Harley Davidson 2008 Touring Models. Service Manual — page 13

NOTE

Wrap banjo fitting with piece of shop towel to absorb any loss
of brake fluid.

Remove banjo bolt to release brake line from master cyl-
inder reservoir. Hold suitable container under banjo bolt
bore to allow reservoir to drain. Discard copper washers.

Using a clean shop cloth, wipe out any remaining fluid in
the master cylinder reservoir.

Remove two screws to release master cylinder from frame
weldment.

Remove locknut with flat washer and pull brake
pedal/master cylinder assembly from pedal shaft. Remove
and discard O-ring on each side of brake pedal shaft bore.

10. Remove cotter pin and flat washer from clevis pin. Remove

clevis pin to separate master cylinder assembly from brake
pedal flange. See

Figure 2-48

Disassembly

NOTE

Exercise care to avoid scratching or nicking banjo sealing
surface during handling. Damage to the sealing surface
requires replacement of the master cylinder reservoir.

Remove dust boot from reservoir pulling it over slotted
end of pushrod. See

Figure 2-49

Pushing down on flat washer to compress pedal return
spring, remove E-clip from groove in pushrod, and then
carefully release spring.

Remove flat washer and pedal return spring from pushrod.

Remove retaining ring from groove in piston bore. As the
piston assembly is also spring loaded, hold parts together
as retaining ring is removed.

Remove pushrod and special washer.

Pull piston assembly from piston bore.

2008 Touring Service: Chassis 2-41

sm05021

12.

Pedal return spring

Master cylinder reservoir

13.

Cover screw (2)

Retaining ring

14.

Special washer

Cover

15.

Gasket

Pushrod

16.

Secondary seal

Screw (2)

17.

Cotter pin

Piston

18.

Flat washer

19.

Clevis pin

Primary seal

20.

E-clip

Dust boot

10.

21.

E-clip

Spring

22.

11.

Sight glass/O-ring

Flat washer

Figure 2-49. Rear Brake Master Cylinder Assembly

2-42 2008 Touring Service: Chassis

CLEANING AND INSPECTION

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)

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)

Clean all parts with denatured alcohol. Wipe dry with a
clean, lint free cloth.

Inspect banjo seating surface for scratches or nicks.

Verify that reservoir is completely free of dust, dirt or
residue.

Using a clean air supply, blow out piston bore and other
drilled passages. Do not use a wire or similar instrument.

Inspect piston bore for scratches, nicks, scoring, pitting,
corrosion or other damage.

Inspect retaining ring and E-clip for wear or distortion.
Inspect retaining ring and E-clip grooves for damage.

Inspect springs for stretching, distortion, kinks, cracks or
broken coils.

Inspect piston seals, dust boot and reservoir cover gasket
for cuts, tears or general deterioration.

ASSEMBLY AND INSTALLATION

Assembly

Lightly lubricate piston bore and OD of piston seals with
D.O.T. 4 brake fluid.

Insert spring end of piston assembly into piston bore.

Slide special washer and retaining ring over pushrod.
Collar on ID of special washer should face slotted end of
pushrod, while flat side of retaining ring should face ball
end.

Fitting ball end of pushrod into piston socket, compress
spring and install retaining ring in groove of piston bore.
Verify that retaining ring is completely seated in groove.

Slide pedal return spring over pushrod until larger diameter
coil is seated on retaining ring in piston bore.

Slide flat washer over pushrod until seated on smaller
diameter coil of pedal return spring.

Using a suitable spring compressor, compress pedal return
spring and install E-clip in inboard groove of pushrod.

Slide open end of dust boot over pushrod and onto reser-
voir until ID on closed end is captured in outboard groove
of pushrod.

Installation

Install master cylinder assembly onto brake pedal flange.
Install clevis pin from the outboard side. Install flat washer
and cotter pin on clevis pin.

Apply a light coat of Wheel Bearing Grease (HD Part No.
99855-89) to the brake pedal shaft and bore. Install new
O-ring on each side of bore.

Install brake pedal/master cylinder assembly on the pedal
shaft. Install flat washer and new locknut on pedal shaft.

Install two screws to fasten master cylinder to frame
weldment. Alternately tighten screws to 10.5-12.5 ft-lbs
(14-17 Nm).

Tighten brake pedal shaft locknut to 15-20 ft-lbs (20-27
Nm).

Start banjo bolt (with new copper washers) to secure brake
line to master cylinder reservoir. Tighten banjo bolt to 13-
15 ft-lbs (17.6-20.3 Nm).

Fill and bleed brake system. See

1.14 BLEEDING

BRAKES

Install right side rider footboard. See

2.49 FOOTBOARDS

AND FOOTRESTS

REAR BRAKE LINE

Removal

Remove right side saddlebag. See

2.27 SADDLEBAGS

Remove right side cover.

Remove right fairing lower, if present. See

2.34 LOWER

FAIRING AND ENGINE GUARD

Remove right side rider footboard. See

2.49 FOOT-

BOARDS AND FOOTRESTS

Cut cable straps to free rear brake line from two rubber
saddles anchored on T-studs at top of lower frame tube.
See

Figure 2-50

Remove hex screw to free brake hose P-clamp from rear
swingarm bracket.

Remove socket terminals from rear brake light switch
spade contacts. Cut cable strap to free rear brake light
switch wires from lower frame tube, if necessary.

Remove hex screw to free brake light switch bracket from
frame weldment. Push on bracket to release locating tab
from slot in frame weldment.

Open two cable clips on rear swingarm T-studs. Free rear
brake line hose from cable clips.

NOTE

For best results, insert blade of small screwdriver into gap at
side of clip and gently rotate end of screwdriver to pop open.

10. Stand motorcycle upright, so that rear master cylinder

reservoir is level.

11. To prevent dirt and other contaminants from entering the

master cylinder reservoir, thoroughly clean the cover
before removal.

12. Remove two screws to release cover from master cylinder

reservoir.

2008 Touring Service: Chassis 2-43

NOTE

Wrap banjo fittings with pieces of shop towel to absorb any
loss of brake fluid.

13. Remove banjo bolt to release brake line from master cyl-

inder reservoir. Hold suitable container under banjo bolt
bore to allow reservoir to drain. Discard copper washers.

14. Using a clean shop cloth, wipe out any remaining fluid in

the master cylinder reservoir.

15. Remove two screws to release master cylinder from frame

weldment.

16. Remove locknut with flat washer and pull brake

pedal/master cylinder assembly from pedal shaft. Remove
and discard O-ring on each side of brake pedal shaft bore.

17. Remove banjo bolt to release brake line from rear brake

caliper. Discard copper washers.

18. Feed rear brake line hose forward to area in front of rear

swingarm bracket. Remove rear brake line from motor-
cycle.

sm05056

Locating tab

Banjo bolt

Copper washers

Screw and weld nut

P-clamp and screw

Brake line tube

Rubber saddles and cable straps

Brake line hose

10.

Cable clips

Rear brake light switch

Figure 2-50. Rear Brake Line Assembly

Installation

Place rear brake line into approximate position along top
of lower right frame tube. From area in front of rear
swingarm bracket, feed brake line hose rearward following
top of rear swingarm.

Start banjo bolt (with new copper washers) to secure brake
line to caliper.

Capture rear brake line hose in two cable clips on rear
swingarm T-studs. Snap cable clips closed. See

Figure 2-51

Index locating tab on brake light switch bracket in slot of
frame weldment. Install hex screw to secure brake light
switch bracket to frame weldment.

Install socket terminals onto rear brake light switch spade
contacts. If removed, install new cable strap to secure
rear brake light switch wires (and main harness conduit)
to lower frame tube.

Install hex screw to secure brake hose P-clamp to rear
swingarm bracket. Tighten screw to 35-45 in-lbs (4.0-5.1
Nm).

Seat rear brake line on two rubber saddles anchored on
T-studs at top of lower frame tube. Engaging slots in
rubber saddles, install new cable straps capturing rear

2-44 2008 Touring Service: Chassis

brake line, main harness conduit and lower frame tube.
Cut any excess cable strap material.

NOTE

Replace rubber saddles if damaged, deteriorated or missing.
With the slotted side up, push hole in rubber saddle over T-
stud to install.

Move front section of brake line (with rubber sleeve)
inboard of frame weldment at bottom of front frame
downtube.

Apply a light coat of Wheel Bearing Grease (HD Part No.
99855-89) to the brake pedal shaft and bore. Install new
O-ring on each side of bore.

10. Install brake pedal/master cylinder assembly on the pedal

shaft. Install flat washer and new locknut on pedal shaft.

11. Install two screws to fasten master cylinder to frame

weldment. Alternately tighten screws to 10.5-12.5 ft-lbs
(14-17 Nm).

12. Tighten brake pedal shaft locknut to 15-20 ft-lbs (20-27

Nm).

13. Start banjo bolt (with new copper washers) to secure brake

line to master cylinder reservoir. Tighten banjo bolt to 13-
15 ft-lbs (17.6-20.3 Nm).

14. Tighten banjo bolt to brake caliper to 17-19 ft-lbs (23.1-

25.8 Nm).

15. Fill and bleed brake system. See

1.14 BLEEDING

BRAKES

16. Install right side rider footboard. See

2.49 FOOTBOARDS

AND FOOTRESTS

17. Install right fairing lower, if present. See

2.34 LOWER

FAIRING AND ENGINE GUARD

18. Install right side cover.

19. Install right side saddlebag. See

2.27 SADDLEBAGS

sm05058

Frame weldment

Lower frame tube

1st saddle with cable strap

Rear swingarm

1st cable clip

2nd saddle with cable strap

Cable strap

2nd cable clip

Figure 2-51. Rear Brake Line Routing (Right Side View)

2008 Touring Service: Chassis 2-45

2.15

REAR BRAKE CALIPER

REMOVAL

NOTE

If only replacing brake pads, see

1.15 BRAKE PADS AND

DISCS

Remove right side saddlebag. See

2.27 SADDLEBAGS

NOTE

Wrap banjo fitting with piece of shop towel to absorb any loss
of brake fluid.

Remove banjo bolt to release brake line from caliper.
Discard copper washers.

Remove two screws to release caliper from caliper bracket.
See

Figure 2-52

Remove caliper from brake disc.

If necessary, retract rear axle to remove caliper bracket.
See

2.4 REAR WHEEL

sm04987

Caliper

Caliper bracket screw

Caliper bracket

Rubber bumper

Retaining clip

Pad pin

Brake pads

Pad spring

Bleeder valve

10. Bleeder valve cap

Figure 2-52. Rear Brake Caliper Assembly

INSTALLATION

Install caliper bracket, if removed. Proceed as follows:

Replace rubber bumper if damaged, worn or missing.
Lubricate anchor of new bumper with isopropyl
alcohol or glass cleaner and pull rubber bead through
hole to the inboard side of the caliper bracket.

Seat caliper bracket on anchor weldment of rear
swingarm.

Complete installation of rear wheel. See

2.4 REAR

WHEEL

If necessary, assemble caliper installing pad spring, brake
pads, pad pin and retaining clip. See

1.15 BRAKE PADS

AND DISCS

NOTE

When replacing or installing the bleeder valve, 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 caliper
bore during bleeder valve installation and prevent proper
torquing or sealing.

Install caliper onto brake disc. Align holes in caliper with
those in caliper bracket and install two screws. Alternately
tighten screws to 43-48 ft-lbs (58.3-65.1 Nm).

Start banjo bolt (with new copper washers) to secure brake
line to caliper. Tighten banjo bolt to 17-19 ft-lbs (23.1-25.8
Nm).

Fill and bleed brake system. See

1.14 BLEEDING

BRAKES

Install right side saddlebag. See

2.27 SADDLEBAGS

2-46 2008 Touring Service: Chassis

2.16

TIRES

GENERAL

Use only Harley-Davidson approved tires. See a Harley-
Davidson dealer. Using non-approved tires can adversely
affect stability, which could result in death or serious
injury. (00024a)

Be sure tires are properly inflated, balanced and have
adequate tread. Inspect your tires regularly and see a
Harley-Davidson dealer for replacements. Riding with
excessively worn, unbalanced or under-inflated tires can
adversely affect stability and handling, which could result
in death or serious injury. (00014a)

New tires should be stored on a horizontal tire rack. Avoid
stacking new tires in a vertical stack. The weight of the stack
compresses the tires and closes down the beads.

Tires should be inspected for punctures, cuts, breaks and wear
at least weekly.

See

Figure 2-53

. The tread wear indicator bars will appear on

tire tread surfaces when 1/32 in. (0.8 mm) or less of tread
remains. Always remove tires from service before they reach
the tread wear indicator bars.

New tires are needed if any of the following conditions exist.
See

1.8 TIRES AND WHEELS

Tire wear indicator bars are visible on the tread surfaces.

Tire cords or fabric are visible through cracked sidewalls,
snags or deep cuts.

A bump, bulge or split in the tire.

Puncture, cut or other damage to the tire that cannot be
repaired.

sm02177

Sidewall

Tread surface

Figure 2-53. Tread Wear Indicators

REMOVAL

NOTE

Care must be taken when removing and installing tire to prevent
cosmetic damage to wheel. This is especially true with wheels
that feature painted surfaces.

Remove wheel from motorcycle:

Front wheel: see

2.3 FRONT WHEEL, Removal

Rear wheel: see

2.4 REAR WHEEL, Removal

Deflate tire.

NOTE

On tube type wheels, it is not necessary to completely remove
tire from rim. Removing one side allows the tube to be replaced
and allows for inspection of tire.

Loosen both tire beads from rim flange. In most cases, a
bead breaker machine will be required to loosen the beads
from the rim.

Remove tire.

CLEANING, INSPECTION AND REPAIR

Clean the inside of tire and outer surface of tube.

2008 Touring Service: Chassis 2-47

If rim is dirty or rusty, clean with a stiff wire brush.

Check wheels for lateral and radial runout before installing
a new tire.

Models with laced wheels: see

2.9 TRUING LACED

WHEELS

Models with cast wheels: see

2.10 CHECKING

CAST WHEEL RUNOUT

Inspect the tire and tube for wear and damage. Inspect
tread depth. Replace worn tires. Replace damaged tubes.

Replace punctured or damaged tires. In some cases, small
punctures in the tread area may be repaired from within
the demounted tire by a Harley-Davidson dealer. Speed
should NOT exceed 50 mph (80 km/h) for the first 24 hours
after repair, and the repaired tire should NEVER be used
over 80 mph (130 km/h). Failure to follow this warning
could result in death or serious injury. (00015a)

Tubeless tires may be repaired in the tread area only if
the puncture is 1/4 in. (6.4 mm) or smaller. All repairs
must be made from inside the tire.

Acceptable repair method involves the use of a patch and
plug combination.

INSTALLATION

Harley-Davidson front and rear tires are not the same.
Interchanging front and rear tires can cause tire failure,
which could result in death or serious injury. (00026a)

Do not exceed manufacturer's recommended pressure to
seat beads. Exceeding recommended bead seat pressure
can cause tire rim assembly to burst, which could result
in death or serious injury. (00282a)

Do not inflate tire beyond maximum pressure as specified
on sidewall. Over inflated tires can blow out, which could
result in death or serious injury. (00027a)

For tire pressures, see

1.8 TIRES AND WHEELS, Tires

Some tires have arrows molded into the tire sidewall. These
tires should be mounted on the rim with the arrow pointing in
the direction of forward rotation. The colored dot on the sidewall
is a balance mark and should be located next to the valve stem
hole.

Tube Type Tires

Match tires, tubes, air valves and caps to the correct wheel
rim. Contact a Harley-Davidson dealer. Mismatching can
result in damage to the tire bead, allow tire slippage on
the rim or cause tire failure, which could result in death
or serious injury. (00023a)

Use inner tubes on laced (wire spoked) wheels. Using
tubeless tires on laced wheels can cause air leaks, which
could result in death or serious injury. (00025a)

NOTES

•

For correct tire and tube types, see

2.1 SPECIFICATIONS

•

Whenever a tube type tire is replaced, the tube should
also be replaced. Inner tubes should be patched only as
an emergency measure. Replace a damaged or patched
tube as soon as possible. Rim bands must be used on all
laced wheels.

See

Figure 2-54

. On laced wheels, install a rim strip into

the rim well. Make sure no spokes protrude through
nipples, and be sure to align the valve stem hole in rim
strip with valve stem hole in rim.

Install tube and tire.

sm02466

Figure 2-54. Installing Rim Strip

Tubeless Tires

Only install original equipment tire valves and valve caps.
A valve, or valve and cap combination, that is too long or
too heavy can strike adjacent components and damage
the valve, causing rapid tire deflation. Rapid tire deflation
can cause loss of vehicle control, which could result in
death or serious injury. (00281a)

See

Figure 2-55

. On tubeless wheels, damaged or leaking

valve stems must be replaced. Install rubber grommet (3)
on valve stem.

Insert valve stem into rim hole.

2-48 2008 Touring Service: Chassis

Install metal washer (2).

Install nut and tighten to 12-15 in-lbs (1.4-1.7 Nm).

Install tire.

sm02467

Nut

Metal washer

Rubber grommet

Figure 2-55. Tubeless Tire Valve Stem

2008 Touring Service: Chassis 2-49

2.17

FRONT FORK

CHANGING FORK OIL

NOTE

If changing the fork oil at the 50,000 mile (80,000 km) service
interval, or if fork is leaking or fails visual inspection, see

2.17 FRONT FORK, Removal

and

2.17 FRONT FORK, Disas-

sembly

, as complete disassembly and inspection of the fork is

required. However, if a decision has been made to replace the
fork oil before the recommended service interval, and the fork
passes visual inspection, see steps 1-5 below.

Disassemble motorcycle and remove fork. See

2.17 FRONT FORK, Removal

Partially disassemble fork. See

2.17 FRONT FORK, Dis-

assembly

Position fork assembly upside down over drain pan. Allow
sufficient time for fork to thoroughly drain (about 10-15
minutes).

Fill and assemble fork. See

2.17 FRONT FORK, Assembly

Install fork and assemble motorcycle. See

2.17 FRONT

FORK, Installation

REMOVAL

Place suitable blocking under frame to raise front wheel
several inches off the floor. For best results, use an
hydraulic center stand on a level surface.

Remove the front wheel and fender. See

2.46 FRONT

FENDER

FLHR/C: Remove headlamp nacelle. See

2.45 HEAD-

LAMP NACELLE: FLHR/C

FLHX, FLHT/C/U:

Remove outer fairing. See

2.35 UPPER FAIRING

AND WINDSHIELD: FLHX, FLHT/C/U

Remove fairing cap. See

2.36 FAIRING CAP: FLHX,

FLHT/C/U

Remove two screws to release front turn signal
lamp/auxiliary lamp bracket, chrome skirt and inner
fairing from lower fork bracket. If necessary, see

8.14 TURN SIGNAL LAMPS

8.11 AUXILIARY

LAMPS AND BRACKETS

FLTR: Remove instrument nacelle. See

2.41 INSTRU-

MENT NACELLE: FLTR

Standing at front of motorcycle, loosen fork cap bolt from
fork tube plug at top of fork tube, but do not remove.

sm04819

Fork cap bolt

Pinch bolt

Rubber fork stop

Figure 2-56. Remove Fork Cap Bolt (FLHR/C Shown)

Loosen pinch bolt (with lockwasher) in lower fork bracket,
but do not remove. See

Figure 2-56

Spray glass cleaner on fork tube above the rubber fork
stop. After lubricating surfaces, move fork stop up fork
tube until it contacts bottom of upper fork bracket.

Holding fork slider to prevent fork from dropping, remove
fork cap bolt from fork tube plug. Slide fork tube down and
out of upper fork bracket, fork stop, lower fork bracket,
and slider cover.

10. Thread fork cap bolt back into fork tube plug to prevent

loss of fork oil while handling.

11. Move front fork to bench area. Place suitable drain pan

on floor beneath vise.

12. In the same fashion, remove other fork.

DISASSEMBLY

TOOL NAME

PART NUMBER

FORK TUBE HOLDER

HD-41177

Remove the fork assembly. See

2.17 FRONT FORK,

Removal

On right side fork, remove nuts, lockwashers, flat washers
and axle holder from studs at end of fork slider.

Exercise caution to avoid scratching or nicking fork tube.
Damaging tube can result in fork oil leaks after assembly.
(00421b)

2-50 2008 Touring Service: Chassis

Obtain the FORK TUBE HOLDER (Part No. HD-41177).
See

Figure 2-57

. Proceed as follows:

Clamp end of tool in vise in a horizontal position with
plastic knobs facing toward you.

With the fork cap bolt topside, clamp fork tube
between rubber pads on inboard side of tool. Tighten
knobs until fork tube is securely held. See

Figure 2-58

Remove fork cap bolt from fork tube plug. Remove and
discard quad ring seal.

Using flat, slowly unthread fork tube plug from fork tube.
Be aware that fork tube plug is under spring pressure, so
have a firm grasp on plug as the last thread is turned.
Remove O-ring from fork tube plug. Discard O-ring.

Remove fork spring from fork tube.

Remove fork assembly from fork tube holder.

Turning fork upside down, drain fork oil into drain pan. For
best results, slowly pump fork tube and slider at least ten
times. Be aware that damper valve, if equipped, may fall
out of inverted fork tube while draining. With the wear ring
at the bottom (spring side up), slide damper valve back
into fork tube when drained.

NOTE

If just changing the fork oil, continue procedure at ASSEMBLY,
step 14. If overhauling the fork assembly, continue with step
below.

Install fork spring back into fork tube.

10. Place a shop rag on the floor, and turning fork assembly

upside down, press end of spring against rag. While
compressing spring to prevent rotation of damper tube,
remove 6mm screw from end of fork slider. Use an air
impact wrench for best results. Discard 6mm screw and
copper crush washer.

11. Remove fork spring, damper valve (if equipped) and

damper tube from fork tube.

12. Remove wear ring and rebound spring from damper tube.

Remove wear ring from damper valve, if equipped.

NOTE

Do not expand or stretch retaining clip to remove from fork
tube or clip may become bent or distorted.

13. Using pick tool, remove retaining clip between fork slider

and fork tube.

14. Remove fork tube from fork slider.

NOTE

To overcome any resistance, use the fork tube as a slide
hammer, that is, first push fork tube into fork slider and then
pull it outward with a moderate amount of force. Repeat this
sequence until fork tube separates from fork slider.

15. Slide fork oil seal, slider spacer and slider bushing off end

of fork tube. Discard fork oil seal and slider bushing.

16. Gently pry at split line to expand fork leg bushing, and

then remove from groove at end of fork tube. Discard fork
leg bushing.

17. Remove lower stop from fork slider.

sm02900

Vise grip

Rubber pad

Figure 2-57. Fork Tube Holder (HD-41177)

sm02898

Flat

Fork tube plug

Figure 2-58. Install Fork Tube Into Fork Holder

CLEANING AND INSPECTION

Thoroughly clean and inspect all parts. Replace any parts
that are bent, broken or obviously damaged.

Inspect fork cap bolt quad ring seal and fork tube plug O-
ring for cuts, tears or signs of deterioration. Replace if
necessary.

Replace the retaining clip if bent or distorted.

Check the slider and fork leg bushings for scratches or
excessive wear. Always replace bushings in a set if either
bushing is damaged or worn.

2008 Touring Service: Chassis 2-51

sm02901

Figure 2-59. Measure Fork Tube Runout

Check the fork tube and slider for scoring, scratches and
excessive or abnormal wear. Replace parts as necessary.
Set the fork tube on V-blocks and measure the runout
using a dial indicator gauge. Replace fork if runout exceeds

0.008 in. (0.2 mm). See

Figure 2-59

Inspect upper fork spring and rebound spring for damage
or distortion. Replace upper fork spring if free length is
less than 18.4 in. (467.3 mm). Replace rebound spring if
free length is less than 0.938 in. (23.8 mm) or whenever
the upper fork spring requires replacement.

ASSEMBLY

TOOL NAME

PART NUMBER

FORK OIL SEAL INSTALLER

HD-34634

FORK OIL LEVEL GAUGE

HD-59000B

Exercise caution to avoid scratching or nicking fork tube.
Damaging tube can result in fork oil leaks after assembly.
(00421b)

Coat fork leg bushing ID with clean fork oil. Expand fork
leg bushing at split line only so far as required to slip over
end and into groove of fork tube.

Install new wear ring in groove at top of damper tube.
Install rebound spring on opposite end.

With the wear ring topside, slide damper tube into fork
tube, so that tube end drops through hole at bottom of fork
tube. Install lower stop at end of damper tube.

Install fork slider in fork tube holder. Slide fork tube into
fork slider.

Coat slider bushing ID with clean fork oil. Slide slider
bushing down fork tube.

Slide slider spacer down fork tube until it contacts slider
bushing.

Obtain the FORK OIL SEAL INSTALLER (Part No. HD-
34634). See

Figure 2-60

. Proceed as follows:

Slide the fork oil seal installer down the fork tube, and
using the tool like a slide hammer, drive slider bushing
into counterbore of fork slider. Remove tool.

NOTE

Place masking tape over edge of fork tube to avoid dam-
aging lip of fork oil seal during installation.

Coat new fork oil seal ID with clean fork oil. With the
lip garter spring side facing down (toward the fork
slider), slide seal down fork tube until it contacts slider
spacer. Remove masking tape from edge of fork tube.

Slide the fork oil seal installer down the fork tube until
it contacts the fork oil seal.

Using the tool like a slide hammer, drive fork oil seal
down fork tube until retaining clip groove is visible in
fork slider ID. See

Figure 2-61

. Remove tool.

NOTE

Do not expand or stretch retaining clip to install on fork
tube or clip may become bent or distorted.

Slide the retaining clip down the fork tube until it
contacts the fork oil seal. Install retaining clip in the
fork slider groove.

Install fork spring into fork tube.

Remove fork assembly from fork tube holder.

sm02902

Figure 2-60. Fork Oil Seal Installer (HD-34634)

is00157

Figure 2-61. Install Fork Oil Seal

2-52 2008 Touring Service: Chassis

sm02903

Figure 2-62. Fork Oil level Gauge (HD-59000B)

sm02904

Figure 2-63. Remove Excess Fork Oil

10. Place a shop rag on the floor, and turning fork assembly

upside down, press end of spring against rag.

11. Install new 6mm screw with copper crush washer. Slide

screw through hole at bottom of fork slider and start into
end of damper tube.

12. While compressing spring to prevent rotation of damper

tube, tighten 6mm screw to 132-216 in-lbs (14.9-24.4
Nm).

13. Remove fork spring from fork tube.

14. With the fork tube topside, clamp fork slider (not the fork

tube) into fork tube holder.

15. Install the drain plug at the bottom of the fork slider, if

removed. Tighten plug to 72-96 in-lbs (8-11 Nm).

NOTE

All touring models with the exception of Road King have the
damper valve type fork on both the left and right sides. Road
King uses the conventional type fork on both sides. See step
16 to set fork oil level on a damper valve type fork; see step
17 to set fork oil level on a conventional type fork.

Table 2-13. Fork Oil Requirements

Amount

Fork Type

Model

IN.

OZ.

142

5.59

319

10.8

Damper Valve

All models

except

Road King

133

5.24

328

11.1

Conventional

Road King

16. Set fork oil level on damper valve type fork (FLHX,

FLHT/C/U, FLTR) as follows:

Pour slightly more than 10.8 oz. (319 ml) of Harley-
Davidson Type E Fork Oil directly into the fork tube.

Slowly pump fork tube until some resistance is felt
and then pump a few more times.

Install new wear ring in groove of damper valve. With
the wear ring at the bottom (spring side up), slide
damper valve into fork tube.

Install fork spring into fork tube. Use fork spring to
push damper valve to bottom of fork tube. Remove
fork spring from fork tube.

Slowly pump fork tube a few more times to discharge
air from damper valve.

See

Figure 2-62

. Obtain the FORK OIL LEVEL

GAUGE (Part No. HD-59000B).

Loosen thumbscrew on metal ring of tool and move
it up or down the rod until bottom of ring is 5.59
in. (142 mm) from end of rod. Tighten thumbscrew.

Push the plunger on the cylinder all the way in.

With the fork tube bottomed in the fork slider, insert
rod until metal ring rests flat on top of fork tube. See

Figure 2-63

Pull out plunger to suck fork oil from fork tube.
Observe fork oil through transparent tube as it is
drawn into cylinder. If no oil is drawn through trans-
parent tube, add enough oil so that tool usage sets
fork oil level.

Remove rod from fork tube. Push plunger into cylinder
to eject excess fork oil into suitable container.

If necessary, repeat steps 16(i) thru 16(k). Level is
correct when no fork oil is observed being drawn
through transparent tube.

Incorrect amount of fork oil can adversely affect handling
and lead to loss of vehicle control, which could result in
death or serious injury. (00298a)

2008 Touring Service: Chassis 2-53

17. Set fork oil level on conventional type fork (FLHR/C) as

follows:

Pour slightly more than 11.1 oz. (328 ml) of Harley-
Davidson Type E Fork Oil directly into the fork tube.

Slowly pump fork tube until some resistance is felt
and then pump a few more times.

See

Figure 2-62

. Obtain the FORK OIL LEVEL

GAUGE (HD-59000B).

Loosen thumbscrew on metal ring of tool and move
it up or down the rod until the bottom of ring is 5.24
in. (133 mm) from end of rod. Tighten thumbscrew.

Push the plunger on the cylinder all the way in.

With the fork tube bottomed in the fork slider, insert
rod until metal ring rests flat on top of fork tube. See

Figure 2-63

Remove rod from fork tube. Push plunger into cylinder
to eject excess fork oil into suitable container.

If necessary, repeat steps 17(f) thru 17(h). Level is
correct when no fork oil is observed being drawn
through transparent tube.

Incorrect amount of fork oil can adversely affect handling
and lead to loss of vehicle control, which could result in
death or serious injury. (00298a)

18. With the closer spaced coils at the bottom, slide fork spring

into fork tube.

19. Remove fork slider from fork tube holder. Clamp fork tube

into fork tube holder.

20. Install new O-ring onto fork tube plug. Compressing fork

spring with end of fork tube plug, thread fork tube plug into
fork tube. Tighten fork tube plug to 22-58 ft-lbs (30-79
Nm).

21. Install new quad ring seal onto fork cap bolt. Thread fork

cap bolt into fork tube plug to prevent loss of fork oil while
handling.

22. On right side fork, loosely install axle holder, flat washers,

lockwashers and nuts on studs at end of fork slider.

2-54 2008 Touring Service: Chassis

sm04820

14.

Slider spacer

Fork cap bolt

15.

Quad ring seal

Slider bushing

16.

Fork leg bushing

Fork tube plug

17.

O-ring

Lower stop

18.

Fork slider

Spring

19.

Damper valve (Fairing equipped only)

Plug

20.

Flat washer

Wear ring (Fairing equipped only)

21.

Wear ring

Copper washer

22.

Screw (6mm)

Damper tube

10.

23.

Rebound spring

Axle holder

24.

11.

Flat washer (2)

Fork tube

12.

25.

Retaining clip

Lockwasher (2)

26.

13.

Nut (2)

Lip seal

Figure 2-64. Right Side Fork

INSTALLATION

Remove fork cap bolt.

Standing at front of motorcycle, slide fork tube up and into
slider cover, lower fork bracket, fork stop, and upper fork
bracket. Install fork cap bolt.

Move rubber fork stop down fork tube until it contacts top
of lower fork bracket. Lubricate surfaces with glass cleaner,
if necessary.

Install pinch bolt (with lockwasher) in lower fork bracket.
See

Figure 2-56

. Tighten pinch bolt to 30-35 ft-lbs (41-48

Nm).

Tighten fork cap bolt to 50-60 ft-lbs (68-81 Nm).

Repeat previous steps on other fork, if removed.

2008 Touring Service: Chassis 2-55

Install the front fender and wheel. See

2.46 FRONT

FENDER

FLHR/C: Install headlamp nacelle. See