Harley Davidson 2008 Touring Models. Service Manual — page 32

Remove right side cover.

Drain brake systems.

NOTE

For best results, use the BASIC VACUUM BRAKE
BLEEDER (Part No. Snap-On BB200A) or equivalent tool.

Remove battery. See

8.8 BATTERY

Remove ABS module connector [166], 20-place Molex.

NOTE

Wrap banjo fittings with pieces of shop towel to absorb leakage
of residual brake fluid.

Remove four banjo bolts to release brake lines from ABS
module. Discard copper washers.

Remove three socket head screws to release ABS module
from right side caddy. See

Figure C-1

Reaching into battery box, remove ABS module from
caddy.

sm04026

Right side caddy

Socket head screw (2)

ABS module

Socket head screw (3)

Bushing (6)

Rubber mount (3)

Figure C-1. ABS Module

INSTALLATION

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN II

HD-48650

Inspect three rubber mounts in right side caddy for damage
or deterioration. If replacement is necessary, proceed as
follows:

Remove bushing from each side of rubber mount.
Remove rubber mount from caddy.

Install new rubber mount in caddy. Install bushing in
each side of rubber mount.

Reaching into battery box, position ABS module on caddy.

Start three socket head screws to fasten ABS module to
right side caddy. Alternately tighten screws to 39-60 in-
lbs (4.4-6.8 Nm). See

Figure C-1

Position banjo fittings adjacent to their respective ports on
the ABS module. Be sure to route banjo fitting of brake
line to front brake calipers beneath brake line from front
master cylinder. Refer to

Table C-1

2008 Touring Service: Appendix C ABS C-1

Table C-1. ABS Module Brake Lines

ABS MODULE

PORT STAMP

BRAKE LINE BANJO FITTINGS

To Front Brake Calipers

To Rear Brake Caliper

From Front Master Cylinder

From Rear Master Cylinder

Start two inboard banjo bolts (with new copper washers)
to secure brake lines to front and rear brake calipers (ports
stamped F and R, respectively).

Install two outboard banjo bolts (with new copper washers)
to secure brake lines from front and rear master cylinders
(ports stamped MF and MR, respectively).

Alternately tighten four banjo bolts to 12.5-14.5 ft-lbs (17-
20 Nm).

Connect ABS module connector.

Install battery. See

8.8 BATTERY

10. Fill and bleed brake systems. See

NOTE

For best results, use the BASIC VACUUM BRAKE
BLEEDER (Part No. Snap-On BB200A) or equivalent tool.

11. To confirm that brake systems are properly connected,

install master cylinder reservoir covers, connect motorcycle
to DIGITAL TECHNICIAN II (Part No. HD-48650) and
perform "ABS Service" procedure in the "Toolbox" menu.

12. Repeat step 10 if brakes feel spongy.

13. Install right side cover.

14. Install right side saddlebag. See

2.8 SEALED WHEEL BEARINGS

C-2 2008 Touring Service: Appendix C ABS

C.2

WHEEL SPEED SENSORS

FRONT WHEEL SPEED SENSOR

Removal

FLHR/C, FLHX, FLHT/C/U: Turn front wheel to right fork
stop. Reaching under headlamp nacelle (FLHR/C) or
fairing cap (FLHX, FLHT/C/U) on left side of steering head,
disconnect front wheel speed sensor connector [167], 2-
place Amp (Tyco). Draw pin housing down through
opening in front of lower fork bracket.

FLTR: Turn front wheel to left fork stop. Gently pull cable
to draw front wheel speed sensor connector [167], 2-place
Amp (Tyco), out left side of fairing bracket. Disconnect
connector.

Carefully cut two cable straps to release front wheel speed
sensor cable from brake hose and front fender tip lamp
wires, if equipped.

See

Figure C-2

. Release front wheel speed sensor cable

from clip as follows:

Push on lip at rear of clip to disengage from bracket.
Rotate tab (stamped ABS) rearward until clip is per-
pendicular to bracket and remove cable.

NOTE

If clip is not reinstalled as described below, tab can slip
out of slot in bracket. If this occurs, remove caliper
mounting screws to release bracket from fork slider and
then reinstall tab in slot. Reinstall bracket alternately
tightening screws to 28-38 ft-lbs (37.9-51.5 Nm).

Rotate tab forward until clip is inline with bracket and
then apply pressure to tab until lip engages.

Retract axle until front wheel speed sensor is free. See

2.3 FRONT WHEEL

NOTE

The wheel speed sensor works in conjunction with the ABS
encoder bearing installed in the wheel hub. If necessary, see

for special removal and

installation instructions.

Installation

NOTE

Always keep the wheel speed sensor away from magnetic
fields (such as magnetic parts trays, magnetic base dial indic-
ators, alternator rotors, etc.) or damage will occur. Never pull
wheel speed sensor cable taut or use to retain wheel, axle or
other components.

Push axle through new front wheel speed sensor and left
fork slider.

Install front wheel. See

2.3 FRONT WHEEL

. Be sure to

rotate front wheel speed sensor until index pin makes
contact with shoulder on fork slider. See

Figure C-3

Route wheel speed sensor cable up to lower fork bracket
following brake hose and front fender tip lamp wires, if
equipped.

FLHR/C, FLHX, FLHT/C/U: Turn front wheel to right fork
stop. Reaching under headlamp nacelle (FLHR/C) or

fairing cap (FLHX, FLHT/C/U) on left side of steering head,
locate socket housing of front wheel speed sensor con-
nector. Feed pin housing up through opening in front of
lower fork bracket and connect to socket housing.

FLTR: Turn front wheel to left fork stop. Connect front
wheel speed sensor connector. Feed connector under
main harness conduit into left side of fairing bracket.

Install two new cable straps as follows:

Install cable strap 2.5 in. (63.5 mm) above the bottom
brake hose crimp capturing front wheel speed sensor
cable, brake hose and front fender tip lamp wires, if
equipped.

Install second 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.

See

Figure C-2

. Install front wheel speed sensor cable in

clip as follows:

If installed, push on lip at rear of clip to disengage
from bracket. Rotate tab (stamped ABS) rearward
until clip is perpendicular to bracket and install cable.

Rotate tab forward until clip is inline with bracket and
then apply pressure to tab until lip engages. Gently
tug on cable to verify that clip is properly installed.

sm04204

Push lip to disengage

Push tab to engage

Figure C-2. Front Wheel Speed Sensor Cable Clip

2008 Touring Service: Appendix C ABS C-3

sm04027

Figure C-3. Front Wheel Speed Sensor Index Pin

REAR WHEEL SPEED SENSOR

Removal

Remove saddlebags. See

2.8 SEALED WHEEL BEARINGS

Remove right side cover.

Pull anchor on rear wheel speed sensor connector [168],
2-place Amp (Tyco), from hole in right side caddy. Discon-
nect connector.

Open rear cable clip on T-stud at top of rear swingarm.
Free rear wheel speed sensor cable from cable clip.

NOTE

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

Retract axle until rear wheel speed sensor is free. See

2.4 REAR WHEEL

NOTE

The wheel speed sensor works in conjunction with the ABS
encoder bearing installed in the wheel hub. If necessary, see

for special removal and

installation instructions.

Installation

NOTE

Push axle through new rear wheel speed sensor, caliper
bracket and right side of rear swingarm.

Install rear wheel. See

2.4 REAR WHEEL

. Be sure to

rotate rear wheel speed sensor until index pin makes
contact with caliper bracket at point shown in

Figure C-4

Route rear wheel speed sensor cable forward outboard
of caliper bracket and then continue forward progression
following top of rear swingarm.

Capture rear wheel speed sensor cable (and brake hose
to rear brake caliper) in rear cable clip on T-stud at top of
rear swingarm. Snap cable clip closed.

At front of rear frame downtube, feed cable to outboard
side of motorcycle staying below right side caddy. Connect
pin and socket housings.

Install anchor on rear wheel speed sensor connector into
hole in right side caddy.

Install right side cover.

Install saddlebags. See

sm04028

Figure C-4. Rear Wheel Speed Sensor Index Pin

C-4 2008 Touring Service: Appendix C ABS

C.3

ABS BRAKE LINES

FRONT MASTER CYLINDER TO ABS
MODULE

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN II

HD-48650

Removal

Remove right side saddlebag. See

Remove right side cover.

Remove fuel tank. See

Remove top caddy. See

FLHR/C: Remove right side headlamp nacelle. See

2.35 UPPER FAIRING AND WINDSHIELD: FLHX,

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

FLHT/C/U

respectively.

FLTR: Remove bezel. See

2.40 INSTRUMENT BEZEL:

. Release brake line as

follows:

Cut cable strap to release brake line from right
handlebar riser (FLHR/C, FLTR) or right handlebar
(FLHX, FLHT/C/U).

Cut cable strap to release brake lines from brake line
bracket at right side of steering head.

Cut cable strap to release brake lines from narrow
ledge at side of wire trough.

Remove three double-sided clips to separate brake
line from master cylinder from brake line to calipers.

Release brake lines from channel at front of wire
trough.

On FLHTCU models, cut cable strap to release audio
harness from upper right frame tube.

NOTE

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

Remove banjo bolt to release brake line from MF port of
ABS module. Discard copper washers.

10. Remove two screws to release cover from master cylinder

reservoir.

11. 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.

12. Feed front section of brake line forward to front of upper

fork bracket and then pull brake line rearward to remove
from motorcycle.

Installation

Orient brake line on motorcycle as follows:

Position brake line along right side of wire trough with
rear banjo fitting adjacent to ABS module.

Feed front section of brake line forward along right
side of steering head, upward to top of upper fork
bracket, and then rearward following right handlebar
to master cylinder.

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

Start banjo bolt (with new copper washers) to secure brake
line to MF port of ABS module.

See

Figure C-5

Figure C-6

. Secure brake line as fol-

lows:

FLHR/C, FLTR: Loosely install new cable strap to
secure handlebar switch conduit and brake hose to
right handlebar riser.

FLHX, FLHT/C/U: Install new cable strap 2.5
in. (63.5 mm) rear of fairing cap opening to secure
handlebar switch conduit and brake line to right
handlebar.

Install new cable strap to secure brake lines to brake
line bracket at right side of steering head. Capture
brake line from master cylinder in top channel, brake
line to calipers in bottom channel.

NOTE

If installing new brake line bracket, tighten flange screw
to 20-30 in-lbs (2.3-3.4 Nm).

Press brake lines into channel at front of wire trough.

Position brake lines on narrow ledge at side of wire
trough. At rear of ledge, install new cable strap to
secure brake lines to wire trough.

Install three double-sided clips to secure brake line
from master cylinder to brake line to calipers. Place
the clips as follows: one in front of ignition coil bracket,
one above wire trough breakouts and one in front of
threaded boss for the rear fuel tank bracket bolt.

On FLHTCU models, install new cable strap to secure
audio harness to upper right frame tube.

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

Tighten banjo bolt to ABS module to 12.5-14.5 ft-lbs (17-
20 Nm).

Fill and bleed brake system. See

2008 Touring Service: Appendix C ABS C-5

sm04341

Brake Line Bracket and Cable Strap

Wire Trough Channel

Wire Trough Ledge and Cable Strap

Double-Sided Clips (2 of 3)

Figure C-5. Brake Line Routing and Retention

sm04383

Figure C-6. Double-Sided Clip (3 of 3)

If more than one brake line was removed:

Confirm that brake system is properly connected. To
accomplish this, install master cylinder reservoir
cover, connect motorcycle to DIGITAL TECHNICIAN
II (Part No. HD-48650) and perform "ABS Service"
procedure in the "Toolbox" menu.

Repeat step 7 if brake feels spongy.

FLHR/C: Install right side headlamp nacelle. See

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

10. FLHX, FLHT/C/U: Install outer fairing and fairing cap. See

respectively.

11. FLTR: Install bezel. See

2.40 INSTRUMENT BEZEL:

FLTR

12. Install top caddy. See

13. Install fuel tank. See

14. Install right side cover.

15. Install saddlebags. See

ABS MODULE TO FRONT BRAKE
CALIPERS

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN II

HD-48650

Removal

Remove right side saddlebag. See

Remove right side cover.

Remove fuel tank. See

Remove top caddy. See

FLHR/C: Remove left side headlamp nacelle. See

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

FLHX, FLHT/C/U:

Remove outer fairing and fairing cap. See

8.11 AUXILIARY LAMPS AND BRACKETS

respectively.

Remove front turn signal lamps (FLHX) or auxiliary
lamps (FLHT/C/U). See

8.14 TURN SIGNAL LAMPS

Remove chrome skirt.

NOTE

FLTR: No disassembly required.

Carefully cut two cable straps to release left caliper brake
hose from front wheel speed sensor cable and front fender
tip lamp wires, if equipped.

C-6 2008 Touring Service: Appendix C ABS

. Release brake line as

follows:

Cut cable strap to release brake lines from brake line
bracket at right side of steering head.

Cut cable strap to release brake lines from narrow
ledge at side of wire trough.

Remove three double-sided clips to separate brake
line to calipers from brake line from master cylinder.

Release brake lines from channel at front of wire
trough.

On FLHTCU models, cut cable strap to release audio
harness from upper right frame tube.

Remove T40 TORX screw at bottom of lower fork bracket
to release brake line bracket.

NOTE

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

10. Remove banjo bolt to release brake line from F port of

ABS module. Discard copper washers. Pull banjo fitting
inboard to remove from under brake line from master cyl-
inder.

11. Remove banjo bleeder bolts to release brake lines to cal-

ipers. Discard copper washers.

12. Pull brake line forward to remove from motorcycle.

Installation

Standing at front of motorcycle, feed long section of brake
line rearward first at bottom of lower fork bracket and then
along right side of steering head and wire trough. When
rear banjo fitting is adjacent to ABS module, route under
brake line from master cylinder.

Align hole in brake line bracket with threaded boss at
bottom of lower fork bracket and start T40 TORX screw.

Start banjo bleeder bolts (with new copper washers) to
secure brake lines to calipers.

Start banjo bolt (with new copper washers) to secure brake
line to F port of ABS module.

. Secure brake line as fol-

lows:

NOTE

If installing new brake line bracket, tighten flange screw
to 20-30 in-lbs (2.3-3.4 Nm).

Press brake lines into channel at front of wire trough.

Position brake lines on narrow ledge at side of wire
trough. At rear of ledge, install new cable strap to
secure brake lines to wire trough.

Install three double-sided clips to secure brake line
to calipers to brake line from master cylinder. Place
the clips as follows: one in front of ignition coil bracket,
one above wire trough breakouts and one in front of
threaded boss for the rear fuel tank bracket bolt.

On FLHTCU models, install new cable strap to secure
audio harness to upper right frame tube.

Verify that brake lines to calipers, as viewed at the rear,
are equal distance from the left and right fork sliders, and
then tighten T40 TORX screw at bottom of lower fork
bracket to 120-180 in-lbs (13.6-20.3 Nm).

Tighten banjo bleeder bolts to calipers to 17-19 ft-lbs (23.1-
25.8 Nm).

Tighten banjo bolt to ABS module to 12.5-14.5 ft-lbs (17-
20 Nm).

Install two new cable straps as follows:

Install cable strap 2.5 in. (63.5 mm) above the bottom
brake hose crimp capturing brake hose, front wheel
speed sensor cable and front fender tip lamp wires,
if equipped.

Install second cable strap 2.5 in. (63.5 mm) below
the top brake hose crimp capturing brake hose, front
wheel speed sensor cable and front fender tip lamp
wires, if equipped.

10. Fill and bleed brake system. See

11. If more than one brake line was removed:

Repeat step 10 if brake feels spongy.

12. FLHR/C: Install left side headlamp nacelle. See

8.11 AUXILIARY LAMPS AND BRACKETS

13. FLHX, FLHT/C/U:

Install chrome skirt. Do not capture brake line between
chrome skirt and front of steering head, as it may
become pinched or kinked when handlebar is turned.
Route brake line above chrome skirt as shown in

Figure C-7

Install front turn signal lamps (FLHX) or auxiliary
lamps (FLHT/C/U). See

8.14 TURN SIGNAL LAMPS

Install outer fairing and fairing cap. See

2.35 UPPER

FAIRING AND WINDSHIELD: FLHX, FLHT/C/U

and

, respectively.

2008 Touring Service: Appendix C ABS C-7

14. Install top caddy. See

15. Install fuel tank. See

16. Install right side cover.

17. Install right side saddlebag. See

sm04556

Figure C-7. Route Brake Line to Front Calipers Above

Chrome Skirt

REAR MASTER CYLINDER TO ABS
MODULE

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN II

HD-48650

Removal

Remove right side saddlebag. See

Remove right side cover.

Remove right side rider footboard. See

2.49 FOOT-

BOARDS AND FOOTRESTS

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

Remove socket terminals from spade contacts of rear
brake light switch.

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

Cut anchored cable strap in hole of middle frame downtube
(adjacent to rear swingarm bracket) to release brake line
and main harness conduit.

NOTE

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

Remove banjo bolt to release brake line from MR port of
ABS module. Discard copper washers.

Remove two screws to release cover from master cylinder
reservoir.

10. 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.

11. Remove two screws to release master cylinder from frame

weldment.

12. Remove locknut with flat washer and pull brake

pedal/master cylinder assembly from pedal shaft.

13. Remove brake line from motorcycle.

Installation

Orient brake line on motorcycle as follows:

Set front section of brake line (with rubber sleeve) on
brake pedal shaft. From bottom inboard side of rear
exhaust header, feed rear section of brake line
upward at front of middle frame downtube crossing
to rear of downtube at bottom of frame crossmember.

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

Start banjo bolt (with new copper washers) to secure brake
line to MR port of ABS module.

Apply light coat of Wheel Bearing Grease (Part No. 99855-
89) to brake pedal shaft and bore. Install brake
pedal/master cylinder assembly 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).

Install flat washer and new locknut on brake pedal shaft
and tighten to 15-20 ft-lbs (20-27 Nm).

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

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

Install socket terminals onto spade contacts of rear brake
light switch.

NOTE

If installing new rear brake light switch, apply Loctite Pipe
Sealant with Teflon 565 to threads and start switch into rear
brake line. Using flats on switch, tighten to 12-15 ft-lbs (16.3-
20.3 Nm).

Position brake line above two rubber saddles anchored
on T-studs at top of lower frame tube. Install new cable
straps capturing brake line, main harness conduit and
lower frame tube.

10. Install new anchored cable strap in hole of middle frame

downtube (adjacent to rear swingarm bracket) capturing
brake line and main harness conduit.

11. Tighten banjo bolt to master cylinder to 13-15 ft-lbs (17.6-

20.3 Nm).

12. Tighten banjo bolt to ABS module to 12.5-14.5 ft-lbs (17-

20 Nm).

13. Fill and bleed brake system. See

C-8 2008 Touring Service: Appendix C ABS

14. If more than one brake line was removed:

Repeat step 13 if brake feels spongy.

15. Install right side rider footboard. See

2.49 FOOTBOARDS

AND FOOTRESTS

16. Install right side cover.

17. Install right side saddlebag. See

ABS MODULE TO REAR BRAKE CALIPER

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN II

HD-48650

Removal

Remove right side saddlebag. See

Remove right side cover.

Remove right side caddy. See

8.6 ELECTRICAL CAD-

DIES

Open two cable clips on T-studs at top of rear swingarm.
Free brake 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.

Carefully cut cable strap to release rear wheel speed
sensor cable from brake hose.

NOTE

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

Remove banjo bolt to release brake line from R port of
ABS module. Discard copper washers.

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

Pull brake line from channels on front edge of battery tray
(top and bottom).

Remove brake line from motorcycle.

Installation

Orient brake line on motorcycle as follows:

Position brake line at top of rear swingarm with rear
banjo fitting adjacent to caliper.

Adjust brake line, so that forward section turns upward
to ABS module just rear of frame crossmember.

Capture brake hose in two cable clips on T-studs at top
of rear swingarm. Rear cable clip also captures rear wheel
speed sensor cable. Snap cable clips closed.

Install brake line into channels on front edge of battery
tray (top and bottom). See

Figure C-8

Start banjo bolt (with new copper washers) to secure brake
line to R port of ABS module.

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

Tighten banjo bolt to caliper to 17-19 ft-lbs (23.1-25.8 Nm).

Tighten banjo bolt to ABS module to 12.5-14.5 ft-lbs (17-
20 Nm).

Install new cable strap 1.25 in. (31.8 mm) in front of the
rear brake hose crimp capturing rear wheel speed sensor
cable and brake hose.

Install right side caddy. See

10. Fill and bleed brake system. See

11. If more than one brake line was removed:

Repeat step 10 if brake feels spongy.

12. Install right side cover.

13. Install right side saddlebag. See