Harley Davidson 2008 Touring Models. Service Manual — page 10
1.24
STORAGE
GENERAL
If the motorcycle will not be operated for several months, such
as during the winter season, there are several things which
should be done to protect parts against corrosion, to preserve
the battery and to prevent the buildup of gum and varnish in
the fuel system.
This work should be performed by your local Harley-Davidson
dealer or other qualified technician following Service Manual
procedures.
PLACING IN STORAGE
TOOL NAME
PART NUMBER
STORAGE COVER
98716-87A
Do not store motorcycle with gasoline in tank within the
home or garage where open flames, pilot lights, sparks or
electric motors are present. Gasoline is extremely flam-
mable and highly explosive, which could result in death
or serious injury. (00003a)
1.
Run motorcycle until engine is at normal operating temper-
ature. Stop the engine then drain the oil pan, install a new
oil filter, and fill oil pan with the proper grade oil. Check
the transmission lubricant level.
Avoid spills. Slowly remove filler cap. Do not fill above
bottom of filler neck insert, leaving air space for fuel
expansion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)
Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00029a)
2.
Prepare your fuel system by filling fuel tank and adding a
gasoline stabilizer. Use one of the commercially available
gasoline stabilizers following the manufacturer's instruc-
tions.
3.
Remove the spark plugs, inject a few squirts of engine oil
into each cylinder and crank the engine 5-6 revolutions.
Reinstall spark plugs.
4.
Inspect rear belt deflection. See
.
5.
Inspect rear belt and sprockets. See
6.
Inspect air cleaner filter. See
7.
Lubricate controls. See
8.
Inspect operation of all electrical equipment and switches.
9.
Check tire inflation and inspect tires for wear and/or
damage. See
. If the motorcycle
will be stored for an extended period of time, securely
support the motorcycle under the frame so that all weight
is off the tires.
Be sure that brake fluid or other lubricants do not contact
brake pads or discs. Such contact can adversely affect
braking ability, which could cause loss of control, resulting
in death or serious injury. (00290a)
10. Wash painted and chrome-plated surfaces. Apply a light
film of oil to exposed unpainted surfaces.
Unplug or turn OFF battery charger before connecting
charger cables to battery. Connecting cables with charger
ON can cause a spark and battery explosion, which could
result in death or serious injury. (00066a)
Explosive hydrogen gas, which escapes during charging,
could cause death or serious injury. Charge battery in a
well-ventilated area. Keep open flames, electrical sparks
and smoking materials away from battery at all times.
KEEP BATTERIES AWAY FROM CHILDREN. (00065a)
11. Remove battery from vehicle. Charge battery until the
correct voltage is obtained. Charge the battery every other
month if it is stored at temperatures below 60° F (16° C).
Charge battery once a month if it is stored at temperatures
above 60° F (16° C). See
.
Unplug or turn OFF battery charger before disconnecting
charger cables from battery. Disconnecting clamps with
charger ON can cause a spark and battery explosion, which
could result in death or serious injury. (00067a)
12. If the motorcycle is to be covered, use a material that will
breathe, such as STORAGE COVER (Part No. 98716-
87A) or light canvas. Plastic materials that do not breathe
promote the formation of condensation, which leads to
corrosion.
REMOVAL FROM STORAGE
The clutch failing to disengage can cause loss of control,
which could result in death or serious injury. Prior to
starting after extended periods of storage, place transmis-
sion in gear and push vehicle back and forth several times
to assure proper clutch disengagement. (00075a)
1.
Charge and install the battery.
2008 Touring Service: Maintenance 1-53
2.
Remove and inspect the spark plugs. Replace if neces-
sary.
3.
Clean the air cleaner element.
4.
If fuel tank was drained, fill fuel tank with fresh gasoline.
5.
Start the engine and run until it reaches normal operating
temperature.
6.
Check engine oil level. Check the transmission lubricant
level. Fill to proper levels with correct fluids, if required.
7.
Perform all of the checks in the PRE-RIDING CHECKLIST
in the Owner's Manual.
1-54 2008 Touring Service: Maintenance
1.25
TROUBLESHOOTING
GENERAL
The Troubleshooting section of this manual is a guide to
diagnose problems. Read the appropriate sections of this
manual before performing any work. Improper repair and/or
maintenance could result in death or serious injury.
(00528b)
The following check list of possible operating troubles and their
probable causes will be helpful in keeping a motorcycle in good
operating condition. More than one of these conditions may
be causing the trouble and all should be carefully checked.
NOTE
For further troubleshooting information, see the ELECTRICAL
DIAGNOSTIC MANUAL.
ENGINE
Starter Motor Does Not Operate or Does Not
Turn Engine Over
1.
Ignition switch not in IGNITION position.
2.
Engine run switch in OFF position.
3.
Discharged battery, loose or corroded connections
(solenoid chatters).
4.
Starter control circuit, relay, or solenoid faulty.
5.
Electric starter shaft pinion gear not engaging or overrun-
ning clutch slipping.
6.
TSM/TSSM/HFSM Bank Angle Sensor tripped and
ignition/light key switch not cycled OFF then back to
IGNITION.
7.
Security system activated.
8.
Motorcycle in gear and clutch not pulled in.
9.
Jiffy stand down and transmission in gear (HDI models
only)
10. Maxi fuse not in place
Engine Turns Over But Does Not Start
1.
Fuel tank empty.
2.
Fouled spark plugs.
3.
Discharged battery, loose or broken battery terminal con-
nections.
4.
Engine lubricant too heavy (winter operation).
NOTE
For cold weather starts, always disengage clutch.
5.
Spark plug cables in bad condition and shorting, cable
connections loose or cables connected to incorrect cylin-
ders.
6.
Damaged wire or loose wire connection at ignition coil,
battery, or ECM connector.
7.
Ignition timing incorrect due to faulty ignition coil, ECM or
sensors.
8.
Bank Angle Sensor tripped and ignition switch not cycled
OFF then back to IGNITION.
9.
Fuel filter clogged.
10. Sticking or damaged valve(s) or wrong length push rod(s).
11. Plugged fuel injectors.
Starts Hard
1.
Spark plugs in bad condition or have improper gap or are
partially fouled.
2.
Spark plug cables in poor condition.
3.
Battery nearly discharged.
4.
Damaged wire or loose wire connection at one of the bat-
tery terminals, ignition coil or ECM connector.
5.
Water or dirt in fuel system.
6.
Intake air leak.
7.
Fuel tank vent hose, filler cap vent or vapor valve plugged,
or fuel line closed off, restricting fuel flow.
8.
Engine lubricant too heavy (winter operation).
NOTE
For cold weather starts, always disengage clutch.
9.
Ignition not functioning properly (possible sensor failure).
10. Faulty ignition coil.
11. Valves sticking.
12. Partially plugged fuel injector(s).
Starts But Runs Irregularly or Misses
1.
Spark plugs in poor condition or partially fouled.
2.
Spark plug cables in poor condition and shorting or leaking.
3.
Spark plug gap too close or too wide.
4.
Faulty ignition coil, ECM, or sensor.
5.
Battery nearly discharged.
6.
Damaged wire or loose connection at battery terminals,
ignition coil or ECM connector.
7.
Intermittent short circuit due to damaged wire insulation.
8.
Water or dirt in fuel system.
9.
Fuel tank vent system plugged.
10. Air leak at intake manifold or air cleaner.
11. Loose or dirty ECM connector.
12. Faulty Sensor(s): Temperature Manifold Absolute Pressure
(TMAP), Crank Position (CKP) or Oxygen (O2).
13. Incorrect valve timing.
14. Weak or broken valve springs.
15. Damaged intake or exhaust valve.
2008 Touring Service: Maintenance 1-55
16. Partially plugged fuel injector(s).
A Spark Plug Fouls Repeatedly
1.
Fuel mixture too rich.
2.
Incorrect spark plug for the kind of service.
3.
Piston rings badly worn or broken.
4.
Valve guides or seals badly worn.
Pre-Ignition or Detonation (Knocks or Pings)
1.
Fuel octane rating too low.
2.
Faulty spark plugs.
3.
Incorrect spark plug for the kind of service.
4.
Excessive carbon deposit on piston head or in combustion
chamber.
5.
Ignition timing advanced due to faulty sensor inputs (TMAP
and/or CKP).
6.
Ignition timing advanced due to ECM or sensors (CKP,
ET or TMAP) defective.
7.
Intake manifold vacuum leak.
Overheating
1.
Insufficient oil supply or oil not circulating.
2.
Insufficient air flow over engine.
3.
Heavy carbon deposits.
4.
Ignition timing retarded due to defective ECM or faulty
sensor(s) (TMAP and/or CKP).
5.
Leaking valve(s).
Valve Train Noise
1.
Low oil pressure caused by oil feed pump not functioning
properly or oil passages obstructed.
2.
Faulty hydraulic lifter(s).
3.
Bent push rod(s).
4.
Incorrect push rod length.
5.
Rocker arm binding on shaft.
6.
Valve sticking in guide.
7.
Chain tensioning spring or shoe worn.
8.
Cam(s), cam gear(s) or cam bushing(s) worn.
9.
Cam timing incorrect.
Excessive Vibration
1.
Wheels bent or damaged and/or tires worn or damaged.
2.
Engine/Transmission/Rear Wheel not aligned properly.
3.
Primary chain badly worn or links tight as a result of
insufficient lubrication or misalignment.
4.
Engine to transmission mounting bolts loose.
5.
Upper engine mounting bracket loose/broken or mounting
bracket pre-loaded.
6.
Ignition timing advanced due to faulty sensor inputs (TMAP
and/or CKP)/poorly tuned engine.
7.
Internal engine problem.
8.
Broken frame.
9.
Stabilizer links worn or loose, or stabilizer link brackets
loose or broken.
10. Isolators worn or isolator bolts loose or broken.
11. Rubber mounts loose or worn.
12. Rear fork pivot shaft fasteners loose.
13. Front engine mounting bolts loose.
Check Engine Light Illuminates During
Operation
1.
Fault detected. See the ELECTRICAL DIAGNOSTIC
MANUAL for more information.
LUBRICATION SYSTEM
Oil Does Not Return To Oil Reservoir
1.
Oil reservoir empty.
2.
Oil pump not functioning.
3.
Restricted oil lines or fittings.
4.
Restricted oil filter.
5.
O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).
Engine Uses Too Much Oil Or Smokes
Excessively
1.
Oil reservoir overfilled.
2.
Restricted oil return line to oil reservoir.
3.
Restricted breather operation.
4.
Restricted oil filter.
5.
Oil pump misaligned or in poor condition.
6.
Piston rings badly worn or broken.
7.
Valve guides or seals worn or damaged.
8.
O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).
9.
Plugged crankcase scavenge port.
10. Oil diluted with gasoline.
Engine Leaks Oil From Cases, Push Rods,
Hoses, Etc.
1.
Loose parts.
2.
Imperfect seal at gaskets, push rod covers, washers, etc.
3.
Restricted breather passages or hose to air cleaner.
4.
Restricted oil filter.
5.
Oil reservoir overfilled.
6.
Lower rocker housing gasket installed incorrectly (upside
down).
7.
Restricted oil return line to oil reservoir.
8.
Porosity.
1-56 2008 Touring Service: Maintenance
Low Oil Pressure
1.
Oil reservoir underfilled.
2.
Faulty low oil pressure switch.
3.
Oil pump o-ring damaged or missing.
4.
Bypass valve stuck in open position.
5.
Ball missing or leaking in cam support plate.
6.
Worn oil pump gerotor(s).
7.
Oil diluted with gasoline.
High Oil Pressure
1.
Oil reservoir overfilled.
2.
Bypass valve stuck in closed position.
ELECTRICAL SYSTEM
NOTE
For diagnostic information see the ELECTRICAL DIAGNOSTIC
MANUAL.
Alternator Does Not Charge
1.
Voltage regulator module not grounded.
2.
Engine ground wire loose or broken.
3.
Faulty voltage regulator module.
4.
Loose or broken wires in charging circuit.
5.
Faulty stator and/or rotor.
Alternator Charge Rate Is Below Normal
1.
Weak or damaged battery.
2.
Loose connections.
3.
Faulty voltage regulator module.
4.
Faulty stator and/or rotor.
Speedometer Operates Erratically
1.
Contaminated vehicle speed sensor (remove sensor and
clean off metal particles).
2.
Loose connections.
TRANSMISSION
Shifts Hard
1.
Primary chaincase overfilled with lubricant.
2.
Clutch not fully disengaging.
3.
Transmission lubricant too heavy (winter operation).
4.
Shifter return spring (inside transmission) bent or broken.
5.
Bent shifter rod.
6.
Shifter forks (inside transmission) sprung.
7.
Corners worn off shifter clutch dog rings (inside transmis-
sion).
Jumps Out Of Gear
1.
Shifter rod improperly adjusted.
2.
Shifter drum (inside transmission) improperly adjusted or
damaged/worn.
3.
Shifter engaging parts (inside transmission) badly worn
and rounded.
4.
Shifter forks bent.
5.
Damaged gears.
Clutch Slips
1.
Clutch controls improperly adjusted.
2.
Insufficient clutch spring tension.
3.
Worn friction discs.
Clutch Drags Or Does Not Release
1.
Lubricant level too high in primary chaincase.
2.
Clutch controls improperly adjusted.
3.
Primary chain badly misaligned or too tight.
4.
Insufficient clutch spring tension.
5.
Clutch discs warped.
Clutch Chatters
Friction discs or steel discs worn or warped.
HANDLING
Irregularities
1.
Improperly loaded motorcycle. Non-standard equipment
on the front end such as heavy radio receivers, extra
lighting equipment or luggage tends to cause unstable
handling.
2.
Damaged tire(s) or improper front-rear tire combination.
3.
Irregular or peaked front tire tread wear.
4.
Incorrect tire pressure.
5.
Shock absorber not functioning normally.
6.
Incorrect air suspension pressure.
7.
Loose wheel axle nuts. Tighten to recommended torque
specification.
8.
Excessive wheel hub bearing play.
9.
Rear wheel out of alignment with frame and front wheel.
10. Steering head bearings improperly adjusted. Correct
adjustment and replace pitted or worn bearings and races.
11. Loose spokes (laced wheel vehicles only).
12. Tire and wheel unbalanced.
13. Rims and tires out-of-round or eccentric with hub.
14. Rims and tires out-of-true sideways.
15. Rear fork pivot assembly: improperly tightened or
assembled, or loose/pitted or damaged pivot bearings.
16. Engine mounts and/or stabilizer links loose, worn or
damaged..
2008 Touring Service: Maintenance 1-57
BRAKES
Brake Does Not Hold Normally
1.
Master cylinder reservoir low on fluid, system leaking or
pads worn.
2.
Brake system contains air bubbles.
3.
Master cylinder or caliper piston seals worn or parts
damaged.
4.
Brake pads contaminated with grease or oil.
5.
Brake pads badly worn.
6.
Brake disc badly worn or warped.
7.
Brake drags - insufficient brake pedal or hand lever free-
play, caliper piston worn or damaged, or excessive brake
fluid in reservoir.
8.
Brake fades due to heat build up - brake pads dragging
or excessive braking.
9.
Brake fluid leak when under pressure.
1-58 2008 Touring Service: Maintenance
NOTE
Use of smaller diameter flat washer with crank sprocket
flange bolt allows room on sprocket face for placement of
straightedge.
c.
. To prevent rotation, position the
CRANKSHAFT/CAMSHAFT SPROCKET LOCKING
TOOL (Part No. HD-47941) between the crank and
primary cam sprockets. The handle of the tool is
stamped "Crank" and "Cam" to ensure proper orient-
ation. Tighten the crank and primary cam sprocket
flange bolts to 15 ft-lbs (20.3 Nm). Remove the
sprocket locking tool.
d.
Rotate engine stand so cam compartment is pointing
upward. Push on crankshaft and rear camshaft to
eliminate endplay.
If engine was not removed from motorcycle, install
compensating sprocket assembly to pull the crank-
shaft to the left side of the engine. Push on crankshaft
and rear camshaft to eliminate endplay.
e.
See
. Place a straightedge across the
crank and primary sprocket faces. Attempt to insert
a 0.010 in. (0.254 mm) feeler gauge between the
straightedge and the each sprocket face. If the feeler
gauge will not fit at either location, sprocket offset is
within specification. Remove both sprockets and dis-
card temporary small washer.
NOTE
Height differences between rear cam sprocket and crank
sprocket can be addressed by changing the spacer behind
the rear cam sprocket. See spacer sizes in
.
f.
If the crank sprocket rises above the face of the rear
cam sprocket more than 0.010 in. (0.254 mm),
remove the flange bolt and rear cam sprocket. Note
the part number stamped on the existing spacer
behind rear cam sprocket. Replace spacer with the
next larger size.
If the rear cam sprocket rises above the face of the
crank sprocket more than 0.010 in. (0.254 mm),
replace the spacer with the next smaller size only.
g.
Repeat height inspection with the new spacer
installed. Remove both sprockets when measurement
is within specification and discard temporary small
washer.
sm02416
Figure 3-63. Camshaft Locking Tool
sm02418
Figure 3-64. Check Alignment of Crank and Rear Cam
Sprocket Faces
Table 3-33. Rear Cam Sprocket Spacers
MM.
IN.
PART NO.
2.54
0.100
25729-06
2.79
0.110
25731-06
3.05
0.120
25734-06
3.30
0.130
25736-06
3.56
0.140
25737-06
3.81
0.150
25738-06
2008 Touring Service: Engine 3-51
2.1
SPECIFICATIONS
SPECIFICATIONS
Table 2-1. Dimensions: 2008 FLHT, FLHTC/U, FLTR and FLHX
FLHX
FLTR
FLHTCU
FLHTC
FLHT
ITEM
MM
IN.
MM
IN.
MM
IN.
MM
IN.
MM
IN.
1612.9
63.5
1612.9
63.5
1612.9
63.5
1612.9
63.5
1612.9
63.5
Wheel base
2400.3
94.5
2380.0
93.7
2496.8
98.3
2476.5
97.5
2380.0
93.7
Overall length (Tour-Pak in
rearmost position)
990.6
39.0
909.3
35.8
990.6
39.0
990.6
39.0
990.6
39.0
Overall width
119.4
4.7
129.5
5.1
129.5
5.1
129.5
5.1
129.5
5.1
Road clearance
1325.9
52.2
1397.0
55.0
1549.4
61.0
1549.4
61.0
1549.4
61.0
Overall height
668.0
26.3
683.3
26.9
693.4
27.3
693.4
27.3
693.4
27.3
Saddle height*
*With 180 lb. (81.7 kg) rider on seat
Table 2-2. Dimensions: 2008 FLHR and FLHRC
FLHRC
FLHR
ITEM
MM
IN.
MM
IN.
1612.9
63.5
1612.9
63.5
Wheel base
2380.0
93.7
2380.0
93.7
Overall length
876.3
34.5
876.3
34.5
Overall width
129.5
5.1
129.5
5.1
Road clearance
1399.5
55.1
1399.5
55.1
Overall height
683.3
26.9
693.4
27.3
Saddle height*
*With 180 lb. (81.7 kg) rider on seat
Table 2-3. Capacities: 2008 Touring Models
LITERS
U.S.
ITEM
22.7
6.0 gal
Fuel tank (total)
3.8
4.0 U.S. qt.
Oil tank with filter
0.95
32.0 fl. oz.
Transmission
(approximate)
1.32
45.0 fl. oz.
Primary chaincase
(approximate)
Table 2-4. Weights: 2008 FLHT, FLHTC/U, FLTR and FLHX
FLHX
FLTR
FLHTCU
FLHTC
FLHT
ITEM
KG
LB.
KG
LB.
KG
LB.
KG
LB.
KG
LB.
341
749
341
752
369
814
359
791
337
743
Weight as shipped
from factory
571
1259
571
1259
571
1259
571
1259
571
1259
GVWR
227
500
227
500
227
500
227
500
227
500
GAWR front
375
827
375
827
375
827
375
827
375
827
GAWR rear
2008 Touring Service: Chassis 2-1
Table 2-5. Weights: 2008 FLHR and FLHRC
FLHRC
FLHR
ITEM
KG
LB.
KG
LB.
335
738
336
740
Weight as shipped from factory
571
1259
571
1259
GVWR
227
500
227
500
GAWR front
375
827
375
827
GAWR rear
NOTES
•
Gross vehicle weight rating (GVWR) (maximum allowable
loaded vehicle weight) and corresponding gross axle
weight rating (GAWR) are given on a label located on the
frame steering head.
•
For important information regarding tire data and tire
inflation, see
.
2-2 2008 Touring Service: Chassis
2.2
VEHICLE IDENTIFICATION NUMBER (V.I.N.)
VEHICLE IDENTIFICATION NUMBER:
TOURING MODELS
The full 17-digit serial number, or Vehicle Identification Number
(V.I.N.), is stamped on the right side of the frame backbone at
the rear of the steering head. A label bearing the V.I.N. code
is also affixed to the left side of the steering head.
An abbreviated V.I.N. is stamped between the front and rear
cylinders on the left side of the crankcase.
NOTE
Always give the full 17-digit Vehicle Identification Number when
ordering parts or making any inquiry about your motorcycle.
1 HD 1 FC 4 1 3 8 Y 600041
1
2
3
4
5
6
7
8
9
10
om00883a
Figure 2-1. Typical Harley-Davidson V.I.N.: 2008 Touring Models
Table 2-6. Harley-Davidson V.I.N. Breakdown: 2008 Touring Models
POSSIBLE VALUES
DESCRIPTION
POSITION
1=Originally manufactured for sale within the United States
Market designation
1
5=Originally manufactured for sale outside of the United States
HD=Harley-Davidson
Manufacturer
2
1=Heavyweight motorcycle (901 cc or larger)
Motorcycle type
3
See V.I.N. model table
Model
4
4=Twin Cam 96
™
, 1584 cc air cooled, fuel injected
Engine type
5
1=Regular
Introduction date
6
2=Mid-year
3=California/regular
4=Cosmetic changes and/or special introductory date
5=California/cosmetic changes and/or special introductory date
6=California/mid-year
Can be 0-9 or X
V.I.N. check digit
7
8=2008
Model year
8
Y=York, PA U.S.A.
Assembly plant
9
Varies
Sequential number
10
Table 2-7. V.I.N. Model Codes: 2008 Touring Models
MODEL
CODE
MODEL
CODE
FLHTCU Ultra Classic
®
Electra Glide
®
FC
FLHR Road King
®
FB
FLHTCU Ultra Classic
®
Electra Glide
®
Shrine
FL
FLHTCU Ultra Classic
®
Electra Glide
®
with sidecar
FG
FLHT Electra Glide
®
Standard
FV
FLTR Road Glide
®
FS
2008 Touring Service: Chassis 2-3
Table 2-7. V.I.N. Model Codes: 2008 Touring Models
MODEL
CODE
MODEL
CODE
FLHX Street Glide
™
KB
FLHTC Electra Glide
®
Classic
FF
FLHRC Road King
®
Classic
FR
FLHR Road King
®
Shrine
FW
2-4 2008 Touring Service: Chassis
2.3
FRONT WHEEL
GENERAL
Maximum tire mileage and good handling qualities are directly
related to care given wheels and tires. Wheels and tires should
be regularly inspected for wear. If handling problems occur,
see
for possible causes.
Always keep tires inflated to the recommended pressure and
balance the wheel whenever a tire or tube is replaced.
REMOVAL
1.
Place the motorcycle on a hydraulic center stand with the
front wheel raised off the ground.
2.
Inspect wheel bearings. See
.
3.
If present, carefully cut two cable straps to release front
wheel speed sensor cable and front fender tip lamp wires
from brake hose to left brake caliper.
4.
. On ABS equipped motorcycles, release
front wheel speed sensor cable from clip as follows:
a.
Push on lip at rear of clip to disengage from bracket.
b.
Rotate tab (stamped ABS) rearward until clip is per-
pendicular to bracket and remove cable.
5.
Remove two brake caliper mounting screws (with cable
clip/bracket if ABS equipped). Slide brake caliper straight
down to remove from brake disc. Using thru hole, cable
strap caliper to rail of engine guard, so that it is not sus-
pended by brake hose.
6.
Remove brake caliper on right side of wheel.
NOTE
Do not operate the front brake hand lever with the front wheel
removed or the caliper pistons may be forced out. Reseating
pistons requires disassembly of the brake caliper.
7.
. Insert screwdriver or steel rod through
hole in axle on right side of motorcycle. While holding axle
stationary, remove the axle nut and flat washer on the left
side.
8.
Loosen the two axle holder nuts at bottom of right side
fork slider.
1
2
sm04204
1.
Push lip to disengage
2.
Push tab to engage
Figure 2-2. Front Wheel Speed Sensor Cable Clip (ABS
Equipped)
9.
Using a soft mallet, gently tap end of axle towards right
side of motorcycle. Catching external spacer(s), pull axle
free of fork sliders, front wheel speed sensor (if ABS
equipped), and wheel hub.
NOTE
If ABS equipped, never pull wheel speed sensor cable taut or
use to retain wheel, axle or other components. Always keep
wheel speed sensor (and ABS encoder bearing) away from
magnetic fields (such as magnetic parts trays, magnetic base
dial indicators, alternator rotors, etc.) or damage will occur.
10. Move wheel to bench area.
NOTE
Do not operate the front brake lever with the front wheel
removed or the caliper pistons may be forced out. Reseating
pistons requires disassembly of the caliper.
11. If necessary, remove five screws to release brake discs
from hub.
2008 Touring Service: Chassis 2-5
16
17
15
10
4
12
6
9
14
5
7
8
13
4
2
3
1
3
11
13
sm04392
10.
1.
Spacer sleeve
Axle nut
2.
11.
Flat washer
Axle
12.
3.
Brake disc (left side)
External spacer
4.
13.
Standard bearing
T40 TORX screw (10)
14.
5.
Brake disc (right side)
ABS encoder bearing
6.
15.
Front wheel speed sensor
Laced wheel
16.
7.
Cast wheel
Cable clip
8.
17.
Clip bracket
Slotted cast wheel
9.
Spacer washer
Figure 2-3. Front Wheel (Exploded View)
CLEANING AND INSPECTION
1.
Thoroughly clean all parts in solvent (wheel speed sensor
and bearings excepted) and inspect for damage or
excessive wear.
2.
Replace brake discs if warped or badly scored. Measure
disc thickness for excessive wear. Minimum acceptable
thickness is stamped on side of disc.
INSTALLATION
1.
If removed, install five new screws to fasten brake discs
to hub. Alternately tighten screws to 16-24 ft-lbs (22-33
Nm).
2.
Place wheel into position between fork sliders with the
valve stem on the right side of the motorcycle.
2-6 2008 Touring Service: Chassis
3.
Apply a light coat of LOCTITE ANTI-SEIZE lubricant to
axle, bearing bores and bore of spacer sleeve.
4.
Slide axle through right fork slider and external spacer into
wheel hub.
NOTE
Be sure that grooves on external spacer(s), or index pin on
front wheel speed sensor (if ABS equipped), are on the out-
board side. If motorcycle is not ABS equipped, external spacers
on left and right side of wheel hub are interchangeable.
5.
When axle emerges from hub on left side of wheel, push
it through front wheel speed sensor (if ABS equipped) or
second external spacer, and then through left fork slider.
6.
Install flat washer and axle nut.
7.
. If ABS equipped, rotate front wheel speed
sensor in a counter-clockwise direction until index pin
makes contact with shoulder on left fork slider.
8.
Insert screwdriver or steel rod through hole in axle on right
side of motorcycle. While holding axle stationary, tighten
axle nut to 60-65 ft-lbs (81.4-88.1 Nm).
9.
Push right fork slider inboard until it contacts external
spacer, and then holding it in this position, tighten axle
holder nuts to 132-180 in-lbs (14.9-20.3 Nm).
10. Install left side brake caliper as follows:
a.
Install caliper at bottom of brake disc. Pry inner and
outer brake pads back for additional clearance, if
necessary.
b.
Slide brake caliper straight up until holes are aligned
with lugs on fork slider. Start two mounting screws
(with cable clip/bracket if ABS equipped).
NOTE
Be sure that tab (stamped ABS) on clip is installed in slot
of bracket from inboard side. Clip cannot be installed once
mounting screws are started.
c.
Alternately tighten mounting screws to 28-38 ft-
lbs (37.9-51.5 Nm)
d.
Repeat applicable steps to install caliper on right side
of wheel.
After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)
11. Depress front brake hand lever several times to set brake
pads to proper operating position within caliper.
12. If ABS equipped, install two new cable straps as follows:
a.
Install cable strap 2.5 in. (63.5 mm) above the bottom
brake hose crimp capturing front wheel speed sensor
cable and brake hose.
b.
Install cable strap 2.5 in. (63.5 mm) below the top
brake hose crimp capturing front wheel speed sensor
cable, brake hose and front fender tip lamp wires, if
equipped.
13. If ABS equipped, install front wheel speed sensor cable
in clip as follows:
a.
Rotate tab (stamped ABS) until clip is perpendicular
to bracket and install cable.
b.
Rotate tab forward until clip is inline with bracket and
then apply pressure to tab until lip engages. Gently
pull on cable to verify that clip is properly installed.
sm04027
Figure 2-4. Front Wheel Speed Sensor Index Pin (ABS
Equipped)
2008 Touring Service: Chassis 2-7
2.4
REAR WHEEL
GENERAL
Maximum tire mileage and good handling qualities are directly
related to care given wheels and tires. Wheels and tires should
be regularly inspected for wear. If handling problems occur,
see
for possible causes.
Always keep tires inflated to the recommended pressure and
balance the wheel whenever a tire or tube is replaced.
REMOVAL
TOOL NAME
PART NUMBER
AXLE NUT TORQUE ADAPTER
HD-47925
1.
Remove saddlebags. See
.
2.
Place motorcycle on center stand with the rear wheel
raised off the ground.
3.
Inspect wheel bearings. See
.
4.
Remove left side muffler as follows:
a.
Open two worm drive clamps to remove heat shield
from crossover pipe on left side of motorcycle.
b.
Using a bungee cord, tie the muffler to the lower
saddlebag support rail.
c.
Loosen TORCA clamp between crossover pipe and
muffler.
NOTE
To facilitate removal, spray suitable penetrating oil in and
around joint of exhaust pipes. Allow sufficient time for the
penetrating oil to work.
d.
Remove two screws (with lockwashers) to detach
muffler from lower saddlebag support rail.
e.
Remove bungee cord to release muffler from lower
saddlebag support rail.
5.
On models equipped with low profile shock absorbers
(FLHX), remove left side lower saddlebag support rail as
follows:
a.
Remove outside screw (and flange nut) to release
saddlebag support rail from saddlebag support
bracket.
b.
Remove screw to release opposite end of saddlebag
support rail from frame weldment.
6.
If ABS equipped, carefully cut cable strap to release rear
wheel speed sensor cable from brake hose to brake cal-
iper.
7.
Remove two socket head screws to release brake caliper
from caliper bracket.
8.
Remove brake caliper from brake disc. Pry inner and outer
brake pads back for additional clearance, if necessary.
Use a putty knife with a wide thin blade to avoid scoring
or scratching the brake disc. Set brake caliper on pas-
senger footboard.
9.
See
. Remove E-clip from groove at end of axle.
10. Loosen cone nut as follows:
a.
Obtain breaker bar with 1/2 inch drive head and AXLE
NUT TORQUE ADAPTER (Part No. HD-47925).
b.
Install torque adapter perpendicular to breaker bar.
See upper frame of
.
c.
Insert tool up between rear wheel and muffler to
capture cone nut. For best clearance with muffler, be
sure torque adapter is on the outboard side.
d.
Rotate cone nut in a counter-clockwise direction.
11. Remove cone nut and adjuster cam from axle.
12. Rotate weld nut on opposite side of axle in a counter-
clockwise direction until wheel is loose.
13. Using a soft mallet, gently tap end of axle towards left side
of motorcycle. Catching external spacer(s), pull axle free
of rear swingarm, caliper bracket, rear wheel speed sensor
(if ABS equipped), and wheel hub.
NOTE
If ABS equipped, never pull wheel speed sensor cable taut or
use to retain wheel, axle or other components. Always keep
wheel speed sensor (and ABS encoder bearing) away from
magnetic fields (such as magnetic parts trays, magnetic base
dial indicators, alternator rotors, etc.) or damage will occur.
14. Remove caliper bracket from anchor weldment on rear
swingarm.
15. Move wheel forward and slip belt off compensator
sprocket.
NOTE
Hold onto compensator sprocket while removing rear wheel.
Compensator sprocket may drop from bowl if isolators are
excessively worn, possibly resulting in parts damage.
NOTE
Do not operate the rear brake pedal with the rear wheel
removed or the caliper pistons may be forced out. Reseating
pistons requires disassembly of the caliper.
16. If necessary, remove five screws to release brake disc
from hub. If wheel is to be assembled with the same disc,
mark both the wheel and disc, so that it can be installed
in its original position.
2-8 2008 Touring Service: Chassis
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