 0.016 in. (0.4 mm) or less above the backing
plate.

NOTE

Refer to the wear indicator lines for a general indication of pad
wear. See

Figure 1-26

.

Always install a new pad pin (provided in brake pad service
kit) whenever the brake pads are replaced.

Inspect the brake lines and hoses for damage or wear.

Brake Disc Thickness

The minimum front brake disc thickness is 0.18 in. (4.5 mm)
and is stamped on the side of the disc.

The minimum rear brake disc thickness is 0.25 in. (6.3 mm)
and is stamped on the side of the disc.

Replace any disc that is excessively worn or badly scored.

Brake Disc Lateral Runout

Maximum brake disc lateral runout or warpage is 0.008 in. (0.2
mm) when measured near the outside diameter of the disc.

BRAKE PAD REPLACEMENT

Rear Brake Caliper

1.

Remove right side saddlebag. See

2.27 SADDLEBAGS,

Removal

.

2.

If ABS equipped, carefully cut cable strap to release rear
wheel speed sensor cable from brake hose to brake cal-
iper.

3.

Remove two screws to release brake caliper from caliper
bracket.

4.

Remove brake caliper from brake disc.

NOTE

Do not operate the brake pedal with the rear brake caliper
removed or the caliper pistons may be forced out. Reseating
pistons requires caliper disassembly.

5.

Stand motorcycle upright, so that rear master cylinder
reservoir is level. Wrap a clean shop cloth around the
outside of the reservoir to protect paint from brake fluid
spills.

6.

Remove two screws to release cover from master cylinder
reservoir.

NOTE

Fluid level will rise as pistons are pushed back into the caliper,
possibly overflowing the master cylinder reservoir. Remove
some fluid from the reservoir if necessary.

7.

Alternately push each pad back until pistons are fully
seated in the bores.

8.

Pull retaining clip from groove in pad pin. See

Figure 1-28

.

9.

Remove pad pin (metric). See

Figure 1-25

.

10. Pull on pad pin side of brake pads to release from caliper.

11. Remove pad spring if damaged or worn.

12. If removed, seat new pad spring on flat in caliper, so that

clips on spring engage indentations in caliper. Be sure
that forked end of pad spring is on the pad pin side of the
caliper.

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

1-32 2008 Touring Service: Maintenance