Home

2008 Softail Models Service Manual

Contents

1. 1 10 1 4 BULB REQUIREMENTS arg eS 1 11 1 5 ENGINE OIL AND FILTER Ghecking and Adding luin take RR nte 1 12 o ES Rz mem 1 12 G eckiRG Ol Lic soda 1 12 Jio eres Gl and EIERE emm 1 12 1 6 BRAKES Fluid InspeciOn iii 1 14 Rear Brake Pedal in 1 14 Pedal Heit 1 14 Pedal Lube et asd pa escenes mir 1 14 SEN E 1 14 1 7 AIR CLEANER AND EXHAUST SYSTEM Removal ee 1 16 ISA UD Duo Senn ctos aten 1 17 Exhaust System Loak Oh Kansas caricia tal 1 18 1 8 TIRES AND WHEELS A e pai eietietee 1 19 TE DC OM casetes 1 19 lg e 1 19 When To Replace TESS rec rir rado S PPrA Esa 1 19 burro 1 20 Wheel Spokes iii 1 20 1 9 PRIMARY CHAIN c r T 1 21 Changing Primary Chaincase Lubricant 1 21 1 10 TRANSMISSION LUBRICANT Changing Transmission Lubrtcant 1 23 1 11 CLUTCH A igre eee 1 25 1 12 REAR BELT AND SPROCKETS col MED 1 27 CACANING 1 27 lineo ee 1 27 lr dc c n 1 27 i Hm 1 27 1 13 REAR BELT DEFLECTION lir leo m M 1 29 ie Tara reset tee 1 29 1 14 THROTTLE CABLES Cable Inspection Lubrication and Adjustment 1 31 Inspection and Lubricaton mames 1 31 SIE II eT 1 31 1 15 BLEEDING BRAKES cci E E ei 1 32 PROCS Ee 1 32 1 16 BRAKE PADS AND DISCS Iro rej ecce 1 33 Brake Pads 1 33 ci DISC T 1 3
2. eese 3 108 Iron ec T E 3 108 Oil Line Fittings Retainers sss 3 110 A ee ee a eo eee eee 3 111 3 31 OIL TANK FXCW C Removal and Disassembly uic eerta nk tee 3 112 SIE c 3 112 Oil Line Fittings Retainers sss 3 114 Duplici E S 3 115 FUEL SYSTEM 4 1 SPECIFICATIONS FUEL SYSTEM A coe ERE UR CE zx Get Eo 4 1 4 2 ELECTRONIC FUEL INJECTION EFI TQS SO TET eode ED cnet ane ee Ra 4 2 4 3 IDLE SPEED A EE E EA 4 3 4 4 AIR CLEANER ASSEMBLY REMOVA EE 4 4 E TEE 4 4 Backplate Assembly HDI Models 4 5 4 5 FUEL TANK TEE EE 4 6 EMOS carrito 4 6 Cleaning and Inspection nc re 4 10 MRS RN EE 4 10 Al But FACW CEPI 4 10 PROG id 4 10 4 6 THROTTLE POSITION SENSOR TPS Gnor RTT TT 4 12 Removal escenas aaa nad 4 12 E e Po 4 12 4 7 INTAKE AIR TEMPERATURE SENSOR IAT EC lee o Som 4 13 Mic Merc lm E 4 13 ME EE 4 13 4 8 ENGINE TEMPERATURE SENSOR ET co ios oiu niteretur equ atra beu 4 14 Remova TT EO TE 4 14 IS EE 4 14 4 9 INDUCTION MODULE Jj e 4 16 a 4 17 4 10 IDLE AIR CONTROL IAC A tia iii 4 18 REM alt atri cens ai 4 18 MI VE EEVIVETN TE DERE TENERE 4 18 4 11 MANIFOLD ABSOLUTE PRESSURE SENSOR MAP A T TOS 4 19 A seacheaeada 4 19 O 4 19 4 12 OXYGEN SENSOR E11 EE 4 20 e E 4 20 TABLE OF CONTENTS taladrar 4 20 4 13 FUEL INJECTORS A EE E Eed 4 22 FSI oco oim ori eti y nb Reds dut
3. GASOLINE BLENDS Your motorcycle was designed to get the best performance and efficiency using unleaded gasoline Most gasoline is blended with alcohol and or ether to create oxygenated blends The type and amount of alcohol or ether added to the fuel is important CAUTION Do not use gasoline that contains methanol Doing so can result in fuel system component failure engine damage and or equipment malfunction 00148a Gasoline containing METHYL TERTIARY BUTYL ETHER MTBE Gasoline MTBE blends are a mixture of gasoline RATING 91 95 RON and as much as 15 MTBE Gasoline MTBE blends can be used in your motorcycle ETHANOL is a mixture of 10 ethanol Grain alcohol and 90 unleaded gasoline Gasoline ethanol blends can be used in your motorcycle if the ethanol content does not exceed 1096 e REFORMULATED OR OXYGENATED GASOLINES RFG Reformulated gasoline is a term used to describe gasoline blends that are specifically designed to burn cleaner than other types of gasoline leaving fewer tailpipe emissions They are also formulated to evaporate less when you are filling your tank Reformulated gasolines use additives to oxygenate the gas Your motorcycle will run normally using this type of gas and Harley Davidson recommends you use it when possible as an aid to cleaner air in our environment Donotuse race gas or octane boosters Use of these fuels will damage the fuel system Some gasolin
4. Keps K amp N Mag naflux Marson Thread Setter Tool Kit MAXI fuse Molex MPZ Mulitilock Novus Packard Pirelli Permatex Philips PJ1 Pozidriv Robinair S100 Sems Snap on Teflon Threadlocker Torca Torco TORX Tufoil Tyco Ultratorch Velcro X Acto and XM Satellite Radio are among the trademarks of their respective owners H D MICHIGAN INC TRADEMARK INFORMATION Harley Harley Davidson H D Bar amp Shield Digital Tech Digital Technician Destroyer Deuce Dyna Electra Glide Evolution Fat Boy Glaze Gloss H D H Dnet com HD Harley Heritage Softail Heritage Springer Low Rider Night Rod Night Train Profile Revolution Road Glide Road King Rocker Softail Sportster Sun Ray Sunwash Tech Link Twin Cam 88 Twin Cam 88B Twin Cam 96 Twin Cam 96B Twin Cam 103 Twin Cam 103B Twin Cam 110 Twin Cam 110B Tour Pak Screamin Eagle Softail Super Guide Super Premium SYNS3 Ultra Glide V Rod VRSC Wide Glide and Harley Davidson Genuine Motor Parts and Genuine Motor Accessories are among the trademarks of H D Michigan Inc CONTENTS All photographs illustrations and procedures may not neces sarily depict the most current model or component but are based on the latest production information available at the time of publication Since product improvement is our continual goal Harley Davidson reserves the right to change specifications equipment or designs at any time without notice
5. 96 Piston Jets Installation iussi kid c zn taa 3 96 Leg Crankcase Hala ana rr priv ROS eG E 3 97 Main Bearing Remowval eese 3 97 Main Bearing Installation seseesssss 3 98 Sprocket Shaft Bearing Inner Race 3 99 Removal cie 3 99 JE TIT MEE OO oo 3 100 CIS dis il P REIS ET EP EA MU ER 3 101 Romo eee T 3 101 at ME M PESE TTE RS 3 101 Pipe Plage and QU FIBI acetate cibo rs 3 101 alo AAA 3 101 Cleaning and Ip liura ii 3 102 Installation Overview seen 3 102 3 28 FLYWHEEL AND CONNECTING RODS Removal Overview imat spear pA FERRUM bed ES ee 3 103 pcc f 3 103 Installation Overview seen 3 103 3 29 COUNTERBALANCER ASSEMBLY Removal Que T n 3 104 Cleaning Inspection and Repair 3 104 E e E E E 3 104 Balance Shaft Removal 3 104 Balance Shaft Installation sss 3 105 Balance Shaft Support Bearings Removal 3 105 Balance Shaft Support Bearings Installation 3 105 Front and Rear Balance Sprockets 3 106 Hydraulic Tension Siri 3 106 Chain Tensioner Guides 3 107 Chain Guide Bracket eene 3 107 EE Dilo ies 3 107 Installation Overview sese 3 107 3 30 OIL TANK ALL BUT FXCW C Removal and Disassembly
6. HEADLAMP ALIGNMENT jg M 1 55 AUS PC EEE 1 56 1 26 CRITICAL FASTENERS la m 1 57 1 27 ENGINE MOUNTS IB e lr e 1 58 1 28 STORAGE Genaral 1 59 Placing n 1 59 Removal from SDE emir 1 59 1 29 TROUBLESHOOTING o suet E E a ioe na cede N 1 61 z p Mee 1 61 Starter Motor Does Not Operate or Does Not Turn Engine EE 1 61 Engine Turns Over But Does Not Start o oonncocc 1 61 A 1 61 Starts But Runs Irregularly or Misses 1 61 A Spark Plug Fouls Repeatedly 1 62 Pre lgnition or Detonation Knocks or Pings 1 62 IV TABLE OF CONTENTS A a E A 1 62 vale Tain NOSO IET a 1 62 Excessive MIDI Micro caja 1 62 Check Engine Light llluminates During Operation 1 62 Lubrication Systemi Rc 1 62 Oil Does Not Return To Oil Tank 1 62 Engine Uses Too Much Oil Or Smokes Excessively 1 62 Engine Leaks Oil From Cases Push Rods Hoses cp c 1 62 E A ENEE as 1 63 High OI PRESSE ionitzants 1 63 Electrical Sumarios recita 1 63 Alternator Does Not Charge 1 63 Alternator Charge Rate Is Below Normal 1 63 Speedometer Operates Erratically 1 63 Mauri e 1 63 c cL mem Pcr 1 63 Jumps Out Of GRAN C 1 63 lr EE 1 63 Clutch Dra
7. When bearings are installed against shoulders be sure that the chamfered side of the bearing always faces the shoulder Lubricate bearings and all metal contact surfaces before pressing into place Only apply pressure on the part of the bearing that makes direct contact with the mating part Install bearings with numbered side facing out Always use the proper tools and fixtures for removing and installing bearings Bearings do not usually need to be removed Only remove bearings if necessary Bushings Do not remove a bushing unless damaged excessively worn or loose in its bore Press out bushings that must be replaced When pressing or driving bushings be sure to apply pressure in line with the bushing bore Use a bearing bushing driver or a bar with a smooth flat end Never use a hammer to drive bushings Inspect the bushing and the mated part for oil holes Be sure all oil holes are properly aligned Gaskets Always discard gaskets after removal Replace with new gas kets Never use the same gasket twice Be sure that gasket holes match up with holes in the mating part But be aware that sections of a gasket may be used to seal passages If a gasket must be made be sure to cut holes that match up with the mating part Serious damage can occur if any flange holes are blocked by the gasket Use material that is the right type and thickness Lip Type Seals Lip seals are used to seal oil or grease and are usually install
8. X X X Spark plugs Inspect X X X X X X Replace X Electrical equipment and switches Check operation X X X X X X Engine idle speed Check adjustment X X X X X X 1 Front fork oil Replace Replace at 50 000 miles 80 000 kilometers 1 Steering head bearings Adjust X X X 1 Softail models Lubricate X X 2 Steering head bearings Adjust Adjust and lubricate every 2500 miles 4000 kilometers 1 5 Springer models Windshield bushings Inspect X X 1 Springer rocker bearings Adjust X X X 1 7 Critical fasteners Check tightness 1 Battery Check battery and clean connections 3 Exhaust system Inspect for leaks cracks and loose X X X X X X 3 or missing fasteners or heat shields Road test Verify component and system func X X X X X X tions NOTES 1 Should be performed by an authorized Harley Davidson dealer unless you have the proper tools service data and are mechanically qualified 2 Disassemble lubricate and inspect every 30 000 miles 48 000 kilometers 3 Perform annually 4 Not all vehicles are equipped with spoke wheels Consult appropriate topic in service manual 5 Disassemble lubricate and inspect every 20 000 miles 32 000 kilometers 6 Change D O T 4 fluid and flush brake system every two years 7 Adjust at 500 miles 800 kilometers 2008 Softail Service Maintenance 1 5 Table 1 2 Softail Quick Reference Maintenance Chart ITEM SERVICED SPECIFICATION DATA Engine oil and filter Drain plug to
9. location and bulb requirements for all Harley Davidson Softail motorcycles See Softail models parts catalog for part numbers All Softail model speedometers tachometers indicator lamps and odometers are illuminated with LEDs All FXCW C model rear turn signal lamps are illuminated with LEDs LEDs are non repairable Entire assembly must be replaced if LED fails Table 1 6 Bulb Chart 2008 Softail Models LAMP DESCRIPTION BULBS CURRENT DRAW HARLEY DAVIDSON ALL LAMPS 12 VOLT REQUIRED AMPERAGE PART NUMBER FL FX FL FX MODELS MODELS MODELS MODELS Headlamp high beam low beam 1 4 7 4 3 68329 03 68329 03 position lamp international 1 0 32 53436 97 Tail and stop lamp tail lamp 1 0 59 68167 04 oe ERN FLSTN Stop lamp 1 2 10 68167 04 tail lamp international 1 0 59 68167 04 stop lamp international 1 2 10 68167 04 Tail and stop lamp tail lamp 1 0 59 68168 89A FLSTN stop lamp 1 2 10 68168 89A tail lamp international 1 0 59 68169 90A stop lamp international 1 2 10 68169 90A Rear turn signal tail stop llluminated with LEDs Replace entire assembly upon failure lamp FXCW FXCWC Turn signal lamp all models front running 2 2 25 0 59 68168 89A EXC en on front international 2 1 75 68163 84 rear 2 2 25 68572 64B rear international 2 1 75 68163 84 Auxiliary lamps FLST FLSTC FLSTN 2 2 50 68351 05 Fog lamp international 2 2 92 68847 98 Fende
10. on pipe fitting threads Threadlocking Agents Always follow specific service manual procedures when working with fasteners containing preapplied threadlocking agents when fastener replacement is recommended When re using fasteners containing threadlocking agents be sure to com pletely remove all existing threadlocking agent from fastener threads with a wire brush or wire wheel Also be sure to remove residual threadlocking agent from fastener hole using an appropriate thread chasing device and compressed air when using new or existing fasteners Always use the recommended threadlocking agent for your specific procedure 1 2 2008 Softail Service Maintenance Wiring Hoses and Lines Hoses clamps electrical wiring electrical switches or fuel lines if they do not meet specifications Instruments and Gauges Replace broken or defective instruments and gauges Replace dials and glass that are so scratched or discolored that reading is difficult Bearings Anti friction bearings must be handled in a special way To keep out dirt and abrasives cover the bearings as soon as they are removed from the package Wash bearings in a non flammable cleaning solution Knock out packed lubricant inside by tapping the bearing against a wooden block Wash bearings again Cover bearings with clean material after setting them down to dry Never use compressed air to dry bearings Coat bearings with clean oil Wrap bearings in clean paper
11. the OIL FILTER WRENCH Part No HD 42311 or OIL FILTER WRENCH Part No HD 44067 Clean the oil filter mounting surface of any old gasket material 5 See Figure 1 5 Lube the gasket on new oil filter with engine oil and install new filter Hand tighten oil filter 1 2 to 3 4 turn after gasket contacts filter mounting surface DO NOT use oil filter wrench for oil filter installation
12. trade of all possible ways in which service might be performed or of the possible hazardous con sequences of each method we have not undertaken any such broad evaluation Accordingly anyone who uses a service procedure or tool which is not recommended by Harley Davidson must first thoroughly satisfy himself that neither his nor the operator s safety will be jeopardized as a result Failure to do so could result in death or serious injury PRODUCT REFERENCES AWARNING Read and follow warnings and directions on all products Failure to follow warnings and directions can result in death or serious injury 00470b When reference is made in this manual to a specific brand name product tool or instrument an equivalent product tool or instrument may be substituted Kent Moore Products All tools mentioned in this manual with an HD J or B preface must be ordered through SPX Kent Moore For ordering Il FOREWORD information or product returns warranty or otherwise visit WWW Spx com Loctite Sealing and Threadlocking Products Some procedures in this manual call for the use of Loctite products If you have any questions regarding Loctite product usage or retailer wholesaler locations please contact Loctite Corp at www loctite com PRODUCT REGISTERED MARKS Allen Amp Multilock Bluetooth Brembo Delphi Deutsch Dunlop Dynojet Fluke G E Versilube Gunk Hydroseal Hylomar Kevlar Lexan Loctite Lubriplate
13. 2 1 9 oz squeeze tube HYLOMAR Gasket and Thread Sealant 99653 85 3 5 oz tube Loctite Pipe Sealant With Teflon 565 99818 97 6 ml squeeze tube Loctite Prism Primer 770 Loctite Prism Superbonder 411 Loctite Superbonder 420 Adhesive Loctite Threadlocker 243 blue 99642 97 6 ml squeeze tube Loctite Threadlocker 262 red 94759 99 6 ml squeeze tube Loctite Threadlocker 272 98618 03 10 ml bottle Special Purpose Grease 99857 97 14 oz cartridge Super Oil 94968 85TV 1 4 fl oz Type E Hydraulic Fork Oil 99884 80 16 oz bottle 1 8 2008 Softail Service Maintenance FUEL AND OIL 1 3 FUEL Refer to Table 1 4 Always use a good quality unleaded gas oline Octane ratings are usually found on the pump AWARNING 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 WARNING 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 Modern service station pumps dispense a high flow of gasoline into a motorcycle fuel tank making air entrapment and pressur ization a possibility Table 1 4 Octane Ratings SPECIFICATION Pump Octane R M 2
14. 29 Countershaft Needle Bearing Replacement 7 29 Shifter Pawl Lever Aesembly 7 29 ELECTRICAL 8 1 SPECIFICATIONS ELECTRICAL SNC EE 8 1 8 2 ELECTRICAL PANEL E AA E RO D 8 2 Removal All But EXOCWJIG anat ues combien tiec a sob tbc Rees 8 2 Installation All But EXGWIC iieui iei eren rnnt 8 2 uidi FACW eege dese 8 2 Installation FXOWG 8 3 8 3 ELECTRONIC CONTROL MODULE ECM Genera E 8 4 Removal All But EXCWIC cocinan 8 4 installation All But FXOWUJIC iiaec ct trente enses 8 4 Removal FXOWIFXGNO iius asas enenist tauri t tatit rne 8 4 installation FXCOCWFXOW GO caricia 8 5 8 4 VOLTAGE REGULATOR EE 8 6 8 5 FRONT ELECTRICAL CADDY Carpe EE 8 7 KE e TH se 8 7 ptor e 8 7 8 6 FUSES o BE 8 8 En e T R 8 8 MESES E dE 8 8 8 7 RELAYS A El o n s mel dp d a P peca tl 8 9 a E 8 9 Lg SES ESTIS REOS 8 9 8 8 MAIN FUSE nii M 8 10 CIL P DP O 8 10 8 9 IGNITION AND LIGHT SWITCH EE 8 11 TABLE OF CONTENTS Removal and Installation All But FXCW C 8 11 Removal and Installation FSCHWIC 8 12 8 10 BATTERY CABLES js AAA s a 8 13 8 11 HEADLAMP cor ec C ETE 8 15 Removal and Installation minimis 8 15 FAST Mode nero 8 15 SA AAA A A S aoc Pena EE a 8 15 FXST FXSTB and FLSTSB Mod els 8 15 FLST FLSTC FLSTF and FLSTN Mod els 8 15 8 12 TAIL LAMP ALL BUT FLSTN c
15. 3 Brake Pad Replacement 1 33 Rear Brake Caper rici eter tips 1 33 Front Brake Gall E 1 35 1 17 BATTERY MAINTENANCE E 1 37 Cleaning and Inspecllbfiuuseeasessesetao eege Kee gin 1 38 O 1 38 Voltmeter Tesi 1 38 Charging DaHleru a 1 38 Safety PrECAUMONS semen ne 1 38 Using a Battery Charter eai three 1 38 Disconnection and Flemoval mn 1 39 CO Ei s ETE 1 40 Installation and Conpnechlon 1 41 TABLE OF CONTENTS TABLE OF CONTENTS 1 18 SUSPENSION ADJUSTMENTS Shock Absorbers Softail Models 1 43 A O TE 1 43 1 19 SPARK PLUGS NS CU A i E 1 44 Spark Plug Cable Imspection mmmmaracanistomasmmes 1 44 1 20 STEERING HEAD BEARINGS ALL BUT FLSTSB Adjustment FLST FLSTC FLSTF FLSTN 1 46 Bearing Adjustment Fall away 1 46 Adjustment FXST FXSTB FXSTC FXOW C 1 47 Bearing Adjustment Fall away 1 47 Uie ior Men S 1 48 1 21 STEERING HEAD BEARINGS FLSTSB ra O tr resem i O 1 49 IET e ipw ols eda UE 1 49 Adjustment KT 1 49 Bearing Adjustment Fall away 1 49 1 22 ROCKER BEARINGS FLSTSB Jis E 1 51 1 23 FRONT FORK OIL Repaci PORK Hisia 1 53 1 24 CABLE AND CHASSIS LUBRICATION EE n E E O 1 54 Cables and Hand WEE 1 54 EEN 1 54 Steering Head Bearings AA 1 54 1 25
16. 4 22 irs cerle ei DEE 4 22 4 14 FUEL PUMP AND FUEL GAUGE SENDING UNIT EE 4 24 xxl EET T TT EE 4 24 Disassembly Assembly accettate rro 4 26 Fuel RTL TT 4 26 DEU eege A 4 26 Mii 4 27 SR cit tomata 4 28 IS UC ie EE 4 28 4 15 FUEL PRESSURE TEST EE coc et dedica 4 30 Ta 4 30 4 16 EXHAUST SYSTEM ALL BUT FLSTF FLSTN FLSTSB TE 4 33 DONA Let ia Debs CR tes cita mel 4 33 oc A nupciaeateneatit eens oiieeemivkanatans 4 33 FACERE TTL ala 4 33 REMO centenes 4 33 dO STR SHOE as Lee EP REED Eme erbe DOMENUS 4 33 4 17 EXHAUST SYSTEM FLSTF FLSTN FLSTSB TE 4 35 ich LEE 4 35 n jj imr 4 35 O 4 35 REMOVA rnana 4 35 iai UM E EE 4 35 4 18 INTAKE LEAK TEST COR acom EEEE E E A e E E ER E 4 37 Leak Tester 4 37 Parts List 4 37 Tester Assembly 4 37 A a EN pepe ebe 4 37 A MP EU 4 37 4 19 EVAPORATIVE EMISSIONS CONTROL CA MODELS CE Oest o ccs dc nti Es iesu patents 4 39 CANES EE 4 39 Ee LEE 4 39 lui MT iaa iaa 4 40 Hose Routing Replacement sess 4 40 TABLE OF CONTENTS IX TABLE OF CONTENTS STARTER 5 1 SPECIFICATIONS STARTER SET CA E 5 1 5 2 STARTER COS E A E D Real 5 3 leout ETT 5 3 REMOVA eet RH E 5 3 jecit M 5 3 TES Oi PE 5 3 dici T i 5 8 Brushes and Brush Holder eres 5 5 Field Coll ASSenbly iaa ax adire AR aD id addi 5 6 Ba e E E 5 6 A mai semana 5 6 PS IID cT 5 6 Dive se ETE TT D m 5 7 Ki
17. 5 7 dicitis re TC eet eines 5 7 RES eeepc tesgel 5 7 5 3 STARTER SOLENOID E VE 5 8 KE 5 8 Ee EE Eelere 5 8 iore uic PINGE URN ge site 5 8 A EE E A E A EEN 5 8 ut E T 5 8 Solenold CGMS sii 5 8 Disassembly 5 8 e est a 5 9 DRIVE 6 1 SPECIFICATIONS DRIVE eE epe E 6 1 6 2 PRIMARY CHAINCASE COVER I i coet Damm ts elits E 6 2 gi e 6 2 A OE 6 2 6 3 DRIVE COMPONENTS Removal M CC 6 3 lacius e 6 5 6 4 PRIMARY CHAINCASE HOUSING Ee 6 9 linc wine sits estadi Ee KEE es 6 9 Mainshaft Bearing and Lip Seal 6 9 A MATT mes 6 9 EEN ocio ici 6 9 Mainshaft Bearing Inner Race sees 6 10 A c eoo rut oii EE dee 6 10 Installation 6 10 Jas SOR atera 6 11 6 5 CLUTCH Removal and Installaliol scort ip 6 13 X TABLE OF CONTENTS ICA PAK bd rd 6 13 Farmal Disassembly iriserai 6 13 Gleaning And Inspection tte 6 13 ASOMO ac ERE e 6 14 Cluteh Pack and Bearing uenerit rn tra 6 15 Complete Disassembiv 6 15 Eu E 6 16 6 6 TRANSMISSION SPROCKET a EG 6 18 Cleaning and InepeotlQfis ase caccu id 6 19 lu lala IE D E TE 6 19 6 7 DRIVE BELT SE 6 21 recs mee 6 21 A EE t EO m 6 21 TRANSMISSION 7 1 SPECIFICATIONS TRANSMISSION RUSCH NO auct X RR OO 7 1 Sorice Woar LEE p 7 1 7 2 TRANSMISSION Power FloW e M 7 2 CU Ei PEE
18. 7 C Poor 2008 Softail Service Maintenance 1 9 WINTER LUBRICATION In colder climates the engine oil should be changed often If motorcycle is used frequently for short trips less than 15 miles 24 kilometers in ambient temperatures below 60 F 16 C oil change intervals should be reduced to 1500 miles 2400 kilometers Motorcycles used only for short runs must have a thorough tank flush out before new oil is put in The tank flush out should be performed by an authorized dealer or qualified technician NOTE The further below freezing the temperature drops the shorter the oil change interval should be 1 10 2008 Softail Service Maintenance Water vapor is a normal by product of combustion in any engine During cold weather operation some of the water vapor condenses to liquid form on the cool metal surfaces inside the engine In freezing weather this water will become slush or ice and if allowed to accumulate too long may block the oil lines and cause damage to the engine If the engine is run frequently and allowed to thoroughly warm up most of this water will become vapor again and will be blown out through the crankcase breather If the engine is not run frequently and allowed to thoroughly warm up this water will accumulate mix with the engine oil and form a sludge that is harmful to the engine BULB REQUIREMENTS 1 4 GENERAL NOTES Refer to Table 1 6 This table gives the
19. A 12 Separating Pin and Socket Housings A 12 Mating Pin and Socket Housings A 12 Removing Socket Terminals A 12 Installing Socket Terminals iere trina A 12 Removing Pin Terminale eet ri te A 14 Installing Pin Terminals rein oat re o trn ten A 14 Cimpina Terminals scs eias ma iii spes lori ta I EE Gg A 15 A 7 DEUTSCH STANDARD TERMINAL REPAIR Deutsch Standard Terminal Crimps A 16 Preparing Wire Leads for Crimping A 16 Crimping Terminal te Lead cesi accen A 16 liceo EE A 16 A 8 DEUTSCH SOLID BARREL MINI TERMINAL REPAIR Deutsch Solid Barrel Terminal Crimps A 17 Preparing Wire Leads For Crimping A 17 Adjusting Crimper Tool A 17 Crimping a Barrel Contact To Wire Lead A 17 IEC a E A 17 A 9 DEUTSCH MINI TERMINAL REPAIR Deutsch Mini Terminal Orimpa iu accetta A 19 TABLE OF CONTENTS Preparing Wire Leads for Crimping A 19 Crimping a Mini Terminal to Wire Lead A 19 Mepecting Crimp cs m A 19 A 10 MOLEX CONNECTORS Molex Connector Repair eese A 20 Separating Pin and Socket Housings A 20 Mating Pin and Socket Housings A 20 Removing Terminals sicui rie prre asii A 20 installing IST se
20. E 2 27 Eccc Mee UL 2 27 Radial TU 2 28 2 11 CHECRING CAST VVHEEL RUNOUT Aena oocyst os a E 2 30 Lateral RUNOT si ica 2 30 EE EEGEN Kg 2 30 2 12 VEHICLE ALIGNMENT disse a c EE 2 31 2 13 FRONT BRAKE MASTER CYLINDER A A E 2 32 Removal and Disassembly esses 2 32 Cleaning and Inepechon sese 2 34 Assembly and Installation rennen 2 34 2 14 FRONT BRAKE CALIPER ALL BUT FLSTSB Ke T A 9 2 36 RI opor rc redil 2 36 Cleaning Inspection and PHepnair 2 38 A 2 39 A 2 39 2 15 FRONT BRAKE CALIPER FLSTSB wire Mr M rM 2 41 DISASSOMIDY m 2 42 Cleaning and Iaspectiohi suceso noa eet retinet retreat tn 2 43 ici e 2 44 Eis e c ri 2 45 2 16 REAR BRAKE MASTER CYLINDER rur E 2 47 aiino e Tm 2 47 A Getnemucanaanne 2 47 RT TREE TT E 2 49 Cleaning and Inspection im 2 50 PE SEM ii tio ris alii 2 50 TABLE OF CONTENTS 2 17 REAR BRARE CALIPER A Me e 2 52 DISSERT sies pne te a cba MEET EN FER S Ma Irt Us 2 52 Cleaning Inspection and Repair sss 2 54 e et MH ETE RS 2 55 s talana e Mg 2 55 2 18 TIRES Ee Eege 2 57 REUS sc LT TT 2 57 Cleaning Inspection and PHenair 2 58 Lucis lone n E 2 58 Tube Type TIGE era 2 58 E NIU eS 2 59 2 19 FRONT FORK TEL
21. ESCOPIC toll ii a 2 60 A T EEN 2 60 ME 2 60 Cleaning and Inspection mem rmt rtr etenim 2 60 ijs Me ens 2 64 E temes attest eal 2 64 2 20 FRONT FORR SPRINGER Ceneta c um ter 2 65 Front SOC BDOODU ueri ba EAR menes 2 65 Kn T 2 65 tad saei Iaia 2 65 gle e M 2 65 Ets 2 65 A ts ia 2 66 cl e T E 2 66 DISSSSE e nnn 2 66 A rH PE 2 68 Fork pci P H 2 70 A ebateaacaadeeancaesows 2 70 A EN Te 2 70 FOU Siam Bos RH 2 71 Removal and Installation naar 2 71 2 21 STEERING HEAD aiio ic MMC MR oi E 2 72 FEST FLSTC FESTE FESTM Models cone 2 72 PAST FASTC FASTB Model ecos 2 72 FAGO Models si 2 72 ELSTS MOSS cri 2 73 SPECIAL iS 2 73 CUR el A o A 2 73 NEE e c 2 73 Removing Lower Bearings From Fork Stem 2 73 Steering Head Bearing Race Removal 2 74 ASOMO rnor a N 2 74 HEUS SEIS E 2 75 FLST FLSTC FESTR FESTM Models e 2 75 FAST FASTC EXSTB Models rtr 2 75 gift ness ellc 2 75 LS TSE Modele citat ee 2 75 2 22 BELT GUARD AND DEBRIS DEFLECTOR qnis Mem ME 2 76 TABLE OF CONTENTS V TABLE OF CONTENTS ST e 2 76 Dobis DSTO CIO E 2 76 SM drid 2 76 CEN UA ets dades 2 76 Debris DOT CHF 2 76 2 23 REAR SHOCK ABSORBERS ET 2 77 o EE 2 77 O 2 77 2 24 REAR FORK EE ale el TET TL E EE 2 79 Cleaning amd Gp EE 2 80 Jee s ERR TN ao aa ETS E ama ENT Maia 2 80 2 25 THR
22. HARLEY DAVIDSON 2008 Softail Models Service Manual ALL RIGHTS RESERVED 99482 08A VISITTHE HARLEY DAVIDSON WEB SITE ABOUT THIS MANUAL GENERAL This Service Manual has been prepared with two purposes in mind First it will acquaint the user with the construction of the Harley Davidson product and assist in the performance of basic maintenance and repair Secondly it will introduce to the pro fessional Harley Davidson Technician the latest field tested and factory approved major repair methods We sincerely believe that this Service Manual will make your association with Harley Davidson products more pleasant and profitable HOW TO USE YOUR SERVICE MANUAL Refer to the table below for the content layout of this manual z o CHAPTER Maintenance Chassis Engine Fuel System Starter Drive Transmission Electrical Appendix A Connector Repair Appendix B Wiring Appendix C Conversions olol CO Jl ol oO comm Appendix D Glossary Use the TABLE OF CONTENTS which follows this FORE WORD and the INDEX at the back of this manual to quickly locate subjects Sections and topics in this manual are sequentially numbered for easy navigation For example a cross reference shown as 2 1 SPECIFICA TIONS refers to chapter 2 CHASSIS heading 2 1 SPECIFIC ATIONS For quick and easy reference all pages contain a section number followed by a page n
23. OTTLE CONTROL Removal DISaSSOmbIy moricoasonansmrseymatsiemimmanm sar 2 82 Cleaning and Inspection rooms 2 82 Assembly lnstallatori iracas 2 82 ES IE RC cost sal 2 83 2 26 CLUTCH CONTROL E MT TRE 2 84 lee r a T 2 84 2 27 HANDLEBARS ALL BUT FLSTF FLSTSB FXCW FXCWC A LTEM 2 86 Trek Ee EE 2 87 2 28 HANDLEBARS FLSTF PENIS a bici SUR ERRARE d 2 88 le UE ETC DUO EE DI 2 89 2 29 HANDLEBARS FLSTSB REMO eegent 2 91 lala id 2 91 2 30 HANDLEBARS FXCW FXCWC Pam lod 2 93 SRAM MON a ea 2 94 2 31 FRONT FENDER ALL BUT FLSTSB e 2 97 A a 2 97 2 32 FRONT FENDER FLSTSB o occorre Dada A 2 98 Trost et ACH EE 2 99 2 33 REAR FENDER FLST FLSTC Pemo EE OE EE 2 100 Tribe ed Orbe EE 2 100 2 34 REAR FENDER FLSTF E et EE 2 102 iste e EE 2 102 VI TABLE OF CONTENTS 2 35 REAR FENDER FXST FXSTB FXSTC FLSTSB XIII UT Du o ee 2 104 a TOT OTT 2 104 2 36 REAR FENDER FXCW FXCWC ESI RE 2 106 IS Tal AON Ga 2 106 2 37 REAR FENDER FLSTN PCE Fal a ipiam UM EM EE 2 108 RSS SINGIN js bis see ca 2 108 O o Ra UM Esp UMS 2 110 IEN A uir AE 2 110 2 38 REAR FENDER WIRE CONDUIT Le ds TRIN cietat DO S D D DT 2 111 2 39 JIFFY STAND QE T e e i 2 113 sensor HDI Models uiuere nan betae eri ive Hio spun 2 113 PREMIA EE 2 114 Ds LS SHOE EE 2 114 2 40 FORK LOCK Let EE 2 115 Le E 2 115 2 41 SEAT AND STRAP RETENTION NUT Huic oe soe quf MENTOR 2 116 2 42 SEAT FXST FXSTB Removal a
24. SM A as oe ne ee eee ee te SE 8 35 TSM HFSM TSSM Configuration sss 8 35 A EE 8 35 Loterie ai tenien 8 35 8 17 CRANR POSITION SENSOR CRP ETT T LE o cen mente ad 8 36 TABLE OF CONTENTS XI TABLE OF CONTENTS En e EE 8 36 A tian 8 36 8 18 IGNITION COIL o UR DR n 8 37 5 actis des P 8 37 guis nemen Hmc eT 8 37 A E A EE A E AE 8 37 All Except ME mem edats 8 37 iss IO Tcu 8 37 8 19 SPARK PLUG CABLES Canal o sou A red 8 39 Ere m9 EE 8 39 Micaela ri 8 39 8 20 ALTERNATOR PA o ed es ol 8 40 Cleaning and Inepechon 8 40 lO Wir ii 8 40 8 21 FUEL GAUGE AIST TOO To 8 42 REMOVA occa ico DIEA ERR FREUD RDUM Ee EUR A 8 42 Ilan 8 42 8 22 INSTRUMENT CONSOLE FXCW C PWG Gall anit tanta metil 8 44 hstala e ieina 8 44 8 23 SPEEDOMETER ALL BUT FXCW C Mee 8 45 A 8 45 8 24 SPEEDOMETER FXCW C A cid osse EE 8 46 SMA rica TOT 8 46 8 25 VEHICLE SPEED SENSOR VSS Sala ad 8 47 o A 8 47 le UE re EE 8 47 8 26 INDICATOR LAMPS ALL BUT FXCW C METTEZ a 8 48 San e EE 8 48 SCE OW ta ten i Ee 8 48 8 27 INDICATOR LAMPS FXCVV C A Le b LEO LE eds 8 50 INS cra 8 50 8 28 NEUTRAL SVVITCH CE iii ls ce pl 8 51 A PET Pdl 8 51 le UE re EE 8 51 8 29 OIL PRESSURE SWITCH o TO TS 8 52 Pre A EE 8 52 XII TABLE OF CONTENTS ISA Ute y epee ee nee Pere 8 52 8 30 REAR STOPLIGHT SWITCH A e E E E E E T 8 53 Renova cia Eege 8 53 litere lenti ET 8 53 8 31 HORN NSRP CON ian 8 54 R
25. Y CHAIN b 10 TRANSMISSION LUBRICANT 11 CLUTCH 12 REAR BELT AND SPROCKETS 13 REAR BELT DEFLECTION 14 THROTTLE CABLES 15 BLEEDING BRAKES dad ii 16 BRAKE PADS AND DISCS sd 17 BATTERY MAINTENANCE 18 SUSPENSION ADJUSTMENTS A9 SPARE PLUGS si orte eaa bnc ires est costae td 1 20 STEERING HEAD BEARINGS ALL BUT FLSTSB En 1 81 STEERING HEAD BEARINGS FLSTSB ios corocririesiciensrc recen n dB 1 22 ROCKER BEARINGS FLSTSB ico e 1 23 FRONT FORK CIL co 1 p GABLE AND CE LUBRICATION m EEN 126 CRITICAL FASTENERS 1 27 ENGINE MOUNTS 1 28 STOBAQGE dia ten apoE 1 29 TROUBLESHOOTING EPAR AT E Cu NOTES GENERAL 1 1 SERVICING A NEW MOTORCYCLE WARNING Perform the service and maintenance operations as indicated in the regular service interval table Lack of regular maintenance at the recommended intervals can affect the safe operation of your motorcycle which could result in death or serious injury 00010a Service operations to be performed before customer delivery are specified in the applicable model year PREDELIVERY AND SET UP MANUAL The performance of new motorcycle initial service is required to keep warranty in force and to ensure proper emissions sys tems operation See 1 2 MAINTENANCE SCHEDULE SAFE OPERATING MAINTENANCE NOTES Do not attempt to retighten engine head bolts Retightening can cause engine damag
26. and without incurring obligation MAINTENANCE 1 1 GENERAL Servicing a New Motorcycle eese 1 1 Safe Operating Maintenance 1 1 o EA 1 1 Repair Nobles m 1 1 EEN dee 1 1 Removing PANTS e ritme cc nica 1 1 A DE 1 1 Disassembly and Assen 1 2 Checking Torques on Fasteners with Lock Patches 1 2 Magnetic Parte TEQVE uu usi tetra Ea Ert ur nt l 1 2 Repair and Replacement Procedures 1 2 Hardware and Threaded Parts 1 2 Threadlocking Agents rrt 1 2 Mim Hoses WEE 1 2 Instruments and Gallges ieo reete rene 1 2 c r qo diene n 1 2 up 1 2 Cei Me 1 2 Lip DES Dita i era El EE EAE AE EIE 1 2 O Rings Preformed Packings 1 3 CI n nM deesses atacat ese eet 1 3 arn m M 1 3 Part opac qo MERERI MUN S 1 3 Exhaust System Leakage AAA 1 3 ECC eR 1 3 Part gie eii m 1 3 Cleaning Practica 1 3 Rust or Corrosion Remowval eese 1 3 Bearings etc 1 3 TM EO 1 3 A 1 3 A RSE Riu 1 3 Plieie Outtere Pry Dalee echec sicci dicis Eer 1 3 gic E LU ST 1 4 A eein 1 4 EENEG REES 1 4 Ratchets and Handles erret 1 4 cH gj MT UE 1 4 cs US D 1 4 1 2 MAINTENANCE SCHEDULE E DE 1 5 1 3 FUEL AND OIL iD er PENNE 1 9 tci rm 1 9 assu rp S 1 9 bon MN cci
27. cket Housings A 3 Mating Pin and Socket Housings A 3 Removing Terminals from Housing A 3 Inserting Terminals into Housing A 4 Preparing Wire Leads for Crimping A 4 Crimping Terminals to Leads A 5 Inspecting Crimped Terminals A 6 A 3 AUTOFUSE ELECTRICAL CONNECTORS Autofuse Connector Repalt aeree ciescaceencetnies A 7 VET a LEE A 7 ENS SS SOM RR A 7 Pon Dao eege A E A 7 A 4 DELPHI CONNECTORS Delphi Connector Mepali iss entire Etna Ears trennt A 8 i o 1 A 8 Separating Pin and Socket Housings A 8 Mating Pin and Socket Housings A 8 Removing Socket Terminals A 8 Installing Socket Terminals ssss A 8 A 5 DELPHI MAXI FUSE HOUSING Delphi Maxi Fuse Housing Repair A 10 E e A E E E S A 10 Removing Max FUSO uui ient troia A 10 Installing WMAXHFUS Gs user e rrr err rines A 10 Removing Socket Terminals A 10 Installing Socket Terminals A 10 A 6 DEUTSCH ELECTRICAL CONNECTORS Deutsch Connector Repair esee A 12 E ee e
28. e D During the initial break in period use only Harley Davidson 20W50 engine oil Failure to use the recommended oil will result in improper break in of the engine cylinders and piston rings A careful check of certain equipment is necessary after periods of storage and frequently between regular service intervals to determine if additional maintenance is required Check Tires for abrasions cuts and correct pressure 2 Secondary drive belt for proper tension and condition 3 Brakes steering and throttle for responsiveness 4 Brake fluid level and condition Hydraulic lines and fittings for leaks Also check brake pads and rotors for wear 5 Cables for fraying crimping and free operation 6 Engine oil and transmission fluid levels 7 Headlamp auxiliary lamp tail lamp brake lamp horn and turn signal operation SHOP PRACTICES Repair Notes General maintenance practices are given in this section NOTES Repair Disassembly Assembly e Replacement Substitute a new part for existing com ponent All special tools and torque values are noted at the point of use All required parts or materials can be found in the appropriate PARTS CATALOG Safety Safety is always the most important consideration when per forming any job Be sure you have a complete understanding of the task to be performed Use common sense Use the proper tools Protect yourself and bystanders with approved ey
29. e blends might adversely affect the starting driveability or fuel efficiency of the motorcycle If any of these problems are experienced try a different brand of gasoline or gasoline with a higher octane blend ENGINE LUBRICATION CAUTION Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed Use of inferior lubricants can damage the engine 00184a Engine oil is a major factor in the performance and service life of the engine Always use the proper grade of oil for the lowest temperature expected before the next scheduled oil change Refer to Table 1 5 Your authorized dealer has the proper oil to suit your requirements If it is necessary to add oil and Harley Davidson oil is not available use an oil certified for diesel engines Acceptable diesel engine oil designations include CF 4 CG 4 CH 4 and Cl 4 The preferred viscosities for the diesel engine oils in des cending order are 20W50 15W40 and 10W40 At the first opportunity see an authorized dealer to change back to 100 percent Harley Davidson oil Table 1 5 Recommended Engine Oils H D TYPE VISCOSITY H D RATING LOWEST AMBIENT COLD WEATHER TEMPERATURE STARTS BELOW 50 F 10 C H D Multi grade SAE 10VV40 HD 360 Below 40 F 40 C Excellent H D Multi grade SAE 20W50 HD 360 Above 40 F 4 C Good H D Regular Heavy SAE 50 HD 360 Above 60 F 16 C Poor H D Extra Heavy SAE 60 HD 360 Above 80 F 2
30. e protection Don t just do the job do the job safely Removing Parts Always consider the weight of a part when lifting Use a hoist whenever necessary Do not lift heavy parts by hand A hoist and adjustable lifting beam or sling are needed to remove some parts The lengths of chains or cables from the hoist to the part should be equal and parallel and should be positioned directly over the center of the part Be sure that no obstructions will interfere with the lifting operation Never leave a part suspended in mid air AWARNING Be sure to check capacity rating and condition of hoists slings chains and cables before use Exceeding capacity ratings or using lifting devices that are in poor condition can lead to an accident which could result in death or serious injury 00466c Always use blocking or proper stands to support the part that has been hoisted If a part cannot be removed verify that all bolts and attaching hardware have been removed Check to see if any parts are in the way of the part being removed When removing hoses wiring or tubes always tag each part to ensure proper installation Cleaning If you intend to reuse parts follow good shop practice and thoroughly clean the parts before assembly Keep all dirt out of parts the unit will perform better and last longer Seals filters and covers are used in this vehicle to keep out environmental dirt and dust These items must be kept in good condition to ens
31. ed with the sealing lip facing the contained lubricant Seal orient ation however may vary under different applications Seals should not be removed unless necessary Only remove seals if required to gain access to other parts or if seal damage or wear dictates replacement Leaking oil or grease usually means that a seal is damaged Replace leaking seals to prevent overheated bearings Always discard seals after removal Do not use the same seal twice O Rings Preformed Packings Always discard o rings after removal Replace with new o rings To prevent leaks lubricate the o rings before installation Apply the same type of lubricant as that being sealed Be sure that all gasket o ring and seal mating surfaces are thoroughly clean before installation Gears Always check gears for damaged or worn teeth Remove burrs and rough spots with a honing stone or crocus cloth before installation Lubricate mating surfaces before pressing gears on shafts Shafts If a shaft does not come out easily check that all nuts bolts or retaining rings have been removed Check to see if other parts are in the way before using force Shafts fitted to tapered splines should be very tight If shafts are not tight disassemble and inspect tapered splines Discard parts that are worn Be sure tapered splines are clean dry and free of burrs before putting them in place Press mating parts together tightly Clean all rust from the machined su
32. emoval and Installation All But FXCW C 8 54 Removal and Installation FSCHWIC 8 55 8 32 ACTIVE EXHAUST ACC Peter etree tear creer tt ERU emer cc FUORUM LEA TE 8 56 BTW e sidsastoscemuccinesianan barons 8 56 SE 8 56 Tt cene A 8 56 8 33 MAIN WIRING HARNESS Removal e 8 57 a A T Cm 8 58 8 34 HANDLEBAR SWITCH ASSEMBLIES C c T 8 60 Repair PNAC eir E ege eege 8 60 8 35 RIGHT HANDLEBAR SWITCH e E 8 61 ls Sl OE o 8 61 Switch PHepairPepnlacement AAA 8 63 Upper Housing Replicar 8 63 Lower Housing Repair screen 8 64 Turn Right Signal Switch coimas 8 64 Rull AE E 8 64 EE EE EE 8 65 8 36 LEFT HANDLEBAR SWITCH A TRI 8 67 A 8 67 Switch Repair Replacement sees 8 68 Upper Housing Fepent corista 8 68 Lower Housing pali scere oret tti ER Feri rSh RS 8 69 Turm Lelt Signal Wilhem 8 69 Clutch Interlock Swilbh uus rre itr eph ta mm een 8 69 rt ge e se 8 69 APPENDIX A CONNECTOR REPAIR A 1 AMP 1 PLACE CONNECTORS A tue S E A R EE A 1 Separating Pin and Socket Housings A 1 Mating Pin and Socket Housings A 1 Removing Socket Terminals A 1 Installing Socket Terminal A 1 Removing Pin TI essiri A 1 Installing Part Toril soii A 2 A 2 AMP MULTILOCK CONNECTORS AMP Multilock Connector Repair ssss A 3 E T X A 3 Separating Pin and So
33. gs Or Does Not Release 1 63 e E 1 63 acis me TE ET 1 63 ET 1 63 Brake e atenta 1 63 Brake Does Not Hold Normally 1 63 CHASSIS 2 1 SPECIFICATIONS EL 2 1 Chassis Specifications 2 1 e SPP O be US 2 2 2 2 VEHICLE IDENTIFICATION NUMBER V L N Vehicle Identification Number esses 2 4 2 3 FRONT WHEEL ALL BUT FLSTSB Removal 2 6 PS SS y eC M R M 2 6 Disc le ee nt 2 6 Laced Well i eara p Rita enigma 2 6 Cleaning and Inspectior iuu sene erar rtn nnne 2 8 Pico gd CR 2 8 Ej lr o mee E 2 8 Eam 2 8 A EET T T armen S 2 9 2 4 FRONT WHEEL FLSTSB e M 2 10 Disassembly 2 10 Cleaning and Inspection ssiri 2 10 e s 2 10 cars eat Ree inci 2 11 2 5 REARWHEEL REMOVAL e 2 12 BICT nC A O PD E 2 12 DIESE and INSPECTION isc 2 13 a T 2 13 Cyr epo emer 2 14 2 6 SEALED WHEEL BEARINGS i5 i e O o x 2 15 HEM m 215 et En C 2 16 2 7 WHEEL LACING 16 INCH RIM tI 2 18 ere cities os enteses 2 18 2 8 WHEEL LACING 17 INCH RIM o e C M 2 21 A AN 2 21 2 9 WHEEL LACING 21 INCH RIM EBD s iade E E EE E T 2 24 Procedur Mee eciacia 2 24 2 10 TRUING LACED WHEELS
34. i ge rm EN 3 70 rari ril Melee NR RE 3 71 Walve and Seat Refacin D 3 74 ll n 3 76 Lari iis VOI mm T 3 77 3 23 CYLINDER Removal QUE EN ei 3 78 de te EE 3 78 gis e 3 79 DBeuglazing a E 3 80 Boring and Honing Cylinder sessss 3 81 ISTMO OVER oca 3 81 3 24 PISTON PP m 3 82 E O 3 82 Piston PINGS 3 82 A O abner 3 82 dise A A 3 83 e mb ms 3 84 Checking Piston Ring Gap 3 84 Installing Piston PADS risen nn deae rivis 3 85 Installation Querview uisus aerei near is 3 86 3 25 COVER AND CAM SUPPORT PLATE Removal Overview essen 3 87 A P 3 87 sup M 3 87 ASSO f M M 3 87 Oil Pressure Relief Vahe AAA 3 89 suc M 3 89 WEST EW IC 3 89 e AA V 3 89 bam Needle Bealllige ccu cei cca ri 3 89 FTO E 3 89 KE meme 3 91 Cleaning and Inepechon eese 3 92 CI Prostre VA rsacicconctisin cid 3 92 Cam UDC PESO asi ia nicis Bre ERE E Ease adios 3 93 Vill TABLE OF CONTENTS Installation Ova imiten 3 93 3 26 OIL PUMP Removal varia 3 94 Cleaning and Inepecton 3 94 Installation Overvlew 3 94 3 27 CRANKCASE Removal DEN iris 3 95 Right eer HAM i incita 3 95 Chain Guide Gereen isssisisiiisrseisiainniinsii kaei 3 95 Crankshaft Roller Bearing Removal 3 95 Crankshaft Roller Bearing Installation 3 96 Piston Jets E 3
35. na A 20 Gimp Tormnal to Leg cocorirra caceria A 21 Prepare Leat iuis A 21 SUN mem A 21 Position Terminal in the Punch Die A 22 ngent Stlpped Leslie scene ei A 22 Crimp Terminal to Lead ron A 22 eet ei P A 23 A 11 PACKARD 150 METRI PACK CONNECTORS 150 Metri Pack Connector Repair A 24 cu e HET A 24 Separating Pin and Socket Housings A 24 Mating Pin and Socket Housings A 24 Removing Socket Terminal A 24 Inserting Socket Terminal cecceiccicaecan eoim A 24 A 12 PACKARD 280 METRI PACK RELAY AND FUSE BLOCK CONNECTORS Fuse Block Repalr uirr rrr teri terrre rk A 26 Removing Socket Terminals A 26 Installing Socket Terminals A 26 Camping Tema Eet A 26 A 13 PACKARD 480 METRI PACK CONNECTORS 480 Metri Pack Connector Repair A 27 EE A 27 Separating Pin and Socket Housings A 27 Mating Pin and Socket Housings A 27 Removing Socket Terminals A 27 Installing Socket Terminals A 27 A 14 PACKARD 630 METRI PACK CONNECTORS 630 Metri Pack Connector Hepair A 28 tl A 28 Separating Pin and Socket Hou
36. nd Insiallaton ee 2 117 Beal i M 2 117 EE 2 117 2 43 SEAT FXSTC Removal and Ineiallaton ee 2 118 SERE SUE E 2 118 ci dec ia 2 118 2 44 SEAT FXCW FXCWC Removal and Installation canaria 2 119 CON E A TO 2 119 Rider Seal FACE Lu ei eh rii oris ar a ter etus 2 119 Passenger Seat Support FXCWC 2 119 2 45 SEAT FLSTN FLSTF FLST FLSTC Removal and Insiallaton ee 2 121 2 46 SEAT FLSTSB e ca EE cH 2 122 Remowval 2 122 dia a 2 122 Adjusting Seat PositiON ocoonncinnoninnicnnannncnnnnarns 2 122 2 47 LUGGAGE RACK FLSTN Removal and Insiallaton ros 2 124 2 48 SADDLEBAGS FLSTC REMOTA e 2125 PP E E sawn E E 2 125 2 49 WINDSHIELD FLSTC REMOVA e ini ia di 2 126 RUE A M 2 126 ENGINE 3 1 SPECIFICATIONS lec cm RTT co Dimc dit ie ia tel 3 1 3 2 SERVICE VVEAR LIMITS c r e ei 33 3 3 ENGINE OIL FLOW BI mE 3 5 Top E E 3 6 Bottom End 5 EP 3 7 Ghain Guide Broke Pp 3 9 CREUS es inicis 3 9 3 4 OIL PUMP OPERATION o UTE 3 10 poco C e E E EE 3 10 3 5 BREATHER OPERATION tur Y S 3 12 3 6 OIL PRESSURE Oil Pressure Indicator Laicos 3 13 Checking Oil Piressute ucciso titii bet erret kennt 3 13 3 7 TROUBLESHOOTING Diagnosing Valve Train Noise AAA 3 14 COMPRESSION Teba dis PELO POM Hide pas 3 14 Cylinder Leskdown Task acicate 3 14 Diagnosi
37. ng Smoking Engine or High Oil Consumption 3 15 Check Prior To Cylinder Head Removal 3 15 Check After Cylinder Head Removal 3 15 3 8 HOW TO USE THIS SECTION Top End FS PAW pr E 3 16 Bottom End Repair 3 16 a de 3 16 3 9 TOP END SERVICE Engine Iri Ghas inscrita 3 17 Engine Removed from Chassis 3 18 3 10 BOTTOM END SERVICE ENG UE DUOBUS AT AA bU LESER Aa LEER FCU RR RA I 3 19 Engine Removed From Chassis ssesss 3 20 3 11 STRIPPING MOTORCYCLE FOR SERVICE PIC ied Ex VEO E IDOL OT GENE 3 21 TABLE OF CONTENTS 3 12 ASSEMBLING MOTORCYCLE AFTER SERVICE E EE 3 22 3 13 REMOVING ENGINE FROM CHASSIS Bice ol EE 3 23 3 14 INSTALLING ENGINE IN CHASSIS PYO CS CUS 3 24 3 15 TOP END OVERHAUL DISASSEMBLY Elei 3 26 ar mM cT 3 26 Rocker Arm Support Plate 3 26 Push Rods Litters and Covers cocinar 3 28 EORR A EO ERR 3 29 Uii A E E 3 30 E MENTRE pit D fre terre D 3 30 3 16 TOP END OVERHAUL ASSEMBLY ET Ur chases cach seni inde ace I T E T UM 3 32 i ee me 3 32 RUIT aeu Pd 3 33 Cylinder M 3 35 Push Rods Lifters and Covers 3 38 Rocker Arm Support Plate como era 3 39 BESAS Geet ssniaa rc arasina 3 40 3 17 BOTTOM END OVERHAUL DISASSEMBLY E e o UU P 3 42 Cover and Cam Support Pl corn cr 3 42 Prepare mec atentament ats o 3 42 Cam Chain and Sprockets sssss 3 42 Cam suppor
38. om off belt strand With motorcycle on Jiffy Stand without rider or FLSTN FXCW C 1 4 5 16 in 6 4 7 9 mm luggage FXST FLST FLSTC FLSTF FXSTB FXSTC 9 16 5 8 in 14 3 15 9 mm Vehicle upright with rear wheel in air FLSTN FXCW C 5 16 3 8 in 7 9 9 5 mm FXST FLST FLSTC FLSTF FXSTB FXSTC 11 16 3 4 in 17 5 19 1 mm Air cleaner Air cleaner cover bracket screw torque 40 60 in Ibs 4 5 6 8 Nm Air cleaner cover screw torque 36 60 in lbs 4 1 6 8 Nm Adhesive for air cleaner cover screw LOCTITE THREADLOCKER 243 Part No 99642 97 6 ml 2008 Softail Service Maintenance 1 7 Table 1 2 Softail Quick Reference Maintenance Chart ITEM SERVICED SPECIFICATION DATA Clutch and throttle Lubricant SUPER OIL cables Part No 94968 85TV 1 4 fl oz Handlebar clamp screw torque 12 15 ft lbs 16 3 20 3 Nm Handlebar switch housing screw torque 35 45 in Ibs 4 5 Nm Table 1 3 Lubricants Greases Sealants ITEM PART NUMBER PACKAGE Anti Seize Lubricant 98960 97 1 oz squeeze tube CCI 420 Brake Grease 42830 05 included in master cylinder squeeze packet rebuild kit D O T 4 Brake Fluid 99953 99A 12 oz bottle Electrical Contact Lubricant 99861 02 1 oz squeeze tube Genuine Harley Davidson Formula 99851 05 1 at bottle Transmission and Primary Chaincase Lubricant G40M Brake Grease 42820 04 squeeze packet Gray High Performance Sealant 99650 0
39. onnector Repair A 36 a a A 36 Preparing Wire Leds escocia resis A 36 Splicing Mire Lead cnica A 36 durer niis SSG enanas eiii A 36 APPENDIX B WIRING B 1 CONNECTORS Connector LocationS emameecass os ia B 1 Funcion GB rod B 1 Place and E e do o E EUR du um dev iR B 1 Ganmector Numan B 1 Repair INSTFUCIONS Cr nim IS eis B 1 XIV TABLE OF CONTENTS B 2 WIRING DIAGRAMS Wiring Diagram Inforfniabiouas aieo ias uida potra barztr acus B3 Wire COI CDC RE B 3 Widng Diagram Symbole cascade ides B 3 2008 Softail Wiring Diagrams eee B 4 APPENDIX C CONVERSIONS C 1 METRIC CONVERSION Gonverelom TASB uiuo iaia C 1 C 2 FLUID CONVERSIONS United States SM incio aiii rt id C 2 Motie Sy SIC Motes C 2 British Imperial Systemsin iniii C 2 C 3 TORQUE CONVERSIONS United States System sss C 3 Meme SYSTEM EE C 3 APPENDIX D GLOSSARY D 1 GLOSSARY Acronyms and Abbreviations eese D 1 REFERENCE MATERIAL TOOLS l TORQUE VALUES csi VII INDE X XIX SUE ECT PAGE NO 1 2 MAINTENANCE SCHEDULE a 45 SPEECH uas ue alg 1 4 BULB REQUIREMENTS E Ted 1 5 ENGINE OIL AND FIETER neos o EK TRA ES sensa antememtmatmetzsmtsea es delia tas UA 1 7 AIR CLEANER AND EXHAUST SYSTEM 16 1 8 TIRES AND WHEELS m dales di heen D 1 9 PRIMAR
40. r Mec HR UE 8 19 Bull Replace uiuat etri rede oe rok erar 8 19 Base Replacement coronas ratita 8 19 8 13 TAIL LAMP FLSTN Bulb Replacement srt ibas 8 21 Tal Lamp RE 8 21 8 14 AUXILIARY LAMPS FLST FLSTC FLSTN Awda Lamo Pla a 8 23 A O 8 23 O DS 8 23 FLST and FESTES Models nan 8 23 Auxiliary Lamp Bracket Removal 8 23 Auxiliary Lamp Bracket Installation 8 24 Auxiliary Lamp Housing Remowval 8 24 Auxiliary Lamp Housing Installation 8 24 a ENEE 8 26 Auxiliary Lamp Bracket Removal 8 26 Auxiliary Lamp Bracket Installation 8 26 Auxiliary Lamp Housing Remowval 8 27 Auxiliary Lamp Housing Installation 8 27 Adjustment FLST FLSTC FLSTN Models 8 28 8 15 TURN SIGNALS AND RUNNING LIGHTS Bulb Replacement Bullet Style 8 30 Bulb Replacement Flat Lens Style 8 30 Lamp Replacements 8 30 TE e EE 8 30 Front Turn Signals All But FLST FLSTC FLSTN 8 31 Front Turn Signals FLST FLSTC FLSTN 8 32 Rear Turn Signals All But FXCW C FLSTN 8 32 Rear Turn Signals FXCW C usse 8 32 Rear T rm Signale PLS TN ea cente eap etas obra aeneo 8 34 8 16 TURN SIGNAL AND SECURITY MODULE TSM TSSM HF
41. r tip lamp FLST FLSTC 2 0 10 68193 95 Instrument panel lamps Illuminated with LEDs Replace entire assembly upon failure 2008 Softail Service Maintenance 1 11 ENGINE OIL AND FILTER 1 5 CHECKING AND ADDING OIL See Figure 1 1 Checking engine oil level As part of the pre ride inspection Atevery scheduled service interval Type of Oil Refer to Table 1 5 Use the proper grade of oil for the lowest temperature expected before the next oil change See 1 3 FUEL AND OIL for specific information regarding winter needs If it is necessary to add oil and Harley Davidson oil is not available use an oil certified for diesel engines Acceptable diesel engine oil designations include CF 4 CG 4 CH 4 and Cl 4 The preferred viscosities for the diesel engine oils in descending order are 20W 50 15W 40 and 10W 40 At the first opportunity see a Harley Davidson dealer to change back to 100 percent Harley Davidson oil Checking Oil Level CAUTION Oil level cannot be accurately measured on a cold engine For pre ride inspection with motorcycle leaning on jiffy stand on level ground oil should register on dipstick between arrows when engine is cold Do not add oil to bring the level to the FULL mark on a COLD engine 00185a Ride motorcycle until engine is warmed up to operating temper ature then do the following 1 ldle motorcycle on jiffy stand for 1 2 minutes 2 Shut motorcycle off and leave moto
42. r to spin dry bearings can cause bearing to fly apart which could result in death or serious injury 00505b Clean open bearings by soaking them in a petroleum cleaning solution Never use a solution that contains chlorine Let bearings stand and dry Do not dry with compressed air Do not spin bearings while they are drying TOOL SAFETY Air Tools Always use approved eye protection equipment when performing any task using air operated tools On all power tools use only recommended accessories with proper capacity ratings Do not exceed air pressure ratings of any power tools Bits should be placed against work surface before air hammers are operated e Disconnect the air supply line to an air hammer before attaching a bit Never point an air tool at yourself or another person Protect bystanders with approved eye protection Wrenches Never use an extension on a wrench handle f possible always pull on a wrench handle and adjust your stance to prevent a fall if something lets go Never cock a wrench Never use a hammer on any wrench other than a STRIKING FACE wrench Discard any wrench with broken or battered points Never use a pipe wrench to bend raise or lift a pipe Pliers Cutters Pry bars Plastic or vinyl covered pliers handles are not intended to act as insulation Do not use on live electrical circuits Do not use pliers or cutters for cutting hardened wire unless
43. rcycle resting on jiffy stand 3 See Figure 1 2 Check oil level on dipstick If necessary add oil until oil registers at upper groove on dipstick Do not overfill oil tank sm03039 C FILED KGRULEROT Figure 1 1 Checking Oil Tank Level 1 12 2008 Softail Service Maintenance Figure 1 2 Oil Tank Dipstick Upper Groove CHANGING OIL AND FILTER PART NUMBER TOOL NAME HD 4231 1 OIL FILTER WRENCH HD 44067 OIL FILTER WRENCH NOTES If the motorcycle is ridden hard under dusty conditions or in cold weather the oil and filter should be changed more often All Softail models are shipped from the factory with SAE 20W50 Harley Davidson 360 Motor Oil All Softail models come equipped from the factory with a premium 5 micron synthetic media oil filter Part No 63798 99 Chrome or 63731 99 Black These are the only recommended replacement filters 1 Ride motorcycle until engine is warmed up to normal operating temperature 2 See Figure 1 1 Remove the engine oil filler plug dipstick by pulling steadily while moving plug back and forth 3 See Figure 1 3 Remove the engine oil drain plug with o ring 2 Allow oil to drain into a suitable container CAUTION Use Harley Davidson oil filter wrench for filter removal This tool can prevent damage to crankshaft position sensor and or sensor cable 00192b 4 See Figure 1 4 Remove the oil filter using
44. rfaces of new parts Part Replacement Always replace worn or damaged parts with new parts Exhaust System Leakage In the event of an exhaust system leak at a muffler or header pipe connection location disassemble and clean all mating surfaces Replace any damaged components If leak still exists disassemble and repair the leak by applying a bead of Harley Davidson High Performance Sealant Part No 99650 02 or an equivalent 02 Sensor Catalyst safe alternative Reassemble components wipe off any excess sealant and allow adequate curing time following sealant product instructions before oper ating vehicle CLEANING Part Protection Before cleaning protect rubber parts such as hoses boots and electrical insulation from cleaning solutions Use a grease proof barrier material Remove the rubber part if it cannot be properly protected Cleaning Process Any cleaning method may be used as long as it does not result in parts damage Thorough cleaning is necessary for proper parts inspection Strip rusted paint areas to bare metal before priming and repainting Rust or Corrosion Removal Remove rust and corrosion with a wire brush abrasive cloth sand blasting vapor blasting or rust remover Use buffing crocus cloth on highly polished parts that are rusted Bearings Remove shields and seals from bearings before cleaning Clean bearings with permanent shields and seals in solution AWARNING Using compressed ai
45. rque 14 21 ft lbs 19 28 Nm Oil capacity 3 0 qt 2 85 L Filter Hand tighten 1 2 3 4 turn after gasket contact Chrome filter part number 63798 99 Black filter part number 63731 99 Primary chain lubricant Lubricant capacity 32 oz 0 95 L wet 40 oz 1 18 L dry Primary chaincase drain plug torque 14 21 ft lbs 19 28 Nm Clutch adjustment Free play at adjuster screw 1 2 1 turn Adjuster screw locknut torque 72 120 in Ibs 8 14 Nm Free play at hand lever 1 16 1 8 in 1 6 3 2 mm Clutch inspection cover torque 84 108 in Ibs 10 12 Nm Transmission lubricant Lubricant level Dipstick at FULL with motorcycle on jiffy stand and filler plug resting on threads Lubricant capacity 32 oz 0 95 L Transmission drain plug torque 14 21 ft lbs 19 28 Nm Filler plug torque 25 75 in Ibs 3 9 Nm Spark plugs Type HD 6R12 Gap 0 038 0 043 in 0 97 1 09 mm Torque 12 18 ft lbs 16 24 Nm Engine idle speed Idle speed 950 1050 RPM Front fork oil Type HYDRAULIC FORK OIL TYPE E Part No 99884 80 16 oz Battery Lubricant ELECTRICAL CONTACT LUBRICANT Part No 99861 02 1 oz Battery terminal torque 60 72 in Ibs 6 8 8 1 Nm 1 6 2008 Softail Service Maintenance Table 1 2 Softail Quick Reference Maintenance Chart ITEM SERVICED SPECIFICATION DATA Tire condition and pres sure Pres
46. sings A 28 Mating Pin and Socket Housings A 28 Removing Socket Terminal A 28 Installing Socket Terminal A 28 A 15 PACKARD METRI PACK TERMINALS Metri Pack Terminal CMPS 11 A 29 Matching Terminal To Crimper A 29 Preparing Wire Leste mmt ect A 29 Lrimplng Wire CO oic ptr Rr inia A 29 Crimping Insulation Seal sss A 29 Kelte AMP PP A 30 TABLE OF CONTENTS XIII TABLE OF CONTENTS A 16 PACKARD ECM CONNECTOR Packard 100W Connector RE Pale amiant A 31 CC UE A 31 Separating Socket Housing From ECM A 31 Mating Socket Housing To ECM A 31 Removing Socket Terminal A 31 Installing Socket Terminal A 31 e Muller Tm sl Es ae tem ets A 31 A 17 PACRARD MICRO 64 CONNECTORS Packard Micro 64 Connector Repair A 33 D OCI uei PECES HAUS ates PPM dU DIMUS A 33 Separating Pin and Socket Housings A 33 Mating Pin and Socket Housings A 33 Removing Toril acostar A 33 Install TOTS dirias A 33 Preparing Wire Leads for Crimping A 34 Crimping Termal Bus caiste A 34 a eg RIDE AAA A 34 A 18 SEALED SPLICE CONNECTORS Sealed Splice C
47. stener that has a lock patch 1 Setthetorque wrench for the lowest setting in the specified torque range 2 Attempt to tighten fastener to set torque If fastener does not move and lowest setting is satisfied torque wrench clicks then the proper torque has been maintained Magnetic Parts Trays Magnetic parts trays are becoming common in the service facility because they are convenient and can keep parts from becoming lost during a repair procedure However hardened steel parts can become magnetized when held in magnetic parts trays Metal fragments that would ordinarily be washed away in the oil and trapped in the oil filter or magnetic drain plug during vehicle operation could be cap tured by magnetized parts in the engine potentially causing accelerated engine wear and damage Parts that will be returned to service inside the vehicle s powertrain such as gears thrust washers and especially bearings should never be kept in magnetic parts trays REPAIR AND REPLACEMENT PROCEDURES Hardware and Threaded Parts Install helical thread inserts when inside threads in castings are stripped damaged or not capable of withstanding specified torque Replace bolts nuts studs washers spacers and small common hardware if missing or in any way damaged Clean up or repair minor thread damage with a suitable tap or die Replace all damaged or missing lubrication fittings Use Teflon pipe sealant or LOCTITE 565 THREAD SEALANT
48. sure for solo rider FLST FLSTC FLSTN Models Front 36 psi 248 kPa Rear 36 psi 248 kPa FXST FXSTC FXSTB Models Front 30 psi 207 kPa Rear 38 psi 262 kPa FLSTF FLSTSB Models Front 36 psi 248 kPa Rear 38 psi 262 kPa FXCW C Models Front 30 psi 207 kPa Rear 38 psi 262 kPa Pressure for rider and passenger FLST FLSTC FLSTN Models Front 36 psi 248 kPa Rear 40 psi 276 kPa FXST FXSTC FXSTB Models Front 30 psi 207 kPa Rear 42 psi 290 kPa FLSTF Models Front 36 psi 248 kPa Rear 42 psi 290 kPa FXCWC Models Front 30 psi 207 kPa Rear 42 psi 290 kPa Wear Replace tire if 1 32 in 0 8 mm or less of tread pattern remains Wheel spokes Spoke nipple torque Steel laced wheel 55 in Ibs 6 2 Nm Chrome aluminum laced wheel 55 in Ibs 6 2 Nm Steering head bearings Lubricant for neck fitting SPECIAL PURPOSE GREASE Part No 99857 97 140z cartridge Brake fluid reservoir level DOT 4 hydraulic brake fluid part number 99953 99A 12 oz Proper fluid level 1 4 1 8 in 6 35 3 18 mm from top Master cylinder reservoir cover torque 6 8 in Ibs 0 7 0 9 Nm Brake pad linings and discs Minimum brake pad thickness 0 04 in 1 02 mm Minimum brake disc thickness See stamp on side of disc Drive belt Upward measurement force applied at midpoint of 10 Ib 4 5 kg bott
49. t PRE 3 43 CCS A E 3 44 Counterbalancer Assembly sess 3 45 3 18 BOTTOM END OVERHAUL ASSEMBLY ET li MR 3 48 Counterbalancer Assembly sess 3 48 A MP NM c eem 3 51 Cover and Cam Support Plate teoria etai 3 55 3 19 BREATHER ASSEMBLY Removal DERE con 3 59 Disasse atm ie datats mite 3 59 Cleaning and Inspection 3 59 Ciro gj o M 3 59 Installation e I EELER 3 59 3 20 ROCKER ARM SUPPORT PLATE Removal COP MO ass xcd ii atan 3 60 Disassembly PT 3 60 Cleaning and SOS CUI as cad eiiis aa Mai ke d re eco 3 60 NEE 3 60 A tr MA a EM ELA CS DLE ELI TAR 3 60 Rocker Arm Shaft to Bushing 3 61 Replace Rocker Arm Bushings 3 61 cie Me Y 3 62 TABLE OF CONTENTS VII TABLE OF CONTENTS Inge baten VS ccoo 3 62 3 21 PUSH RODS LIFTERS AND COVERS ele 3 64 Bcc pip mw P 3 64 Cleaning and Inspection 3 64 Liner ach sper 3 65 Dro m 3 65 Installation Overvigw iucac sese ten tnter 3 66 3 22 CYLINDER HEAD Romov OVON W a octies ai pde ac Ea aded a a Ec EiaM iuda 3 67 Dies Som iot TN ED eae 3 67 e e E E E E E E T 3 68 ken AA E E O 3 69 erar c M 3 69 Vake CES E 3 69 KC tel 3 69 Kee eds 3 69 Tapered eeneg ona 3 70 vake CEEB fr ETE 3 70 Valve Guide PHeplacement AAA 3 70 K
50. table for the recommended service interval If necessary see the quick reference table Table 1 2 for the required specifications If more detailed information is needed turn to the sections which follow for step by step instructions Also throughout this manual you will be instructed to use various lubricants greases and sealants Refer to Table 1 3 for the correct part numbers of these items Table 1 1 Regular Service Intervals 2008 Softail Models ITEM SERVICED PROCEDURE 1000 MI 5000 MI 10 000 MI 15 000 MI 20 000 MI 25 000 MI NOTES 1600 KM 8000 KM 16 000 KM 24 000 KM 32 000 KM 40 000 KM Engine oil and filter Replace X X X X X X Oil lines and brake system Inspect for leaks X X X X X X 1 Air cleaner Inspect service as required X X X X X X Tires Check pressure inspect tread X X X X X X Wheel spokes Check tightness X X X 1 4 Primary chaincase lubricant Replace X X X Transmission lubricant Replace X X Clutch Check adjustment X X X X X X 1 Rear belt and sprockets Inspect adjust belt X X X X X X 1 Throttle brake and clutch controls Check adjust and lubricate X X X X X X 1 Jiffy stand Inspect and lubricate X X X 1 Fuel lines and fittings Inspect for leaks X X X X X X 1 Fuel filter in fuel tank Replace X 1 Brake fluid Check levels and condition X X X X X X 6 Brake pads and discs Inspect for wear X X
51. they were designed for that purpose Always cut at right angles Do not use any pry bar as a chisel punch or hammer 2008 Softail Service Maintenance 1 3 Hammers D Never strike a hammer against a hardened object such as another hammer Always grasp a hammer handle firmly close to the end Strike the object with the full face of the hammer Never work with a hammer which has a loose head Discard hammer if face is chipped or mushroomed Wear approved eye protection when using striking tools Protect bystanders with approved eye protection Punches Chisels Never use a punch or chisel with a chipped or mush roomed end dress mushroomed chisels and punches with a file Hold a chisel or a punch with a tool holder if possible When using a chisel on a small piece clamp the piece firmly in a vise and chip toward the stationary jaw Wear approved eye protection when using these tools Protect bystanders with approved eye protection Screwdrivers Do not use a screwdriver for prying punching chiseling scoring or scraping Use the right type of screwdriver for the job match the tip to the fastener Do not interchange POZIDRIV PHILLIPS or REED AND PRINCE screwdrivers Screwdriver handles are not intended to act as insulation Do not use on live electrical circuits Do not use a screwdriver with rounded edges because it will slip Redress with a file 1 4 2008 Softail Service Maintenance Ratche
52. tits cn 7 2 E E un i apace dene A ALIIS 7 2 Cant ctc m 7 2 ME c me D EE 7 2 di RAN EEUU TU 7 2 A Eh 7 2 DIEI mec 7 2 7 3 SHIFTER LINKAGE AUSIN Q VA Mt d 7 4 A A TE E EA E 7 4 7 4 CLUTCH RELEASE COVER Removal and Disassembly esee 7 5 Cleaning and Inspector 7 5 Assembly and Installation eese 7 6 7 5 TRANSMISSION ASSEMBLY O E E E 7 7 DIAM ci TER 7 8 Shifter Cany Shilter Fre iioi euni see actrices 7 8 A T 7 10 COI RS em bibi 7 13 Replacing Side Door Bearings 7 14 Cleaning and Inspection iusso errare ennn 7 15 DII gor aT 7 15 Installing Side Door Bearings 7 15 RT eM E a ci 7 15 ISO RT 7 16 shifter Gam oer FORK emana 7 16 Lua a fe EET O 7 18 7 6 MAIN DRIVE GEAR AND BEARING EID oasis ste ku s O 7 20 Gleaning and Irepeoctlofi a iunc eie eeisacu remat actas 7 21 Needle Bearing Replacement 7 22 EE Le M 7 23 Installing Main Drive Gear Bearing 7 23 Installing Main Drive Gear esses 7 24 Installing Main Drive Gear Large Seal 7 24 7 7 TRANSMISSION CASE ue RR Rom UR Um 7 27 NS E etat setanta amena 7 27 DIS iocos e setem te 7 28 Shifter Arm Assembly sese 7 28 Gleani a amd Inspection rica 7 28 Reese Eege EE ATEM PURA 7
53. ts and Handles Periodically clean and lubricate ratchet mechanisms with a light grade oil Do not replace parts individually ratchets should be rebuilt with the entire contents of service kit Never hammer or put a pipe extension on a ratchet or handle for added leverage Always support the ratchet head when using socket extensions but do not put your hand on the head or you may interfere with the action of its reversing mechanism When breaking loose a fastener apply a small amount of pressure as a test to be sure the ratchet s gear wheel is engaged with the pawl Sockets Never use hand sockets on power or impact wrenches Select the right size socket for the job Never cock any wrench or socket Select only impact sockets for use with air or electric impact wrenches Replace sockets showing cracks or wear Keep sockets clean Always use approved eye protection when using power or impact sockets Storage Units Do not open more than one loaded drawer at a time Close each drawer before opening up another Close lids and lock drawers and doors before moving storage units Do not pull on a tool cabinet push it in front of you Set the brakes on the locking casters after the cabinet has been rolled to your workspace MAINTENANCE SCHEDULE 1 2 GENERAL The table below lists the periodic maintenance requirements for Softail model motorcycles If you are familiar with the pro cedures just refer to the
54. umber For example page 3 5 refers to page 5 in section 3 A number of acronyms and abbreviations are used in this document See the D 1 GLOSSARY for a list of acronyms abbreviations and definitions PREPARATION FOR SERVICE dNVARNING Stop the engine when refueling or servicing the fuel system Do not smoke or allow open flame or sparks near gasoline Gasoline is extremely flammable and highly explosive which could result in death or serious injury 000022 Good preparation is very important for efficient service work A clean work area at the start of each job will allow you to perform the repair as easily and quickly as possible and will reduce the incidence of misplaced tools and parts A motorcycle that is excessively dirty should be cleaned before work starts Cleaning will occasionally uncover sources of trouble Tools instruments and any parts needed for the job should be gathered before work is started Interrupting a job to locate tools or parts is a distraction and causes needless delay NOTES To avoid unnecessary disassembly carefully read all rel ative service information before repair work is started dn figure legends the number which follows the name of a part indicates the quantity necessary for one complete assembly When servicing a vehicle equipped with the Harley Davidson Smart Security System H DSSS you must first disarm the security system Either keep the fob in close proximity to the
55. ure satisfactory operation When you are instructed in a step to clean fastener threads or threaded holes proceed as follows Clean all LOCTITE material from fastener threads and threaded holes Use a wire brush to clean fastener threads Use a thread chaser or other suitable tool to clean threaded holes Use PJ 1 cleaner or equivalent to remove all traces of oil and contaminants from threads Blow out all threaded holes with low pressure compressed air Clean and inspect all parts as they are removed Be sure all holes and passages are clean and open After cleaning cover all parts with clean lint free cloth paper or other material Be sure the part is clean when it is installed Always clean around lines or covers before they are removed Plug tape or cap holes and openings to keep out dirt dust and debris Always verify cleanliness of blind holes before assembly Tightening a screw with dirt water or oil in the hole can cause castings to crack or break 2008 Softail Service Maintenance 1 1 Disassembly and Assembly Always assemble or disassemble one part at a time Do not work on two assemblies simultaneously Be sure to make all necessary adjustments Recheck your work when finished Be sure that everything is done Operate the vehicle to perform any final check or adjustments If all is correct the vehicle is ready to go back to the customer Checking Torques on Fasteners with Lock Patches To check the torque on a fa
56. us injury 00119a CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury 00139a CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage 00140a NOTE Refers to important information and is placed in italic type It is recommended that you take special notice of these items Proper service and repair is important for the safe reliable operation of all mechanical products The service procedures recommended and described in this service manual are effective methods for performing service operations AWARNING Always wear proper eye protection when using hammers arbor or hydraulic presses gear pullers spring com pressors slide hammers and similar tools Flying parts could result in death or serious injury 00496b Some of these service operations require the use of tools specially designed for the purpose These special tools should be used when and as recommended It is important to note that some warnings against the use of specific service methods which could damage the motorcycle or render it unsafe are stated in this service manual However please remember that these warnings are not all inclusive Inadequate safety precau tions could result in death or serious injury Since Harley Davidson could not possibly know evaluate or advise the service
57. vehicle or use Digital Technician to disable the security system while the vehicle is being ser viced and re enable the system after service is completed SERVICE BULLETINS In addition to the information presented in this Service Manual Harley Davidson Motor Company will periodically issue Service Bulletins to Harley Davidson dealers Service Bulletins cover interim engineering changes and supplementary information Consult the Service Bulletins to keep your product knowledge current and complete USE GENUINE REPLACEMENT PARTS FOREWORD WARNING Do not use aftermarket parts and custom made front forks which can adversely affect performance and handling Removing or altering factory installed parts can adversely affect performance and could result in death or serious injury 00001a To ensure satisfactory and lasting repairs carefully follow the Service Manual instructions and use only genuine Harley Davidson replacement parts Behind the emblem bearing the words GENUINE HARLEY DAVIDSON stand more than 100 years of design research manufacturing testing and inspecting experience This is your assurance that the parts you are using will fit right operate properly and last longer WARNINGS AND CAUTIONS Statements in this service manual preceded by the following words are of special significance WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serio

Download Pdf Manuals

Related Search

Related Contents

DVD RECORDER CONTENTS  manual  bomba manual    Bedienungsanleitung    Downloads - eQ-3  Operating Instructions  L` ORACLE - Les Foyers Mirabel  

Copyright © All rights reserved. Failed to retrieve file