Home

2008 FLT Police Models Service Manual Supplement

1. et00097 Yellow Tubing co HR Ignition o fw Coil Twist Grip 1 mk Sensor o ER pe Crank Pos L w m BK Rear Front Sensor Injector Injector TMAP Throttle Control Black Tubing W Y Sensor Actuator Es gt SW Engine Temp E z 3 c Sensor ooga 5 5852 A Sade A 4A A 211A ES Data Link miimmiim 83A BUE E 85A 84A 80A on oo Connector En ad y 123456 V 2206 V AB v X8 V V N 1234 90A Y 123456 Y ABCD Y as Y as Y 1234 Y 654321 WT nna TH TT MA z gt gt Y 204B gt 2220 B3B ABCD B5B zz 84B zx 80B 2341 211B 679 4 9 2 1 So Y AB OoSESES Tale so oz BIT GY 36 2 ow Z u w O gt 2 gt 222 20rOxz ml AB a a oma y OsFS ZZZYLxY 90B LA gt gt gt m 25T ao Gora ECM 78A gt gt 78B gt E o 53 E a der ull COS eee 1 ACR 19 19 IR V GY CT __ __ _ e Purge Solenoid 20 20 GY Y pem Exhaust Actuator 21 21 f v o mt Cruise Set Coast 22 22 Cues E 3 AHH EL E BE BK mmi Rear Injector 23 23 me Saat i Za Evi ER IMM en dl ie iln IT System Relay Enable 27 27 ERGN O 36 aS GNE EE Front Injector 28 28 E WY it A rg EA Twist Grip High 29 29 EEBK O a RT LI a EEE Y BK GN EE E lon Sense 33
2. R GY Radio Power PRL EIE E Lt 1D 1H Siren 15A B m mut a O O CN Bar oH 3013 BEER Ss 1 1 LGNIV A aren ee T EBEN ee ee Oe A BEER BKR t nd Relay EEENBIBEGY IET B mug OA Ei Hn BRH u NM BM 3D uU i TN GN 3G 85 2 EE 1 mm mms i E E WBK E 2B Radio Memory 15A 2A BEERRID NEEREEEEENEENN E es b R R Kar LGN R i LE SES I 9 Tu E E Front a BK BN GY swa enoia POTETE ID O p p p oF EOM Pouer 15A 2E I 13 R Dirty m BK BE GY y To GND1 l lof BE GY 4B FuelPump 15A 4A 11 HE Fairing 10 EII O GY VON Y GN Harness 3 LAN IS o ee ee rx i BK 6 ARA z 4C 87 5 1 System BK l wer 40 s61 Relay 4 EEE NEED IE E HE Ah Ai U ee _ 1 GN O SC 85 2 E 0 HM MM m Inm oon ee ee JA mw 37 04 gt 1 1 De st W NM SY I u uni er 4 Rear GND GND2 O Stud JH BK GN gt Clean A 1B P amp A 15A 1A E 10 IN 1T o 1D INSTRS 15A To 9 EGN Y o R BK Fairing 8 mPNGN Ill Ignition 15A 2A 6 mues Eu T RR oe a 5 YW bi 1H Engine CNTRL 15A 1G m E T m oes ILI i 3 BE E 7 2 m BK R s 1 T IRIN FL TIT TTTT Tr nc dla Hendamp 19A 20 To p m BK as Pt Lights 15A Harness p BE BE i 15A A R O Lll o ee MIL A ood i 3H Spare15A 3G
3. 888 PS FUN om m u R GY 13 13 TN j R GY m 3H ao 3 GN m 4G 87 5 T Start fi BK R m 4H 86 1 YY Relay 1208 fo TN GN 3G 85 2 l LH GND Tr Stud En ei a GND 1A Dirty 131 A Neutral m Switch Front Powertrain Starter Dirty Grounds GND O 33B 33A Rear LE IGNITION SWITCH LEGEND GND 2 Front X INDICATES CONTINUITY GND 1 a EN LEAD WIRES Box H picid A ui SWITCH IN POSITION INDICATED gt sale Ignition POSITION RED RED RIB R BK Switch RED GRAY BLACK LOCK X 648 OFF X m er IGN x X X ACC X X Lighting Figure A 15 2008 FLHP and FLHPE DOMESTIC and INTERNATIONAL Models Starting and Charging Figure A 15 Figure A 15 2008 FLHP and FLHPE DOMESTIC and INTERNATIONAL Models 2008 FLHP and FLHPE DOMESTIC and INTERNATIONAL Models Starting and Charging Starting and Charging et00093 i Speedom
4. 1 Retaining pin 2 Rear seat bracket 3 Support post Figure 2 2 Seat Latch Police Models sm04695 Cap Air fitting Fastener 2 Air reservoir Fastener 2 Flat Washer Flange nut 2 Rubber bumper 2 ONO PHN 9 Seat 10 Seat bracket 11 Flange nut 2 12 Fastener 2 13 Acorn Nut 14 Seat bracket mount 15 Hex scrwe 16 Pivot bolt 17 Seat fairing 18 Retaining pin 19 Air spring 20 Nut 2 21 Set screw 22 Top plate 23 Fastener Figure 2 3 Air Seat Assembly 2008 FLT Police Service Chassis 2 5 SEAT REMOVAL 1 Remove air pressure from air spring and reservoir 2 See Figure 2 2 Standing on left side of motorcycle press down on rear of seat and pull pin 1 from post 3 on top plate See Figure 2 3 Remove front pivot bolt 16 and nut 13 4 Lift seat and bracket assembly from motorcycle 5 Remove two flange nuts 11 and hex screw 15 to release seat from seat bracket 10 6 Inspect two rubber bumpers 8 on seat bracket for cuts tears or general deterioration If damaged deteriorated or missing replace as follows a Remove old rubber bumper and discard b Moisten bead on new rubber bumper with soapy water Place rubber bumper into position at bottom of seat bracket Feed tail on bead up through hole in seat bracket Using a needle nose pliers grasp tail as close to bead as possible and then pull bead up through hole in seat
5. 20 35 138 241 AWARNING Do not exceed the motorcycle s Gross Vehicle Weight Rating GVWR or Gross Axle Weight Rating GAWR Exceeding these weight ratings can affect stability and handling which could result in death or serious injury 00016e 2 10 2008 FLT Police Service Chassis NOTE An AIR SUSPENSION PUMP AND GAUGE Part No HD 34633 is available at your Harley Davidson dealer 16 Observe air pressure gauge while filling If leakage occurs remove tubes and inspect ends for burrs or damage If either condition is found snip off end of tube and insert back into fitting 17 When air pressure remains constant install protective cap on air valve 18 Install saddlebags Tighten saddlebag front mounting bracket bolts to 60 96 in Ibs 6 8 10 8 Nm SADDLEBAGS LOCKSET Removal 1 Atinside of saddlebag lid remove hex nut internal tooth lockwasher cam hook and cam washer Remove jam nut and lock guide See Figure 2 9 2 At outside of saddlebag lid remove lockset See Figure 2 10 Installation 1 With cam stop facing outboard side of saddlebag lid install lockset into hole See Figure 2 10 2 Install lock guide over threaded body of lockset oriented with finger on inboard side of saddlebag lid and pointing toward bottom See Figure 2 9 Install jam nut and tighten to 30 45 in Ibs 3 4 5 1 Nm 4 Verify that groove in threaded stud of lockset is facing inboard side of saddleba
6. 4 Using internal hex remove the oil filter adapter Remove the oil cooler adapter and gasket See Figure 3 2 Installation NOTE Skip first step if hose fittings are already installed 1 Install hose fittings as follows a Install hose fittings until finger tight b Using wrench on flats rotate hose fittings an addi tional 2 3 turns 2 Position oil cooler adapter flange against oil filter mount Index tabs on flange engage a recess on each side of the oil filter mount oil outlet hole See Figure 3 3 3 Apply Loctite High Temperature Medium Strength Threadlocker 246 to threads of oil filter adapter With the internal hex on the outboard side thread oil filter adapter into oil filter mount Holding the oil cooler adapter to pre vent rotation tighten oil filter adapter to 18 22 ft lbs 24 4 29 8 Nm 4 Slide new clamp onto free end of return hose stamped COOLER BOTTOM Install hose on upper fitting of oil cooler adapter Crimp clamp using HOSE CLAMP PLIERS Part No HD 97087 65B 5 Slide new clamp onto free end of supply hose stamped COOLER TOP Install hose on lower fitting of oil cooler adapter Crimp clamp 6 Install new oil filter and check engine oil level See ENGINE OIL AND FILTER in the Touring Models Service Manual 7 Start engine and inspect oil cooler adapter fittings and hoses for leaks sm04713 Index tabs Adhesive gasket Socket screw 2 Inspection cover ROPS Fi
7. o ocoo ooooo 3 4 Installation 200 ee ee 3 4 Oil Cooler Adapter and Thermostat Replacement 3 4 Operations ass se lee ern ren 3 3 Removal oi ani RENE RES AUS 3 3 R Rear Marker Lights Installation coi eee eee 8 5 Marker Lights Replacement 8 5 Removal o eite iar i e ie Rab ae 8 5 S Saddlebag Hinge Replacement eee 2 11 Knob and Spring Latch 2 22 2220 2 12 L ckset ont wiper ie naar 2 11 Lockset Catch 2 222222 cece eee eee 2 11 Spring Latch Bracket 22222n 2er 2 13 Tether tev tee es 2 12 Tether Brackets nnan naaar cee eee eee 2 12 Scheduled Maintenance 00 00000 1 1 Seat Air Reservoir Installation 2 9 Air Reservoir Removal ooooocoooocooo 2 8 Air Spring Replacement ooccccccoccoo o 2 6 General Informati0M oooooooooooo 2 4 Seat Bracket Replacement o o oo ooo 2 7 Seat InstallatiOM oooooooooooo 2 6 Seat Removal 0 0000 cece eee eee 2 6 Service Aids Lubricants Greases Sealants 1 3 Service BulletinS o ooooooooooo o i l Service Preparation u un aaua cece eee eee i Service Wear Limits Generali er En en 3 2 Specifications Chassis u Oe RA iud RN ade 2 1 ENgINE ape a a arena 3 1 Quick Reference ee 1 1 SPX Kent Moore llssseee RII i Il System Fuses and Relays
8. 0 00 eee 8 3 T Tachometer Bracket FLHP E Installation iilo Ik p m 2 15 Remioval mdr atr Rev m ehe 2 14 B OMITTI 2 3 Trademarks Harley Davidson 2 222222 nern eee eee i l Referenced Products oooooococooooooo i Il V Vehicle Identification Number VIN 2 2 W Wiring Diagrams 2222er rennen nen A 7 INDEX NOTES VI INDEX INSIDE BACK COVER GOES HERE OUTSIDE BACK COVER GOES HERE
9. 208A 208B i i i i i i i i i i i i i Move Y BK wire to terminal 11 when using Whelen Siren Amplifier amp Air Horn function GY BK Right Hand Controls Off Aux Pursuit Switch Right Directional Switch Engine Off Run Switch Starter Switch Stoplamp Switch 22A gt ows 1 R BEm 2 GY m 3 WBK 4 WBNS 5 To Fairing 6 Harness 7 22B 8 BK BK R E ON amp GN RE 9 10 11 12 24A gt ows Yu BE mM wo PK BK 9 TN BK 10 mE FLHTP Only To Fairing Harness 24B GY Y BK a 2 3 4 wv 5 6 BKRE 7 8 Y BK 11 BK wm 12 Clutch Lockout Switch Siren Off Run Switch Headlamp Hi Lo Switch Left Directional Switch Horn Siren Switch Left Hand Controls Figure A 10 2008 FLHTP DOMESTIC and INTERNATIONAL Models Handlebar Switches Indicator Lamps Fairing Cap Switches and HFSM Antenna Figure A 10 Figure A 10 2008 FLHTP DOMESTIC and INTERNATIONAL Models 2008 FLHTP DOMESTIC and INTERNATIONAL Models Handlebar Switches Indicator Lamps Fairing Cap Switches and Handlebar Switches Indicator Lamps Fairing Cap Switches and HFSM Antenna HFSM Antenna et00013 ABS Control Module 166A gt gt 1668 pee i 1 m BK Rear brake input 3 3 ECU Solenoid ground 1 f PK BN Rear wheel sp
10. A SERERAREN i gt Receive Antenna 1 1 Y Br Xmit Antenna A 2 2 O Y ONE 1 Antenna A Xmit Antenna B 3 3 BK BK 2 Antenna B V Unused 4 4 u i y gt gt 208A 208B 209B 209A Hands Free Antenna Figure A 16 2008 FLHP and FLHPE DOMESTIC and INTERNATIONAL Models Handlebar Switches Indicator Lamps Tail Lamp Pursuit Lamps Directional Lamps Accessory Spot Switch Speedometer Tachometer and HFSM Antenna Figure A 16 Figure A 16 2008 FLHP and FLHPE DOMESTIC and INTERNATIONAL Models 2008 FLHP and FLHPE DOMESTIC and INTERNATIONAL Models Handlebar Switches Indicator Lamps Tail Lamp Pursuit Lamps Handlebar Switches Indicator Lamps Tail Lamp Pursuit Lamps Directional Lamps Accessory Spot Switch Speedometer Directional Lamps Accessory Spot Switch Speedometer Tachometer and HFSM Antenna Tachometer and HFSM Antenna et00090 UPS 54C UPS 64C Right front strobe bulb blue A POWER SUPPLY e EH 5 9 7 I V Use terminals and terminal housings supplied by Whelen for connections at power supply 4 CONTROL INPUT 257 A u h X Indicates unterminated strobe harness wires in fairing cavity on FLHTP models or headlight nacelle on FLHP models nit motorcycle de Power down circuit BE optional Existing pole lighting wire 22 Ga wires supplied
11. 1 Remove windshield See WINDSHIELD FLHR C in the Touring Models Service Manual 2 Remove Phillips screw at bottom of headlamp door chrome ring Remove headlamp door 3 Remove seven Phillips screws to free headlamp housing from headlamp nacelle 4 Remove headlamp connector at back of headlamp bulb Remove headlamp housing assembly from motorcycle 5 From inside the headlamp nacelle a Disconnect tachometer harness connector 20 6 place Deutsch See Figure 2 16 b Remove flange nut from weld stud to release chrome strip at top of nacelle c Catch Keps nut and flat washer while removing Phil lips screw from tab at front of handlebar clamp shroud 6 Carefully pry off the fork lock plate at the rear of the handlebar clamp shroud Remove two Phillips screws beneath the lock plate 7 Remove the handlebar clamp shroud from the motorcycle while gently pulling the tachometer harness conduit and connector out of the headlamp nacelle 8 Remove two acorn nuts with flat washers to release tachometer bracket from studs at top of handlebar clamp shroud NOTE Do not operate ABS equipped motorcycles with the tachometer removed While the ABS remains operational the rider will receive no warning if a malfunction occurs The means to report DTC s also will be eliminated 2 14 2008 FLT Police Service Chassis sm04707 FEN PS L5 Fo Figure 2 16 Disconnect Tac
12. 33 ju GY BE AA IEA E IE Cruise Resume Accelerate 34 34 EW BE SS a gt E ESI E Jg A A E E W BEi 5 Throttle Pos Sensor 2 36 36 att EEE IE UN de LN a OEE Eee Throttle Pos Sensor 1 37 37 Exhaust Feedback 38 38 ia VIBE zl d UI gsSil X 1 Twist Grip Sensor 2 39 39 L 8 1 Crank Position Sensor 43 43 Il BK m HI II L gt a GY a 8 Rear O2 Sensor Unheated 46 46 MM PK GN j ial Lj Intake Air Temperature 49 49 inca Ei nme 5V Sensor Power 1 50 50 p Engine Temperature 51 51 Bey A AP O O Twisted 12 V Power 52 52 rY GN Y GN Pair A es e o pea cor En En Y BE AA eee eee uiii LJ E HE TIT Jiffy Stand Sensor 56 56 B GN BN il j mmmmimummm n mu I BEJGN EL E MW II Twist Grip Sensor 1 59 59 i 5V Sensor Ground 61 61 pim AH 5 po 5V Sensor Ground 2 62 62 EE Ra crani Poor Sera e 65 lma E Vehicle Speed Ground 64 64 EBK Y 7 i a l 7 ee re HL IS EN 5V Sensor Power 2 68 68 R W Oo p o 12V Battery 71 71 IR BE GY 12V Run Stop Switch 72 72 E W BK m E S 1 A E gt p SS es A NE eem T_T eee eee LGN R ac z Ww 3 zZ os z 0 gt Q a6 Z gt Z gt m0x zc z gt LS 202 222 o 0 o o i79B gt gt 53 o 95B 1388 amp 137B 2 65B 55 1338 4 55 203FB gt S 203RB gt gt A 54321 BAJA A 12 A 12 A 123 A f 123 A 12 A 12
13. 45A 93A 93B i pairing Fairing l I arness Harness Left Rear 31RA E 31LA Direction O deu ums i BIRB x x z w S1LB x x gt u Al I tn cn m e a l Right I Pursuit I Lamp Blue O diii FLH Yo i l l l l Right Directional and DOM Running Lamp Figure A 8 2008 FLHTP DOMESTIC and INTERNATIONAL Models Pursuit Lamps Directional Lamps Tail Lamp and Fender Tip Lamps Figure A 8 Figure A 8 2008 FLHTP DOMESTIC and INTERNATIONAL Models Pursuit 2008 FLHTP DOMESTIC and INTERNATIONAL Models Pursuit Lamps Directional Lamps Tail Lamp and Fender Tip Lamps Lamps Directional Lamps Tail Lamp and Fender Tip Lamps et00070 208A 208B 209B 209A Hands Free HFSM N z vee lt lt ri Receive Antenna ooy Y Xmit Antenna A 2 2 OY O Y Xmit Antenna A odule Xmit Antenna B 3 3 BK BK Xmit Antenna B Unused 4 4 Turn Signal TSMTSSMHFSM i Battery 1 1 BN GY Turn Signa Ignition 2 2 cy ecurity Serial Data 3 3 La LGN V Module Neutral Switch 4 4 TN Starting System Start Relay Control 9 9 f TN GN Clutch Switch 10 10 E Bk A memm m Ground 12 12 B BK GN EEEEEEEEEEEEE mm Right Hand Controls gt gt 30A 30B 78A 78B ECM gt gt Serial Data 69 69 LGN V Engine Off Run Sw
14. BULB CHART 8 1 GENERAL The table below gives the bulb requirements for FLHTP and FLHP E police model motorcycles Table 8 1 Bulb Chart FLHTP FLHP E AWARNING The rear strobe is a source of high voltage and must be off at least 10 minutes before servicing Inadequate safety precautions may result in death or serious injury 00097a LAMP DESCRIPTION NUMBER OF BULBS CURRENT DRAW WATTAGE HARLEY DAVIDSON ALL LAMPS 12V REQUIRED AMPERAGE PART NUMBER Head Lamp Low Beam 1 4 58 55 68329 03 High Beam 5 00 60 Tail Stop Lamp Tail Lamp 1 0 59 6 68167 88 Stop Lamp 2 10 24 Turn Signal Lamp Front Running 2 2 25 0 59 27 7 68168 89 Rear 2 2 25 27 68572 64B Rear Fender Tip Lamp Rear Fender Tip Bulb 2 0 33 3 7 53439 79 Pursuit Lamp Left Red 1 2 5 30 68727 64A Right Blue 68728 64 Rear Strobe if provided N A 20 67598 88 Instrument Panel Lamps FLHTP Indicator Module with LEDs High Beam Indicator N A 0 05 N A 68859 07 Oil Pressure Indicator Neutral Indicator Turn Signal Indicator Gauge Lamps FLHTP Speedometer N A N A N A N A Tachometer Voltmeter 1 0 24 3 4 67445 00 Fuel Gauge Engine N A N A N A N A Pursuit fairing 1 0 08 1 1 68642 96 Instrument Gauge Lamps FLHP E Indicator Module with LEDs High Beam Indicator N A 0 05 N A 68113 99B Oil Pressure Indicator Neutral Indicator Turn Signal
15. Part No 99851 05 32 oz 0 95 liters Transmission drain plug torque 14 21 ft lbs 19 0 28 5 Nm Transmission filler plug dipstick torque 25 75 in Ibs 2 8 8 5 Nm Tire pressure and wear Pressure solo rider Front 36 psi 248 kPA Rear 36 40 psi 248 276 kPA Wear Replace if less than 1 32 in 0 8 mm of tread pattern Wheel spokes Spoke nipple torque 55 in Ibs 6 2 Nm minimum Brake fluid level D O T 4 hydraulic brake fluid part number 99953 99A 12 oz Fluid level from top of master cylinder reservoir Front 0 20 in 5 0 mm Rear 0 26 in 6 5 mm Master cylinder reservoir cover screw torque Front 7 10 in Ibs 0 8 1 1 Nm Rear 12 15 in Ibs 1 4 1 7 Nm Brake pads and discs Minimum brake pad thickness 0 016 in 0 4 mm Brake caliper pad pin torque 75 102 in Ibs 8 5 11 5 Nm Minimum brake disc thickness Front 0 18 in 4 5 mm Rear 0 25 in 6 3 mm Maximum brake disc lateral runout warpage 0 008 in 0 2 mm Drive belt deflection Upward force applied at midpoint of bottom belt strand 10 Ib 4 5 kg FLHTP 3 8 7 16 in 9 5 11 1 mm FLHP FLHPE 1 4 5 16 in 6 4 7 9 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 Ibs 4 1 6 8 Nm Air cleaner cover screw Threadlocker LOCTITE MEDIUM STRENGTH THREADLOCKER 243 BLUE Part N
16. 12 Fill air reservoirto 40 psi 275 8 kPa then add or remove pressure to the rider s comfort Install protective cap on air valve See Figure 2 5 NOTE To set minimum air pressure have rider sit on seat and bounce to simulate riding conditions Visually check for any contact between air spring and frame components Add air as neces sary 13 Observe air pressure gauge If leakage occurs then remove tube and inspect end for burrs or damage If either condition is found snip off end of tube and insert back into fitting 14 Depress collar on compression fitting of each shock and insert air tube until it bottoms Gently tug on tube to verify that it is locked in place CAUTION Do not exceed maximum air pressure for rear suspension Air components fill rapidly Therefore use low air line pressure Failure to do so may result in possible damage to components 00165a NOTE Initial suspension fill pressure for a normally equipped police motorcycle is 25 psi 172 4 kPa 15 Fill shocks to 25 psi 172 4 kPa then add or remove pressure to the rider s comfort Refer to Table 2 8 2008 FLT Police Service Chassis 2 9 Table 2 8 Rear Air Suspension Pressures SHOCK LOADING RECOMMENDED PRESSURES PSI 0 35 kPa 0 241 Solo rider up to 150 lbs 68 kg 0 0 Solo rider 150 200 lbs 68 91 kg 0 10 0 69 Solo rider 200 250 lbs 91 113 kg 5 15 35 103 Maximum GVWR see 2 1 SPECIFIC ATIONS CHASSIS
17. 2 EHE E Y 3 1Y Gay YO 123 Y ri Tum Food 6 IN BN mea mm sco Y 233 Mal 211288 Y ir NE 160Ble gt r 33B Right Turn SW Input 7 7 EWBNE ee 141B TOP Gon xy x BATT 5B amp amp 77B oct 33B Left Turn SW Input 8 8 EW V i Fuel Pump o 55 123 cac Start Relay Control 9 9 ka TN GN Of i Clutch Switch 10 e Assembly Intank amp a Alarm Signal 11 11 kLGN BN ee A te l mE Ground 12 12 BK GN Em gt Z z gt z S2 S Turn Signal 30A 30B Gz x soo Te AN Turn Signal Security GY 3B i ea 1B Cruise Brake 15A 1A Module i P 1234 Mee eed O 1D Accessory 15A 1C DR EE E TI 1234 See mr a E EEE m GN 0 y 13A 623 1F P amp A 15A o EET EM F I E Radio Power EEEEEBKGNEEEEEEEE un y E 1H Siren 15A Police Stealth o non e UE Amber cap removed a when stealth switch I sars TT L E O m GN m 46 87 5H start Option is used c I een a a Y A I qmi 2 BK R Relay i 2 Dee _ IE a ee 8 8 H s TN GN 3G 85 2 m o E EEEE OO EE E 1 tc dam WBK i E 2B Radio Memory 15A 2A coc 207A EBEERERRDK ERE E R O R LGN R a m m 2D Battery 15A 2C i 131 O EN BILE pF P BN GY n 1 3 Y z swa enoa TTT TT Lom EY gore Dirty O BK r i E BE GY R O BE GY 4B Fuel Pump 15A 4A Png eo TTT ae von Fairing 10
18. 2008 Police Models right front frame downtube NOTE See 2 3 TIRES for important information regarding tire data and tire inflation Table 2 4 Rear Air Suspension Pressures ITEM FLHTP FLHP IN MM IN MM Wheel base 63 5 1612 9 63 5 1612 9 Overall length 93 7 2380 93 7 2380 Overall width 39 0 990 6 34 5 876 3 Road clearance 5 1 129 5 5 1 129 5 Overall height 61 0 1549 4 55 1 1399 5 Saddle height 27 3 693 4 27 3 693 4 With 180 Ib 81 7 kg rider on seat SHOCK LOADING RECOMMENDED PRESSURES PSI 0 35 kPa 0 241 Solo rider up to 150 Ibs 68 kg 0 0 Solo rider 150 200 Ibs 68 91 kg 0 10 0 69 Solo rider 200 250 Ibs 91 113 kg 5 15 35 103 At maximum GVWR 20 35 138 241 NOTE Initial suspension fill pressure for a normally equipped police motorcycle is 25 psi 172 4 kPa 2008 FLT Police Service Chassis 2 1 VEHICLE IDENTIFICATION NUMBER V I N 2 2 GENERAL Sample V I N as it appears on the steering head 1HD1FHM137Y110000 See Figure 2 1 The full 17 digit serial number or Vehicle Identification Number V I N is stamped on the right side of Sample abbreviated V I N as it appears on the crankcase the frame backbone at the rear of the steering head and under FHM7110000 the main harness conduit A label bearing the V I N code is NOTE also affixed to the left side of the steering head An abbreviated V I N is stampe
19. 4 1 7 Nm 1 1 SCHEDULED MAINTENANCE General rear Oil cooler adapter inspection cover 90 120 in Ibs 10 2 13 6 Nm 3 3 OIL COOLER Cleaning and Inspection Use socket screws Loctite Medium Strength Threadlocker 243 blue Oil Cooler mounting bracket flange nuts 70 100 in Ibs 7 9 11 3 Nm 13 3 OIL COOLER Installation Oil filter adapter 18 22 ft lbs 24 4 29 8 Nm 3 3 OIL COOLER Oil Cooler Adapter and Thermo stat Replacement Apply Loctite High Temper ature Medium Strength Threadlocker 246 Primary chaincase drain plug 14 21 ft lbs 19 0 28 5 Nm 1 1 SCHEDULED MAINTENANCE General Saddlebag lockset hex nut 25 35 in Ibs 2 8 4 0 Nm 2 6 SADDLEBAGS Lockset Saddlebag lockset jam nut 30 45 in Ibs 3 4 5 1 Nm 2 6 SADDLEBAGS Lockset Saddlebag mounting bracket hex bolt 60 96 in Ibs 6 8 10 8 Nm 2 5 AIR SEAT RESERVOIR Installation Saddlebag tether T15 TORX screw 20 25 in Ibs 2 3 2 8 Nm 2 6 SADDLEBAGS Tether Use Loctite High Strength Threadlocker 262 red TORQUE VALUES 2008 FLT Police Models Service Manual Supplement FASTENER TORQUE VALUE NOTES Seat bracket mount fasteners 15 20 ft lbs 20 3 27 1 Nm 2 4 SEAT Seat Bracket Mount Replacement Seat fairing fastener 60 120 in Ibs 6 8 13 6 Nm 2 4 SEAT Seat Installation Seat fairing fastener 60 120 in Ibs 6 8 13 6 Nm 2 4 SEAT Air Spring Replacement Seat hex screw front 60 120 in Ibs 6 8 13 6 Nm 2 4 SEAT Seat Installation Sea
20. 8 F GY BK pP 9 j Control Ee S iu e e o 1D INSTRS 15A 22B s Ewen 1 Jm o RIBK x II BK 4 EWIBK El E IN LII 1F Ignition 15A e oe 3 E GY a E BIN HE A ay ak u HEE 2 B R BE Ennn 1 Fow 1H Engine CNTRL 15A 1G Sean 126B LGN R i 588 V 11m V PK 2D Headlamp 15A 2C i Y 10 F TN BK BE R BK Va m 9 PK BK i me A JL LLL C LE noon 7 B BK R BE ightin AES 5 ves A OOOO ee ee NI mni l Relay GY Ew s E 3 i BE E l 4B Spare 15A ya l 24B IT a su FE Spare 15A I EN gt pare 1 al j m BK 2 He To Siren 2F amp PK BK R Y i 3 a Amplifier 1F a TN BK gt 42 d i ON h4 ae 1D EE 10 V PK m l H 72B Horn EX a 5 BK en ax E u 298 2 x a ae IL 1 A R BE Does sca lan l A a gt a 1 38B os E Ho H 5 C x c e szi l AE ey TA Bale ALEA le MA gues BAR e im aua TA m SeA yg ae el Je e hallo on ne eni eine Headlamp Fender HDI S 122 i Neutral 120B Rear vhesa yle Lies sez Jy P nye SE aie FIDE d Tip Lamp Lamp gt gt Switch Stop Light Accessory Accessory To Rear Lighting 131 Switch Connector Switch 121 Figure A 12 2008 FLHP and FLHPE DOMESTIC and INTERNATIONAL Models Main Harness without ABS 1 of 2 Figure A 12 Figure A 12 2008 FLHP and FLHPE DOMESTIC and INTERNATIONAL Models 2008 FLHP and FLHPE DOMESTIC and INTERNATIONAL Models Main Harness without ABS 1 of 2 Main Harness wi
21. Indicator 2008 FLT Police Service Electrical 8 1 Table 8 1 Bulb Chart FLHTP FLHP E LAMP DESCRIPTION NUMBER OF BULBS CURRENT DRAW WATTAGE HARLEY DAVIDSON ALL LAMPS 12V REQUIRED AMPERAGE PART NUMBER Fuel Gauge N A N A N A N A Speedometer Odometer Engine Pursuit LED illuminated LEDs are not repairable Assembly must be replaced if LED fails 8 2 2008 FLT Police Service Electrical SYSTEM FUSES AND RELAYS 8 2 Removal Always use replacement fuses that are of the correct type 1 Verify that the Ignition Light Key Switch is turned to the and amperage rating Use of incorrect fuses can result in OFF position damage to electrical systems 00222a 2 3 See Figure 8 1 Remove wing nut style bolt to release Remove left side saddlebag bottom of siren amplifier mounting bracket from clamp on saddlebag guard Rotate bracket upward to gain complete access to side cover area Loosen top bolt if necessary 4 Gently pull side cover from frame downtubes no tools required Exercise caution to avoid scratching side cover on amplifier mounting bracket 5 Raise the fuse block cover NOTE The fuse block cover has a fuse puller attachment that may be used to remove fuses 6 Remove fuse from fuse block and inspect the element 7 See Figure 8 2 to identify fuse location Replace fuse if element is burned or broken Au
22. Lyall Bottom of voltage regulator left side 57 Siren PA speaker 2 place Deutsch Top rail of engine guard right side 59 Rear pole lamp 2 place Deutsch Under luggage rack left side 64 Fuse block Packard Under left side cover 65 VSS 3 place Delphi Top of transmission case under Starter 67 Accessory switch 4 place Amp Inside headlamp nacelle 69 Pursuit flasher domestic only Relay connector Inside headlamp nacelle 72 Siren amplifier 18 place Packard Top rail of saddlebag guard left side 73 Pursuit lamps 2 place Multilock white Inside headlamp nacelle 77 Voltage regulator 2 place Lyall Bottom of voltage regulator right side 78 ECM 73 place Packard Under right side cover 79 CKP sensor 2 place Deutsch Electrical caddy at bottom of lower frame crossmember 80 MAP sensor 3 place Packard Top of induction module 83 Ignition coil 4 place Delphi Below fuel tank left side 84 Front injector 2 place Delphi Below fuel tank left side 85 Rear injector 2 place Delphi Below fuel tank left side 87 IAC 4 place Delphi Below fuel tank right side 88 TP sensor 3 place Delphi Below fuel tank right side 89 IAT sensor 2 place Delphi Below fuel tank right side 90 ET sensor 2 place Delphi Back of Front Cylinder left side 91 Data link 4 place Deutsch Under right side cover 93 Tail lamp 4 place Multilock Circuit board under tail lamp assembly 94 Rear fender lights harness to circuit board 6
23. Service Appendix A Wiring INDEX TO WIRING DIAGRAMS A 2 WIRING DIAGRAM INFORMATION Wire Color Codes Wire traces on wiring diagrams are labeled with alpha codes Refer to Table A 3 For Solid Color Wires See Figure A 3 The alpha code ed01269 Y identifies wire color 3 gt For Striped Wires The code is written with a slash between 2 the solid color code and the stripe code 4 For example a z F trace labeled GN Y is a green wire with a yellow stripe era y O ll Wiring Diagram Symbols ip Y 3 instructions connectors are identified by a number in brackets 1 The letter 2 inside the brackets identifies whether the housing is a socket or pin housing N See Figure A 3 On wiring diagrams and in service repair gt RSS A Pin The letter A after a connector number and the pin 10 symbol 6 identifies a pin housing B Socket The letter B after a connector number and the socket symbol 5 identifies a socket housing Other symbols found on the wiring diagrams include the symbol for a diode 7 a symbol for a wire to wire connection 8 a 1 Connector number symbol that verifies that no connection 9 between two wire 2 Terminal code A pin B socket traces exists and a symbol identifying two wires that are twisted 3 Solid wire color together 10 4 Striped wire color 5 Socket symbol 6 Pin symbol 7 Diode 8 Connection 9 No connection 10 T
24. fail ACR STATUS PSI kN m2 Connected 130 170 896 1 173 Disconnected 200 220 1 379 1 517 ma DIAGNOSTICS PART NUMBER TOOL NAME ET 95 HD 41404 B TEST CONNECTOR KIT PS ACR 19 19 m V GY HD 48637 BREAK OUT BOX Diagnostic Tips Refer to flow charts that follow for troubleshooting Diagnostic Notes The step numbers below correlate with the circled numbers in the flow chart 1 Use TEST CONNECTOR KIT Part No HD 41404 B with NOTE gray terminal probes and patch cords 2 Connect BREAK OUT BOX Part No HD 48637 to ECM Table 8 3 Connectors Fuse in ACR Circuit COMA m ex ESSIG 1 VIGY Y GN IGY gt gt 203FB AD 3 A 203RB Figure 8 14 ACR Circuit NUMBER DESCRIPTION TYPE LOCATION 78 ECM 73 place Delphi Under seat 203F ACR 2 place Amp Tyco Between cylinders 203R ACR 2 place Amp Tyco Between cylinders 119 System relay Lugs ESPFI fuse block 8 12 2008 FLT Police Service Electrical ACR Diagnostics Part 1 of 2 Is battery voltage 12 6 VDC or higher YES Perform starter current draw test while cranking engine at room temperature Remove system relay and repeat starter current draw test Is current draw 20 40 Amps greater with system relay removed Charge battery YES Review symptoms Issue i
25. m mm Y GN Harness Oi BE GY 3D 30 3 pal ASEO RA 4C 87 5 System BK 8 HH 5 7 W BK 4D 86 N Relay 4 A I 2 E E 3 P IN mE LL u u 4 i e E H A Rear GND__ GND if Stud BK GN Clean mu n 12 n Bun Mr 1D INSTRS 15A a To 4 NON AM ul Ignition 15A c or c Ware Pam ii 6 creas 2A YN Di 1 1H Engine CNTRL 15A 1G ezexz 126B GY j BN GY LGN R 0M 0 A A E BEE E T an a 1 ooo LE U E DEE E 1 2D Headlamp 15A 2C j pa Wu A il is Mens us se ur Fairing 2F Lights 15A Harness p BE I BE Relay 15A A R O El A SE oodd 4 3H Spare 15A 3G a BK gt 1 15B 4g Spare 30A gn pom f H J 1 ABS Only F x RIY 2B 30 3 SAN ile el T CI Sedet pae al Tl H Ei 3 BK 1 L bs E es orn x HH A 5 2H oil N A IM ne 4A S50 ral x feu A 3 gt SER 7A lle enger B BN GN Bin m Bi mum mum No 1394 A EONY Br Neutral Rear virizs4 Alsz1 Lies ser ly ile gt in Switch Stop Light Accessory Tour Pak To Rear Lighting 139B 131 Switch Connector 12A 121 Figure A 4 2008 FLHTP DOMESTIC and INTERNATIONAL Models Main Harness without ABS 1 of 2 Figure A 4 Figure A 4 2008 FLHTP DOMESTIC and INTERNATIONAL Models Main 2008 FLHTP DOMESTIC and INTERNATIONAL Models Main Harness without ABS 1 of 2 Harness without ABS 1 of 2 et00068 To Main Harn
26. nn E 4 u I ZEE Ti t 1 T mn U O I omo Mein Tiu a ER sc m g Harness 15B gt Bk 2 c 15A of 558 LN 39B 56789 1l 1088 2 45567 99A 56789 11 108A 1 2 Io Cigar BK Lighter BK GY Bk x 132B 132A z A EET E EET ua Romx 10 LH Front Turn Signal Odometer Reset Switch 154A Speedometer Tachometer Figure A 7 2008 FLHTP DOMESTIC and INTERNATIONAL Models Interconnect Harness Figure A 7 Figure A 7 2008 FLHTP DOMESTIC and INTERNATIONAL Models 2008 FLHTP DOMESTIC and INTERNATIONAL Models Interconnect Harness Interconnect Harness et00071 73RB From Main IN ES LUE Rear Lighting 7B Vel gi giu A Right Rear From V BN Directional Fairing Lamp Harness 68772 06 BK 32A Y 32B 55 pee Tail Lamp 94B Brake Light 654321 A Fender Tip Lamp 143B 143A 654321 DOM Only lt lt 19B lt lt 94A C3 ON M cowzijdmpow ven i 19A BK BKE 2 2 BK BKE 2 2 gmm License 18A Running Light DOM ny Plate Lamp 18B O Hg HDI Only 55 V BNB 1 1 BKE 2 E Running Light HDI x 4 4 mer En ae E da BK 2 EOw gt ender Tip Lamp 3 3 1 1 EBEW BK DOM Only a H lt lt gt gt From From i 45B
27. stamp reading COOLER TOP With the script facing upward install hose onto top fitting of oil cooler Crimp clamp NOTE If the paint stamps are not present the long hose is the return and the short hose is the supply Install both hoses so that the 90 bend goes to the oil cooler adapter 4 Slide threaded studs at bottom of oil cooler through holes in mounting bracket Install flat washers and flange nuts on studs Alternately tighten flange nuts to 70 100 in Ibs 7 9 11 3 Nm 5 Slide new clamp onto free end of return hose stamped COOLER BOTTOM Install hose on upper fitting of oil cooler adapter Crimp clamp using HOSE CLAMP PLIERS Part No HD 97087 65B 3 4 2008 FLT Police Service Engine 6 Slide new clamp onto free end of supply hose stamped COOLER TOP Install hose on lower fitting of oil cooler adapter Crimp clamp 7 Check engine oil level See ENGINE OIL AND FILTER in the Touring Models Service Manual OIL COOLER ADAPTER AND THERMOSTAT REPLACEMENT PART NUMBER HD 97087 65B TOOL NAME HOSE CLAMP PLIERS Removal NOTE A faulty thermostat requires replacement of the oil cooler adapter 1 Place a suitable drain pan beneath the oil cooler and oil filter 2 Using a side cutters cut and remove clamps on oil cooler adapter side of supply and return hoses Pull hoses from fittings 3 Remove the engine oil filter See ENGINE OIL AND FILTER in the Touring Models Service Manual
28. z 1B Cruise Brake 15A 1A ow R GY O W fat m a a is l l ia l T S ji E E Yie U U igi Y 5 9 eS PE eee ee n A I l1 Police Stealth D GN Amber cap removed S BK R when stealth switch I i um m mum m DEI CEELI m um TN GN i option is used 1 na m i a p i i EEE EE L 2A R Ms 1 m m Re T Battery 15A ce 207A I cl nil E duals zz BN GY R i 5 a LGN R IF BE GY 2F ECM Power 15A ajy Pursuit S 13A 7 LL Ir mmm aps R Bay Lamps 2 Ju GY BN Front GND i i w t Row sud nor ET 3 QE E Er E EHE Dirty f l c 69A gt gt 69B GND1 u z 4B FuelPump 15A 4A Pursuit M chai pn O GY Y GN i i o 2 a civ i _____ i NENNEN ERN i 3 E GY BN I e al ae d System Pole gt 59B E hd BUB Relay E Lanes emek GN O mm 30 85 2 ame ein Jr puo 22B Stud Ojem BK GN pa 9 B GN R Clean ano 18 P amp A 2A 1A D Right Hand
29. 06 V AB v X8 V V N 1234 90A Y 123456 Y ABCD Y as Y as Y 1234 Y 654321 TE IU m m TW YT MA z2 Y 204B gt gt 2220 B3B LABOD 85B zz 848 gz 8608 234 218 mr GY 23 Y AB 3 gt 32 Z u w O 2 gt F23Z 20rOxrZz SN 908 LAS m m gagy ggas Ga GNSS ECM 78A gt gt 78B gt O aa amp d A gt dl WE Rd po e I ACR 19 19 IR V GY ne EEE EEE l Purge Solenoid 20 20 GY Y EO Exhaust Actuator 21 21 ka V O T E Ss Cruise Set Coast 22 22 ONE a 5 n m _ _ BE BK 44 Rear Injector 23 23 SS TMAP Sensor Input 24 24 VW m z EEE N E p on TI IT I Tr System Relay Enable 27 27 EGN O lt E e SS GNOsz25 Front Injector 28 28 EW Y E PE 5 55 A p yg E Twist Grip High 29 29 E BK O EEE Fre a gt LT L 2 0 I BK GN BB E L0 M a a LL D ill pun Sn lon Sense 33 33 Im GY BE a m Cl i E ee Cruise Resume Accelerate 34 34 EW BE E cae Heli gt EE Cruise Enable 35 35 R GN s az Throttle Pos Sensor 2 36 36 att ee ee LLLI SS Throttle Pos Sensor 1 37 37 Exhaust Feedback 38 38 ia VIBE zb eee ESA Twist Grip Sensor 2 39 39 a Vehicle Speed Input 40 40 EW GN E E _ gt gt o n LGNN Crank Position Sensor 43 43 Il BK m p _ BERRRER Rear Oz Sensor Unheated 46 46 PK GN EBEN a Int
30. 2 Purge Front Rear Vehicle Jiffy Stand Front Rear xhaus Speed ensor HDI Only Solenoid O Sensor O Sensor ar HDI Only ACR ACR From Main Harness Page 1 Figure A 6 2008 FLHTP DOMESTIC and INTERNATIONAL Models Main Harness 2 of 2 Figure A 6 Figure A 6 2008 FLHTP DOMESTIC and INTERNATIONAL Models Main 2008 FLHTP DOMESTIC and INTERNATIONAL Models Main Harness 2 of 2 Harness 2 of 2 et00088 Front Fender To Siren Amplifier bru BK Voltmeter Headlamp 32A Triple Clamp x z a YI 10B ND 3 gt ZO 88A Lo Beam YG af A a SE 5 Es Vi y 111A Hi_Beam Y rf Yi 11B xs ox 3 m BK ND HDI Onl m d nly 38B T p ES 1 bow _ SU d LA E T To 3 m GY glas Ee L 31 Controls 6 f BK R E m 1A 7 BON 22A 8 GY BK es E EEE U U EI I U EEE gt BK 9 B GN R LGN V 13 wv 3 11 gt weg Main 22B Harness 7 WIBKS 6 A LA ______ a PS haue DU SRE To ase i iis Oe _ Cm T 1i Controls d I ne nn 24A 5 Wi L I FH mu Le 4 GY 3 dr To Harness 2B 5 PA PO ME O EEE
31. 3 27 1 Nm 2 Install seat and insert pin into post on top plate of air spring See 2 4 SEAT Seat Installation 2008 FLT Police Service Chassis 2 7 AIR SEAT RESERVOIR 2 5 REMOVAL Remove both saddlebags 2 On the right side of the motorcycle locate the air seat reservoir air valve under the luggage rack and on the left side the rear shock air valve just below the chrome frame cover See Figure 2 5 and Figure 2 6 AWARNING Use caution when bleeding air from the suspension Moisture combined with lubricant may leak onto the rear wheel tire and or brake components and adversely affect traction which could result in death or serious injury 00084a om00465 _ Air reservoir Air pressure gauge 3 Seat air valve N Figure 2 5 Seat Air Valve Police Models 2 8 2008 FLT Police Service Chassis om00282 Figure 2 6 Rear Air Suspension Air Valve sm04700 Figure 2 7 Raise Luggage Rack Remove protective cap from each air valve and depress pin to bleed air from both reservoir and shocks To purge rear air suspension lines of any oil add 3 5 psi 20 7 34 5 kPa before releasing air Depress collar on each compres sion fitting and pull out air tube Remove bolt with flat washer to remove saddlebag front mounting bracket from chrome frame tube cover Remove Phillips screw and chrome frame tube cover Repeat step on opp
32. 39 5 27 50HMS Harness y SU d PK BK amp 9 facer 41A Empty 280 0040 0 OHMS I Ww High nenn Left jd BK jiii Beam m i a aaa Y BK 11 fee Fuel Pump Assembly In Tank i 7 Left BK 12 I Red i BK y Turn i 7 Clutch 73B T fei EE n RN MEE RI il Lockout Switch 21 A Dan pear i Siren Off Run i Switch To odul HESM gt um Headlamp Hilo Main i f BK Saite Harness For Turn Signal amp Security Module From Main Harness Left TSM TSSM i 94B Brake Ligt eee 3 Directional pc EN i UE Horn Siren Switch 80A gt i Switch E odes FE 1 1 i Batey 4 MERE A 9A 9a Lett Hand i ontrols Ignition 2 i 18B lt O HDI Only j al i VSS Serial Data Link 3 VENH Ts Tail Taillamp 67A Neutral Switch 4 BK 2 2 I DOM Only Left Turn Feed 5 akaa ia 3 l4 m c E 678 Y 12 1234 4 i Right Turn Feed 6 BK 3 A qur Right Turn Switch Input 7 i lt Z Fendertip Lamp DOM i Rear view of toggle amp Ul i Left Turn Switch Input 8 45B 45A gt 93A gt 93B License Plate Lamp HDI switch with Start Relay Control 9 BK Left R BK On Normally Closed Clutch Switch 10 V BN el i diri AE m cAW f Kommen l Alarm Signal 11 BK Lamp i Ground gt camp Normally Open Ground 12 Off Keyway Down al i Accessory Switch
33. A Wiring A 5 Table A 2 FLHP E Wire Harness Connectors NO DESCRIPTION TYPE LOCATION 143 Front fender tip lamp DOM 2 place Multilock black Under front fender tip lamp bracket 160 B 1 place Packard Upper frame cross member under seat 166 ABS module 20 place Molex Under right side cover 167 Front wheel speed sensor 2 place Amp Tyco Inside headlamp nacelle left side 168 Rear wheel speed sensor 2 place Amp Tyco Under right side cover 173 Rear marker lights harness 3 place Multilock Inboard of left upper frame tube 176 Main to main harness 4 place Deutsch Under left side cover beneath harness 178 Active intake solenoid 2 place Amp Tyco Back of air cleaner backplate 179 Active exhaust actuator 5 place Amp Tyco Domestic not used under right side HDI under right side cover behind elec trical bracket 177 Main to main harness 2 place Deutsch Inside headlamp nacelle left side 201 ABS diode pack 4 place Deutsch Under right side cover 203F ACR solenoid 2 place Amp Tyco Between cylinders 203R ACR solenoid 2 place Amp Tyco Between cylinders 204 Twist Grip sensor 6 place Molex Inside Headlamp Nacelle 207 Stealth disable lighting circuit 3 place Molex Inside headlamp nacelle 211 Throttle Control Actuator 6 place Molex Throttle body 222 Ignition switch interconnect 4 place Packard Under the seat A 6 2008 FLT Police
34. ACR SOLENOID SOCKET 8 5 AUTOMATIC COMPRESSION RELEASE Removal HD 48637 BREAK OUT BOX 8 5 AUTOMATIC COMPRESSION RELEASE Dia gnostics HD 97087 65B HOSE CLAMP PLIERS 3 3 OIL COOLER Installation TOOLS NOTES II TOOLS 2008 FLT Police Models Service Manual Supplement FASTENER TORQUE VALUE NOTES Air cleaner cover bracket screw 40 60 in Ibs 4 5 6 8 Nm 1 1 SCHEDULED MAINTENANCE General Air cleaner cover screw 36 60 in Ibs 4 1 6 8 Nm 1 1 SCHEDULED MAINTENANCE General Air reservoir bracket rear top Phillips 20 30 in Ibs 2 3 3 4 Nm 2 5 AIR SEAT RESERVOIR Installation screws Air reservoir bracket rear top Phillips 20 30 in Ibs 2 3 3 4 Nm 2 5 AIR SEAT RESERVOIR Installation screws Air spring set screw flange nuts 50 70 in Ibs 5 7 7 9 Nm 12 4 SEAT Air Spring Replacement Air spring top plate fasteners 36 60 in Ibs 4 1 6 8 Nm 2 4 SEAT Air Spring Replacement Automatic compression release ACR 11 15 ft lbs 14 9 20 3 Nm 8 5 AUTOMATIC COMPRESSION RELEASE Installation Apply three equally spaced dots of LOCTITE 246 THREADLOCKER MEDIUM STRENGTH HIGH TEMPERATURE around lower third of threads Battery cable terminal bolt 10 mm 60 96 in Ibs 6 8 10 9 Nm 2 4 SEAT Air Spring Replacement Battery hold down clamp T40 TORX 15 20 ft lbs 20 27 Nm 2 4 SEAT Air Spring Replacement screw Battery terminal bolt 60 96
35. Capturing conduit about 1 4 in 6 mm from end securely tighten cable strap to draw conduit to bracket Remove any excess cable strap material 9 On opposite side install second 7 inch cable strap cap turing conduit and wire splices Securely tighten cable strap to draw splices to conduit Remove any excess cable strap material 10 Route wire bundle to upper switch housing in channel next to angular arm of bracket Secure bundle to arm placing new cable strap 1 4 in 6 mm from end of conduit Cut any excess cable strap material If necessary bend 11 angular arm of bracket downward to firmly secure Front Stoplight Switch in installed position See HANDLEBAR SWITCH ASSEMBLIES in the Touring Models Service Manual ed01650 1 7 cable strap 2 Bracket 3 Right turn signal switch Figure 8 7 Hole Location Cable Strap Switch Bracket 2008 FLT Police Service Electrical 8 9 AUTOMATIC COMPRESSION RELEASE GENERAL See Figure 8 8 The Automatic Compression Release ACR is opened and closed by the ECM to assist starting See Figure 8 9 When open compressed gases are released through the exhaust port REMOVAL PART NUMBER TOOL NAME HD 48498 ACR SOLENOID SOCKET 1 While preparing motorcycle for service separate the ACR rear 203R and front 203F connectors from the main wiring harness Remove the rocker cover and the rocker box See STRIPPING MOTORCYCLE FOR SERVICE an
36. FLHP and FLHPE DOMESTIC and INTERNATIONAL Models Main Harness 2 of 2 Figure A 14 2008 FLHP and FLHPE DOMESTIC and INTERNATIONAL Models Starting and Charging Figure A 15 2008 FLHP and FLHPE DOMESTIC and INTERNATIONAL Models Handlebar Switches Indicator Lamps Figure A 16 Tail Lamp Pursuit Lamps Directional Lamps Accessory Spot Switch Speedometer Tachometer and HFSM Antenna 2008 FLHTP FLHP and FLHPE DOMESTIC and INTERNATIONAL Models Optional Strobe System Figure A 17 A 8 2008 FLT Police Service Appendix A Wiring et00067 Ta i Poe ea i Qptional i ecurity m l f Ignition Battery 1 jh BN GY 141A 1 Siren Ig a Main Power 40 Amp Voltage B Switch Ignition 2 2 fa GY po pu TSC Snol at Starter MAXIFUSE Regulator Connector 33A Neat Data
37. HARLEY DAVIDSON 2008 FLT Police Models Service Manual Supplement ALL RIGHTS RESERVED 99483 08SP VISIT THE HARLEY DAVIDSON WEB SITE ABOUT THIS MANUAL GENERAL PREPARATION FOR SERVICE This Service Manual Supplement has been designed to be used with the current Service Manual and 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 professional Harley Davidson Technician the latest field tested and factory approved major repair methods We sincerely believe that this Service Manual Sup plement will make your association with Harley Davidson products more pleasant and profitable NOTE This Service Manual Supplement provides information unique to this model motorcycle Any information not presented in this supplement can be found in the appropriate Service Manual or Electrical Diagnostic Manual HOW TO USE YOUR SERVICE MANUAL SUPPLEMENT 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 z o CHAPTER Maintenance Chassis Engine Fuel System Electric Starter Drive Transmission Electrical Appendix A Wiring W gt 0 J O UOI A O
38. INI Appendix B Glossary For example a cross reference shown as 2 1 SPECIFICA TIONS refers to chapter 2 CHASSIS heading 2 1 SPECIFIC ATIONS If the subject you seek is not in this supplement refer to the corresponding section in the appropriate Service Manual Check the title page located in the front of each section to find the subject For quick and easy reference all pages contain a section number followed by a page number For example page 3 5 refers to page 5 in section 3 In figure legends the number following the name of a part indicates the quantity necessary for one complete assembly AWARNING 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 00002a 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 disa
39. KM Engine oil and filter Replace 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 x x X X X X tread Wheel spokes Check tightness x x x 1 Primary chaincase lubricant Replace x x X Transmission lubricant Replace X X Clutch Check adjustment x x X X X x 1 Drive belt and compensator Inspect adjust belt x x X X X 1 sprocket Compensator sprocket isol Inspect for wear 5 ators Brake and clutch controls Check adjust and lubricate x X X 1 Jiffy stand Inspect and lubricate X X X X X X 1 Fuel lines and fittings Inspect for leaks X X X 1 Fuel tank filter Replace X 1 Brake fluid Check levels and condition X X X X X X 4 Brake pads and discs Inspect for wear X X X X Spark plugs Inspect x x X X X Replace X Electrical equipment and Check operation X X X X X X switches Front fork oil Replace 1 2 Steering head bearings Lubricate X X X 2 Adjust X 1 Air suspension Check pressure operation X X X X X X 1 and leakage Windshield bushings if Inspect X X 1 applicable Fuel door Tour Pak saddle Lubricate hinges and latches X X X X X X bags Critical fasteners Check tightness x x X 1 Engine mounts and Inspect check tightness X 1 stablizers Battery Check battery and clean 3 connections Exhaust system Inspect for leaks cracks and X X X X X X 3 loose or missing fasteners or heat shields Road test Verify component and X X X X X X System functions NO
40. ONTENTS TABLE OF CONTENTS i um een 8 10 COMPBISSSION Tesauro 8 11 ittee e ee 8 12 Diagnostie Tips inner 8 12 Diagn stie Notes nun en 8 12 APPENDIX A WIRING A 1 CONNECTORS rgo A 1 A 2 INDEX TO WIRING DIAGRAMS Wiring Diagram Information Wire Color Codes Wiring Diagram Symbols treten A 7 IV TABLE OF CONTENTS A e ES A 8 APPENDIX B GLOSSARY B 1 GLOSSARY Acronyms and Abbreviations eeeeeeeee B 1 REFERENCE MATERIAL TOQOL l SUBJECT PAGE NO NOTES SCHEDULED MAINTENANCE 1 1 GENERAL The table below lists the maintenance requirements for police motorcycles If you are familiar with the procedures refer to the table for the recommended service interval If necessary refer to the quick reference table Table 1 2 for the required specifications If more detailed information is needed turn to the Touring Models Service Manual for step by step instruc tions Various lubricants sealants and greases are recommended in certain service operations Refer to Table 1 3 for the appro priate part numbers for these items Table 1 1 Regular Service Intervals 2008 Touring 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
41. R GN R 1 To optional 70A BK 2 pole lamp 4 Y PK 4 Biens 59B gt 2 TN BK 1 O BE gt 708 Figure A 11 2008 FLHTP DOMESTIC and INTERNATIONAL Models Anti Lock Brake System ABS Siren Amplifier and Strobe Harness Figure A 11 Figure A 11 2008 FLHTP DOMESTIC and INTERNATIONAL Models Anti Lock 2008 FLHTP DOMESTIC and INTERNATIONAL Models Anti Lock Brake System ABS Siren Amplifier and Strobe Harness Brake System ABS Siren Amplifier and Strobe Harness et00091 TSM TSSM HFSM Ss Battery 1 1 erial Data Neutral Switch 4 4 TN Left Turn Feed 5 5 mv Right Turn Feed 6 6 MON IE EEE Right Turn SW Input 7 7 EWIBN Left Turn SW Input 8 8 w Start Relay Control 9 9 TN GN an Clutch Switch 10 10m BK R ma Alarm Signal 11 11 ELGNIEN H Ground 12 12IB BK GN EEEEEEEEEEI _ Turn Signal RO Turn Signal Security 30A 30B Module GY 111 AREE In I11GNO EE 1 Front Turn N 1 Signals 23456 i Console Harness Interconnect Y E 23456 9 1011121314 15 20B Ta TTM gt gt gt x 20B oz 3g 86 ESE EGE OZ x o 484 a Fuel Gauge 5 ZZ Y 12 4 mom 78153 E gt 2 a Ignition Start Main Power 40 Amp Voltage B Switch Solenoid at Starter MAXIFUSE Regulator Connector 222A Gey Gey xx 160B 5 222B e c 5B 77B gr 1 u 1258 E BATT L
42. SPECTION 1 Using a clean shop cloth or soft bristle brush gently clean oil cooler fins of dirt and debris 2 If engine failure and or oil contamination requires inspec tion and cleaning of oil passageways then remove oil cooler adapter and proceed as follows a See Figure 3 3 Remove two socket screws 3 to release inspection cover 4 and gasket 2 b Thoroughly flush oil passageways with solvent and blow out with compressed air c Install inspection cover with new gasket d Apply a small dab of Loctite Medium Strength Threadlocker 243 blue to threads of socket screws Install screws and alternately tighten to 90 120 in Ibs 10 2 13 6 Nm INSTALLATION PART NUMBER HD 97087 65B TOOL NAME HOSE CLAMP PLIERS NOTE If mounting bracket is already installed proceed to next step 1 Install mounting bracket as follows a With the TOP stamp facing upward install mounting bracket onto studs on lower frame crossmember b Install front electrical caddy and voltage regulator See VOLTAGE REGULATOR in the Touring Models Service Manual 2 Slide new clamp onto oil cooler side of return hose which can be identified by the paint stamp reading COOLER BOTTOM With the script facing upward install hose onto bottom fitting of oil cooler Crimp clamp using HOSE CLAMP PLIERS Part No HD 97087 65B 3 Slide new clamp onto oil cooler side of supply hose which can be identified by the paint
43. TES 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 50 000 miles 80 000 kilometers 3 Perform annually 4 Change D O T 4 and flush brake system every two years 5 Perform at each rear tire change 2008 FLT Police Service Maintenance 1 1 Table 1 2 Quick Reference Maintenance Chart 2008 Police Models ITEM SERVICED SPECIFICATION DATA Engine oil and filter Drain plug torque 14 21 ft lbs 19 0 28 5 Nm Oil capacity 4 qt 3 8 L Filter Hand tighten 1 2 3 4 turn after gasket contact Chrome filter part number 63798 99A Black filter part number 63731 99A Primary chain lubricant Lubricant type and capacity FORMULA TRANSMISSION AND PRIMARY CHAIN LUBRICATION Part No 99851 05 Wet 38 oz 1124 ml Dry 45 oz 1331 ml Primary chaincase drain plug torque 14 21 ft lbs 19 0 28 5 Nm Clutch adjustment Adjuster screw free play 1 2 1 turn Adjuster screw locknut torque 72 120 in Ibs 8 1 13 6 Nm Free play at hand lever 1 16 1 8 in 1 6 3 2 mm Clutch inspection cover torque 84 108 in Ibs 9 5 12 2 Nm Transmission lubricant Lubricant level Dipstick at FULL with motorcycle on jiffy stand and filler plug resting on threads Lubricant type and capacity FORMULA TRANSMISSION AND PRIMARY CHAIN LUBRICATION
44. ade connector Inner fairing back of fuel gauge 117 Fuel gauge Spade connector Inner fairing back of fuel gauge 119 EFI fuses Fuse terminals Fuse block under right side cover 121 Rear brake light switch Spade terminals Bottom of rear frame downtube right side 122 Horn Spade terminals Between cylinders left side 123 Starter relay Relay connector Fuse block under left side cover 124 Brake light relay Relay connector Fuse block under left side cover 126 Ignition keyswitch relay Relay connector Cavity in crossmember at rear of battery box under seat 128 Starter solenoid Spade terminals Top of starter 129 Harness grounds Ring terminals Upper frame cross member under seat 131 Neutral switch Post terminals Top of transmission right side 132 Cigarette lighter Spade terminals Inner fairing left side 133 Jiffy Stand Sensor 3 place Molex black HDI Electrical caddie at bottom of lower frame crossmember Not used on Domestic 135 EFI system relay Relay connector Fuse block under right side cover 137 O2 sensor rear exhaust header 2 place Amp Tyco Under chrome starter cover 138 O2 sensor front exhaust header 2 place Amp Tyco Back of cross brace between front frame downtubes left side 139 Oil pressure sender 4 place Delphi Front right crankcase 141 Fuel level sender and fuel pump 4 place Packard Top of canopy under console 156 Main to interconnect harness 6 place Deutsch Inner fairi
45. age regulator right side 78 ECM 73 place Packard Under right side cover 79 CKP sensor 2 place Deutsch Electrical caddy at bottom of lower frame crossmember 80 MAP sensor 3 place Packard Top of induction module 83 Ignition coil 4 place Delphi Below fuel tank left side 84 Front injector 2 place Delphi Below fuel tank left side 85 Rear injector 2 place Delphi Below fuel tank left side 87 IAC 4 place Delphi Below fuel tank right side 88 TP sensor 3 place Delphi Below fuel tank right side 89 IAT sensor 2 place Delphi Below fuel tank right side 90 ET sensor 2 place Delphi Back of front cylinder left side 91 Data link 4 place Deutsch Under right side cover 93 Tail lamp 4 place Multilock Circuit board under tail lamp assembly 94 Rear fender lights harness to circuit board 6 place Multilock Circuit board under tail lamp assembly A 2 2008 FLT Police Service Appendix A Wiring Table A 1 FLHTP Wire Harness Connectors NO DESCRIPTION TYPE LOCATION 105 Fairing cap switches 12 place Multilock Inner fairing above upper fork bracket right side 108 Tachometer 12 place Packard gray Inner fairing back of tachometer 110 Voltmeter lamp Spade connector Inner fairing back of voltmeter 111 Voltmeter Spade connector Inner fairing back of voltmeter 116 Fuel gauge lamp Sp
46. ake Air Temperature 49 49 inca 5V Sensor Power 1 50 50 Engine Temperature 51 51 Bey HT a Twisted 12 V Power 52 52 Y GN am d m rm Y GN aa air A A AA Rear Coil 53 53 Y BE pig new NL Jiffy Stand Sensor 56 56 B GN BN t i cs ll lo es ee E I BEE E E es E TM E BE GN baec bid li EI IS 5V Sensor Ground 61 61 pim Sl j 5V Sensor Ground 2 62 62 D Crank Position Sensor 63 63 jm R p p p Vehicle Speed Ground 64 64 EBK Y 7 i l T ek SSE HL 1I EN 5V Sensor Power 2 68 68 F R W AHF F A 12V Battery 71 71 8 BE GY 5 n i BE GY m m m 12V Run Stop Switch 72 72 Ew Bk IEEE p i __ AS i WK TER o DL isl e T_T ed l s LGN R c zz Wo 2 zZ oz oz 253 omo z gt z gt 179B 5559 58 95B 138B E 5 137B iA 65B FF i 133B 5 203FB SS 203RB SS A E EA ADe AT A re Apre k pel Age Active Vehicle Jiffy Stand Purge Front Rear Front Rear Exhaust A Speed Sensor HDI Only Solenoid O Sensor O Sensor or HDI Only ACR ACR Figure A 14 2008 FLHP and FLHPE DOMESTIC and INTERNATIONAL Models Main Harness 2 of 2 From Main Harness Page 1 Figure A 14 Figure A 14 2008 FLHP and FLHPE DOMESTIC and INTERNATIONAL Models 2008 FLHP and FLHPE DOMESTIC and INTERNATIONAL Models Ma
47. al 1 SeeHANDLEBAR SWITCH ASSEMBLIES in the Touring Models Service Manual 2 From inside the switch housing carefully cut cable strap to free conduit from the turn signal switch bracket 3 Remove the Phillips screw with lockwasher to release the turn signal switch bracket Remove the switch assembly from the housing 4 Remove the clutch interlock switch from the housing 5 Out wires 1 4 in 6 mm from old switch Discard switch assembly NOTE Replacement clutch interlock switch wires are cut to length Looking at rear side left side switch wire is 2 1 4 in 57 mm and right side is 2 3 4 in 70 mm and partially stripped 6 Connect wires of new switch See HANDLEBAR SWITCH ASSEMBLIES in the Touring Models Service Manual Installation 1 Install clutch interlock switch in bore of lower switch housing 2 Insert tapered end of new 7 inch cable strap into round hole in turn signal switch bracket and then feed back through using the adjacent hole Reserve the oblong hole for the bracket screw NOTE Be sure that all splices are positioned above the turn signal switch bracket 3 Place the turn signal switch assembly into the housing aligning the oblong hole in the bracket with the lower bracket weld nut Be sure that bracket is fully seated Tabs on each side are captured in slots cast into switch housing 4 Install Phillips screw with lockwasher to secure bracket inside housing If routed incorrectly wires m
48. ay be pinched by casting or handlebar resulting in switch failure CAUTION If routed incorrectly wires can be pinched by casting or handlebar resulting in switch failure 00542b 5 Loop switch wires so that spliced lengths are positioned directly over bracket screw 6 Capturing conduit about 1 4 in 6 mm from end securely tighten cable strap to draw conduit to bracket Remove any excess cable strap material 7 On opposite side install second 7 inch cable strap cap turing conduit and wire splices Securely tighten cable strap to draw splices to conduit Remove any excess cable strap material 8 Route wire bundle to upper switch housing below and then forward of the main wire harness positioning conduit in channel next to angular arm of bracket Secure bundle to arm placing new cable strap 1 4 in 6 mm from end of conduit Cut any excess cable strap material If necessary bend angular arm of bracket downward to firmly secure clutch interlock switch in installed position 9 See HANDLEBAR SWITCH ASSEMBLIES in the Touring Models Service Manual 2008 FLT Police Service Electrical 8 7 ed01649 Figure 8 6 Lower Switch Housing PURSUIT AND AUXILIARY SWITCH NOTE Pursuit lamps are operational on domestic motorcycles only Removal 1 See HANDLEBAR SWITCH ASSEMBLIES in the Touring Models Service Manual 2 From inside the switch housing carefully cut cable strap to free co
49. bracket 7 If necessary remove two flange nuts 7 and washers 6 and remove seat fairing 17 under seat SEAT INSTALLATION 1 See Figure 2 3 If removed install seat fairing 17 under seat Tighten flange nuts 7 to 60 120 in Ibs 6 8 13 6 Nm 2 Install seat onto seat bracket and start two flange nuts 11 Align threaded hole in seat with hole in front of seat bracket and start hex screw 15 3 Tighten flange nuts to 96 144 in Ibs 10 9 16 3 Nm 4 Tighten hex screw to 60 120 in Ibs 6 8 13 6 Nm 5 Place seat and bracket assembly on motorcycle and install front pivot bolt 16 Tighten nut 13 to 48 84 in Ibs 5 4 9 5 Nm 6 See Figure 2 2 Align post 3 on top plate with hole in rear seat bracket While pressing down on rear of seat insert pin 1 into post on top plate CAUTION Maximum air pressure for the seat is 100 psi 689 kPa Normal air pressure is 30 45 psi 207 310 kPa Do not operate with air pressure so low that system bottoms out on bumpy roads 00167a 7 Fill air reservoir to 40 psi 275 8 kPa then add or remove pressure to the rider s comfort Install protective cap on air fitting AIR SPRING REPLACEMENT Removal 1 Remove seat and seat fairing See 2 4 SEAT Seat Removal 2 6 2008 FLT Police Service Chassis WARNING Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks
50. by Whelen located at left rear side of Route through spotlight stems Left front strobe bulb red Existing strobe harness routed XX indicates under tank unterminated strobe harness wires located under left side cover E E Connect to O R wire of ACC fuse Remove GY BK wire from terminal X of the pursuit flasher and terminate it to W GN wire of the strobe harness located under left side cover Not used Ground to left ground stud in front of battery Cable E C color w 8 RED BLUE y TAN BLACK VIOLET BROWN Pursuit flasher is located in arina 9 WHITE GREEN fairing on FLHTP models and a wire an GRAY under left side cover on May BO LBUILSO to canner YELLOW harness to power supply ORANGE PINK FLHP models Figure A 17 2008 FLHTP FLHP and FLHPE DOMESTIC and INTERNATIONAL Models Optional Strobe System Figure A 17 Figure A 17 2008 FLHTP FLHP and FLHPE DOMESTIC and INTERNATIONAL 2008 FLHTP FLHP and FLHPE DOMESTIC and INTERNATIONAL Models Optional Strobe System Models Optional Strobe System SUBJECT PAGE NO NOTES GLOSSARY B 1 ACRONYMS AND ABBREVIATIONS Table B 1 Acronyms and Abbreviations ACRONYM OR ABBREVIATION DESCRIPTION A Amperes AC Alternating Current ACC Accessory ACR Automat
51. can cause a battery explosion which could result in death or serious injury 00049a 2 Disconnect battery negative cable first 3 Remove battery from battery box 4 Remove air pressure from air spring and reservoir 5 Depress collar on compression fitting and remove air tube from air reservoir 6 See Figure 2 3 Holding air spring to prevent twisting remove two fasteners 23 to release top plate 22 from air spring 19 7 Remove two flange nuts 20 under frame weldment at rear of battery box Remove air spring from motorcycle sm04699 SZ Figure 2 4 Air Spring Assembly Installation 1 Feed air tube through large center hole in frame weldment at rear of battery box and then route rearward following inboard side of right upper frame tube to air reservoir 2 Depress collar on compression fitting of air seat reservoir and insert air tube until it bottoms Gently tug on tube to verify that it is locked in place 3 Connect air tube to compression fitting at bottom of air spring if removed 4 See Figure 2 3 Place air spring on frame weldment while engaging the two set screws 5 Install two flange nuts 20 onto set screws 21 Tighten flange nuts to 50 70 in Ibs 5 7 7 9 Nm 6 Position top plate 22 onto air spring and start two fasteners 23 Holding air spring to prevent twisting tighten screws to 36 60 in Ibs 4 1 6 8 Nm 7 Place battery into battery box terminal si
52. d TOP END OVERHAUL in the Service Manual for procedures See Figure 8 13 Use ACR SOLENOID SOCKET Part No HD 48498 to remove the ACR from the cylinder head Figure 8 9 ACR Exhaust Port Release 8 10 2008 FLT Police Service Electrical Figure 8 10 ACR in Head INSTALLATION PART NUMBER TOOL NAME HD 48498 ACR SOLENOID SOCKET Verify that the copper seal washer is in place on the ACR See Figure 8 11 Identify a location around the threads of the ACR approximately 1 3 of the way up from the end See Figure 8 12 Apply three equally spaced dots of LOCTITE 246 THREADLOCKER MEDIUM STRENGTH HIGH TEMPERATURE blue on threads To prevent cross threading install and finger tighten See Figure 8 13 Using ACR SOLENOID SOCKET Part No HD 48498 tighten to 11 15 ft lbs 14 9 20 3 Nm Before installing the rocker box on each cylinder head route the wire harness toward the inside of the cylinder V With rocker boxes installed and the engine in the chassis mate the ACR connectors 203R and 203F to the corres ponding socket housings on the main wiring harness ed01626 ed01628 ed01627 Figure 8 12 Three Dots of Loctite 246 Medium Strength High Temperature Figure 8 13 ACR Solenoid Socket HD 48498 and ACR COMPRESSION TEST PART NUMBER TOOL NAME HD 33223 1 CYLINDER COMPRESSION GAUGE A co
53. d between the front and rear cylinders on the left side of the crankcase Always give the complete V I N when ordering parts or making an inquiry about your motorcycle om01103 Figure 2 1 Typical Harley Davidson V I N 2008 Police Models Table 2 5 Harley Davidson V I N Breakdown 2008 Police Models POSITION DESCRIPTION POSSIBLE VALUES 1 Market designation 1 Originally manufactured for sale within the United States 5 Originally manufactured for sale outside of the United States 2 Manufacturer HD Harley Davidson 3 Motorcycle type 1 Heavyweight motorcycle 901cc or larger 4 Model See V I N model table 5 Engine type M Twin Cam 103 1690cc air cooled fuel injected 6 Introduction date 1 Regular 2 Mid year 3 California regular 4 Cosmetic changes and or special introductory date 5 California cosmetic changes and or special introductory date 6 California mid year 7 V I N check digit Can be 0 9 or X 8 Model year 8 2008 Assembly plant Y York PA U S A 10 Sequential number Varies Table 2 6 V I N Model Codes 2008 Police Models CODE MODEL FM FLHTP FH FLHP FT FLHPE 2 2 2008 FLT Police Service Chassis TIRES 2 3 GENERAL The rear tire on FL police model motorcycles is fit for solo riding only If converted to a two up bike that is configured for pas senger use with luggage then the rear tire needs to be changed to one
54. d side of the housing 5 Carefully remove the keycap disengaging slot from hook on ramp 6 While holding down the ramp pull both switches from the housing 7 Cut the wires from the old switches as follows a Yellow Black wire 1 1 4 in 32 mm b Orange White wires 1 7 8 in 48 mm c Brown Black wire 1 1 2 in 38 mm NOTE Replacement Horn Siren Yelp Switch wires are cut to length and partially stripped Yellow Black wire 3 3 4 in 95 mm Orange White wires 3 1 2 in 89 mm Brown Black wire 3 3 8 in 86 mm 8 Connectwires of new switch See HANDLEBAR SWITCH ASSEMBLIES in the Touring Models Service Manual NOTE If the ramp and spring mechanism becomes loose install as follows Using the blade of a small screwdriver compress spring and place in wider portion of channel at bottom of ramp Verify that spring is evenly compressed and is not cocked or skewed Push spring so that it bottoms in channel With tab side of ramp facing inboard and hook end on switch side of casting install ramp so that narrow channels engage pins cast into housing 8 6 2008 FLT Police Service Electrical ed01654 Engine start switch Front stoplight switch Engine stop switch Off Run Pole and pursuit lamp switch Off Auxiliary Pur suit Turn right signal switch PONZ a Figure 8 4 Right Handlebar Switch Housing ed01655 Clutch starter interlock switch Siren switch On Off Ligh
55. de forward AWARNING Connect positive battery cable first If positive cable should contact ground with negative cable connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a 8 Connect battery cables positive cable first Tighten to 60 96 in Ibs 6 8 10 9 Nm 9 Apply a light coat of petroleum jelly or ELECTRICAL CONTACT LUBRICANT Part No 99861 02 1 oz tube to both battery terminals 10 Install hold down clamp so that the lip with rubber pad rests on the edge of the battery Tighten T40 TORX screw to 15 20 ft lbs 20 27 Nm 11 Install seat fairing Tighten fasteners to 60 120 in Ibs 6 8 13 6 Nm 12 Install seat and insert pin into post on top plate or air spring See 2 4 SEAT Seat Installation CAUTION Maximum air pressure for the seat is 100 psi 689 kPa Normal air pressure is 30 45 psi 207 310 kPa Do not operate with air pressure so low that system bottoms out on bumpy roads 00167a 13 Fill air reservoir to 40 psi 275 8 kPa then add or remove pressure to the rider s comfort Install protective cap on air valve SEAT BRACKET MOUNT REPLACEMENT Removal 1 Remove seat See 2 4 SEAT Seat Removal 2 See Figure 2 3 Remove two fasteners 12 to release seat bracket mount from frame backbone Installation 1 Install seat bracket mount using two fasteners 12 Tighten fasteners to 15 20 ft lbs 20
56. der seat 5 MAXIFUSE 2 place Packard Under left side cover 7 Rear fender lights harness 8 place Multilock Top of rear Fender under seat 18 Left rear turn signal 2 place Multilock Circuit board under tail lamp assembly 19 Right rear turn signal 2 place Multilock Circuit board under tail lamp assembly 20 Tachometer harness 6 place Deutsch Inside headlamp nacelle 21 Indicator lamps 8 place Deutsch Under console 22 Right handlebar switches 12 place Molex Inside headlamp nacelle fork stem nut lock plate right side 24 Left handlebar switches 12 place Molex Inside headlamp nacelle fork stem nut lock plate left side 30 TSM HFSM 12 place Deutsch Cavity in crossmember at rear of battery box under seat 31 Front turn signals 6 place Multilock Inside headlamp nacelle fork stem nut lock plate left side 32 Front fender tip lamp jumper harness 2 place Multilock black Inside headlamp nacelle 33 Ignition light key switch 3 place Packard Under console 38 Headlamp Headlamp connector Inside headlamp nacelle 39 Speedometer 12 place Packard Back of speedometer under console A 4 2008 FLT Police Service Appendix A Wiring Table A 2 FLHP E Wire Harness Connectors NO DESCRIPTION TYPE LOCATION 45 Rear fender tip lamp 3 place Multilock Circuit board under tail lamp assembly 46 Stator 3 place
57. e on inboard side of new keycap Position ball on end of spring Use a small amount of grease to hold ball in place Install keycap so that ball engages detent in switch housing Slide ramp over keycap shaft so that tongues on ramp engage grooves in keycap shaft Installation 1 Install lower bracket with the weld nut side down 2 Slide the T8 TORX screws through holes in lower bracket and switches and thread into lower casting until snug 3 Install Phillips screw with lockwasher to secure lower bracket to threaded boss in housing Work Auxiliary and Pursuit switches to ensure smooth operation 4 See Figure 8 7 Insert tapered end of new 7 inch cable strap into round hole in turn signal switch bracket and then feed back through using the adjacent hole Reserve the oblong hole for the bracket screw NOTE Be sure that all splices are positioned above the turn signal switch bracket 5 Place the turn signal switch assembly into the housing aligning the oblong hole in the bracket with the lower bracket weld nut Be sure that bracket is fully seated Tabs on each side are captured in slots cast into switch housing 6 Install Phillips screw with lockwasher to secure turn signal switch bracket inside housing CAUTION If routed incorrectly wires can be pinched by casting or handlebar resulting in switch failure 00542b 7 Loop switch wires so that spliced lengths are positioned directly over bracket screw 8
58. e 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 FOREWORD INTO WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury 00119a ACAUTION 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 sp
59. ealth switch oOptionisused m i e x m m t c 207A i au f 1 s Y o 207B a i i ct r c R ERE c FSIS 126B 5288 ale y Va MM if 126A Lighting Relay gt ES ERN ERN II oleole o le Roo N 0 30 lla 31579 04 31579 04 eee mee 1 E cce D ZEZEON Figure A 13 2008 FLHP and FLHPE DOMESTIC and INTERNATIONAL Models Main Harness with ABS 1 of 2 Figure A 13 Figure A 13 2008 FLHP and FLHPE DOMESTIC and INTERNATIONAL Models 2008 FLHP and FLHPE DOMESTIC and INTERNATIONAL Models Main Harness with ABS 1 of 2 Main Harness with ABS 1 of 2 et00097 Yellow Tubing co HR Ignition 1 Lw Coil Twist Grip 1 EBK Sensor o R pe Crank Pos a CW pee Er Rear Front Sensor an Injector Injector TMAP men Control ack Tubing W W Sensor ctuator Es ES DE Engine Temp us z Sensor er ETE LH USE 204a Drame 83A S322 85A B4A BOA 211A amp oo Connector En ad y 123456 V 22
60. ecial 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 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 Il FOREWORD 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 information or product returns warranty or otherwise visit WWW Spx co
61. eed 7 7 m BE V Rear wheel speed 8 8 m BE BN Serialdata 9 9 LGN V ECU Solenoid power 10 10 Im R V Motor ground 11 11 mi BK Front brake input 13 13 a R BN Front wheel speed 18 18 Ignition wake up 19 19 Front wheel speed 17 E Motor power 20 20 RBE m 4 4 RBE m3 3 ABS R Diode BN mm 2 2 D PK BN md 1 1 Pack 168B 167B AB AB lt lt 167A A B AB 168A 201B 201A zu ES mem o gt Oeractrio SRR 9 9 JIJ To main harness page 1 Front Wheel Rear Wheel Speed Sensor Speed Sensor Ref Siren wires are not polarity sensitive 57A 57B PS 728 lt lt 72A gt gt 72 Siren PA O 1 Qo RR GY R mm 30 3C z Speaker I 2 2 GY R 9 3A 230B 229B R PK ma 2D 2D z as E W PK zd 1E 1E L u 7 ee Micropnone BE PK mal 3F 3F 2E 3B eT 2 R 2 4 me 68 R PK Siren 3 3 o optiona pn 3E d E a ed e dealer installed ln WIPK Amplifier strobe lights W 4 strobe power 72A 5 supply FLHTP FRG BE PK 2F 1F1D1A 1C Y WEN Siren Amplifier Harness Y 728 IT c 12 BK 2F 1F1D1A 1C gt FLHTP FRG Strobe Harness lt BK I i g m 22 q To interconnect edi 6 GN
62. ess Page 2 Battery Ignition Serial Data Neutral Switch Left Turn Feed Right Turn Feed Right Turn SW Input Left Turn SW Input Start Relay Control Clutch Switch Alarm Signal Ground OoN RAUN Nn o 1 BN GY 2 m GY f LGN V TN W BN V E EN m aay E W V TN GN BK R EEEEEEE o 0 40 01 43 C5 LGN BN BK GN z A mA Nu O gt Turn Signal 30A 30B Turn Signal Security Module REE Ss E IGN O es E JN e 2 es mn RVIBEBE GYIEBEBH R BEIEENRE LGNV R BNI E PK BN 8 8 pe 141A m M8 J Fuel Pump 26 Gx Assembly Intank K i 520 138 95 p ull 1234 12 Optional Security je PELA Main Power 40 Amp Voltage B Ignition Switch m Solenoid at Starter MAXIFUSE Regulator Connector 33A Y aA B Y caly Y m 123 i 2f E EAT 128B 5B EE 77B 160B la 288 Vi g A BATT c c x x rs GE x 1238 Y cic 123 142B HIN R BN GY LGN BN BK GN OW O R 1B Cruise Brake 15A 1A 1D Accessory 15A 1C JE P amp A 15A
63. eter EN 73R Tachometer gt 108B l i Rear Lighting Harness Right Hand Does 2 gt Controls atabus NC 3 3 Right RPM x 100 NES Off Aux Pursuit Accessory JE From Main Pursuit Switch Lamp Abs Warn 8 8 Harness 7A Right Directional Blue NC 9 9 Switch Cruise Active 10 H0 87654321 Y NC 11 11 i NIE NIIN Engine Off Cruise Enable 12 12 j wrx gt 22 7B Run Switch fa O Tachometer Harness i Starter Switch A mee 3 Sioplaiin Switch 2 2 dz Bi as 5 85828 S258 HE E 8 948 22A gt BH coovo00 8 225525 oo0zzm a OFLOFO ows 1 Right Brown Tape To Main i y owg 1 RBE d 2 Directional H 123456 789101112 BN ml 2 and Running 31B lt Ar i i BE m 3 GYw 3 Lamp AAA PRU A el Sa ies to al i R M E W BK3 4 i W BNa 5 i p nsing ek md From From Main Harness BK mm 6 BRE 6 a 31R VEN Main l 21A i ova 7 1298 sema Harness i To y GY BK e 8 vien m 5 31A j MET i ara 9 ie i gt 5252 8x 21B 4 pos E i Fuel Gauge i BK i Move Y BK wire to cavity 11 Running Violet Tape i Indicator when using Whelen siren Left BK i Lamps amplifier amp air horn function i j BEBE A MW i 24A gt GY manning V BN BN 4 Right d i eu BK Lamp Turn i Turn yak Oil BE E 3 zx i a0 A Pressure W74 117A oS d i WVa 5 From Main Y TN J i vek e Harness x i Om Neutral BkRm 7 248 73L To Main Full
64. eup O 8 H Stud GND1A Dorm BK GND1 RH GND Stud Hu BK GN Clean GND2 8 7 6 22B 5 4 3 2 Left Hand Control I 24B GY To Siren 2F amp 4 4 PK BK Amplifier 1F a TNBK 72B 1D ga 1v PK 38B A Headlamp Fender Tip Lamp 82A y ize E 3n b i 1 HDI undo Lamp 122 gt gt BE GY 2F ECM Power 15A 4B FuelPump 15A 4A e IA zZ 2 amp z 3 5 BORA 1 2 LS Al n Oil Pressure Neutral 1 20B Rear Switch Stop Light 131 Switch 121 o gt o c u zz xx 4A 2 E 67A Y 5 Sa aa VA i234 yla a h23 567 q Accessory Accessory To Rear Lighting Connector Switch n omo no lt 7 o o 3 i 1B P amp A 2A 1A X 00 0 in R BK 1D INSTRS 15A 1C o F4 R BK i 1F Ignition 15A 1E f GY E F4 1H Engine CNTRL 15A 1G i LGN R Ma R BK 2D Headlamp 15A 2C i BE R BK i 2F Lights 15A_ 2E BE a i j 4B ABS 30A 4A RIV F4 R Y i Oy Brake BK Relay R BE 3H Spare 15A 3G _ E 4H Spare 30A 4G BK __ H B Connector E E 17781116081 Ignition Switch 222A coc gt e x GE y 222B rac Police Stealth Amber cap removed when st
65. f air reservoir bracket to right side of motorcycle Engage catches on each side of rear marker lights bracket into oblong holes in license plate bracket On inboard side of rear marker lights bracket gently push electrical connectors onto prongs on marker lights Install new cable strap to secure rear marker lights and pole lamp conduit to left side of bottom support tube Cut any excess cable strap material ed01647 Rear marker light 2 Rear marker lights bracket Rear marker lights harness License plate bracket Bottom support tube IRONS Figure 8 3 Rear Marker Lights Assembly 2008 FLT Police Service Electrical 8 5 HANDLEBAR SWITCHES 8 4 HORN AND SIREN YELP SWITCH NOTE Install new cable strap to secure rear marker lights and pole lamp conduit to left side of bottom support tube Cut any excess cable strap material Removal 1 Gain access to the inside of the switch housing See HANDLEBAR SWITCH ASSEMBLIES in the Touring Models Service Manual 2 From inside the switch housing carefully cut cable strap to free conduit from the turn signal switch bracket 3 Remove the Phillips screw with lockwasher to release the turn signal switch bracket Remove the switch assembly from the housing 4 Remove the two T8 TORX screws and the Phillips screw with lockwasher to release the lower bracket Carefully lift out the bracket so as not to disturb the spring loaded ramp on the inboar
66. g latch at bottom of saddlebag lid with the flat side facing opposite the hinges See E 2 Slide two new rivets through holes in saddlebag lid and spring latch Compress rivets using a suitable rivet tool Peel paper backing off adhesive side of knob seal Place knob seal over post so that the adhesive side contacts the saddlebag lid Press knob seal firmly into place 5 Install knob onto post and alternately work each side down until it bottoms Figure 2 13 Saddlebag Knob and Seal Figure 2 14 Spring Latch SPRING LATCH BRACKET Removal 1 From outside saddlebag loosen two Phillips screws 2 Inside saddlebag remove two Keps nuts and spring latch bracket Remove Phillips screws See Installation 1 From outside saddlebag slide two Phillips screws through holes in saddlebag 2 Inside saddlebag install spring latch bracket and two Keps nuts See 3 Alternately tighten Phillips screws until snug 1 Spring latch bracket 2 Keps nut 2 3 Phillips screw 2 Figure 2 15 Spring Latch Bracket 2008 FLT Police Service Chassis 2 13 TACHOMETER BRACKET FLHP E 2 7 REMOVAL NOTE The two rear holes in the handlebar clamp shroud allow the rider to adjust the handlebars without having to remove the shroud To keep out moisture and debris be sure to install plastic plugs back into holes after handlebar adjustment See Figure 2 18
67. g lid Use key to rotate threaded stud if necessary 5 Align cam hook and cam washer as shown in Figure 2 10 With the cam hook toward the outboard side of saddlebag lid and cam washer on the inboard side slide assembly down threaded stud 6 Install internal tooth lockwasher and hex nut onto threaded stud Tighten hex nut to 25 35 in Ibs 2 8 4 0 Nm Lock guide Jam nut Lockset Cam washer Cam hook Lockwasher Hex nut NOOPoOns Figure 2 9 Lockset Assembly sm04804 Lockset Thin washer Cam stop Threaded stud Cam washer Cam hook 1 2 3 4 5 6 Figure 2 10 Lockset Mechanism LOCKSET CATCH Removal 1 Drill out two rivets using a 5 32 inch drill bit 2 Remove backplate lockset catch and flat washers Installation 1 Slide two new rivets through holes in backplate saddlebag lockset catch and flat washers 2 Compress rivets using a suitable rivet tool HINGES PART NUMBER TOOL NAME HD 39787A RIVET TOOL Removal 1 Remove tether See 2 6 SADDLEBAGS Tether 2 Drill off peened end of hinge pin rivet using a 3 8 inch drill bit Use a punch to tap rivet shaft out of hinge 3 Drill out eight rivets using a 3 16 inch drill bit 4 Remove hinge and backplates 2008 FLT Police Service Chassis 2 11 sm03552 1 Adjuster thumbscrew 2 Drive head Figure 2 11 Rivet Tool HD 39787A Installation 1 Slide new ri
68. gt um BK 15B i 15B ala 4B ABS 30A 4A i MITT u R Y 2B 30 3 AL OILIL pe Ed s BK 3B 86 15 Relay Horn loa 85 l2 s B Ha 1 2 R BE i Oil A A A an Y ll l y i pics LE m BK S208 128 Sek Z5 gt LEE 7A auo re ag aa m mu m BK mumm o EN A EGN Y 139A jia Neutral Rear yliz34 Alaz1 123 567 y gt gt Switch Stop Light Accessory Tour Pak To Rear Lighting 139B 131 Switch Connector 12A EN 121 m x P RBI c m R BK LF Y 33B Police Stealth Amber cap removed when stealth switch option is used 207A Y Y o x 2078 Us c rdc 3 Bee GzS c 126B Brass yan Ea Lighting Relay G 15A 15A 30A H Figure A 5 2008 FLHTP DOMESTIC and INTERNATIONAL Models Main Harness with ABS 1 of 2 Figure A 5 Figure A 5 2008 FLHTP DOMESTIC and INTERNATIONAL Models Main 2008 FLHTP DOMESTIC and INTERNATIONAL Models Main Harness with ABS 1 of 2 Harness with ABS 1 of 2
69. gure 3 3 Oil Cooler Adapter 2008 FLT Police Service Engine 3 5 NOTES 3 6 2008 FLT Police Service Engine SUBJECT PAGE NO NOTES FUEL SYSTEM NO UNIQUE CONTENT Any information not presented in this supplement can be found in the Touring Models Service Manual 4 1 2008 FLT Police Service Fuel System 4 1 NOTES 4 2 2008 FLT Police Service Fuel System SUBJECT PAGE NO NOTES ELECTRIC STARTER NO UNIQUE CONTENT Any information not presented in this supplement can be found in the Touring Models Service Manual 5 1 2008 FLT Police Service Electric Starter 5 1 NOTES 5 2 2008 FLT Police Service Electric Starter SUBJECT PAGE NO NOTES DRIVE NO UNIQUE CONTENT Any information not presented in this supplement can be found in the Touring Models Service Manual 6 1 2008 FLT Police Service Drive 6 1 NOTES 6 2 2008 FLT Police Service Drive SUBJECT PAGE NO NOTES TRANSMISSION NO UNIQUE CONTENT Any information not presented in this supplement can be found in the Touring Models Service Manual 7 1 2008 FLT Police Service Transmission 7 1 NOTES 7 2 2008 FLT Police Service Transmission SUBJECT PAGE NO 0 1 BULB CARA Msi al 8 2 SYSTEM FUSES AND RELAYS 8 3 REAR MARKER GEHT Scene 8 4 HANDLEBAR SWITCHES 8 5 AUTOMATIC COMPRESSION FUEL EAE SE IRRE EHER EEE NR 85 10 NOTES
70. hometer Connector Headlamp nacelle Keps nut Flat washer Flange nut Chrome strip Phillips screw 2 Tachometer bracket Acorn nut 2 Fork lock plate 10 Handlebar clamp shroud 11 Stud plate COPADA sm04709 Figure 2 17 Headlamp Nacelle Assembly 1 Tachometer bracket 2 Handlebar clamp shroud 3 Forklock plate 4 Handlebar adjustment access hole plug Figure 2 18 Install Handlebar Clamp Shroud INSTALLATION 1 Place tachometer bracket over studs at top of handlebar clamp shroud Install two acorn nuts with flat washers onto studs and alternately tighten to 72 108 in Ibs 8 1 12 2 Nm See Figure 2 18 NOTE A peel and stick foam tape on the stud plate holds it in place on the inboard side of the handlebar clamp shroud 2 Feedtachometer harness connector and conduit through opening at top of headlamp nacelle Install handlebar clamp shroud over mating flange while routing tachometer harness conduit through opening for left side handlebar 3 From inside the headlamp nacelle a Start flat washer and Keps nut onto Phillips screw installed in tab at front of handlebar clamp shroud Tighten Phillips screw to 10 20 in Ibs 1 1 2 3 Nm See Figure 2 17 b Install flange nut onto weld stud of chrome strip installed into hole at the top of headlamp nacelle Tighten flange nut to 15 20 in Ibs 1 7 2 3 Nm c Connect tachometer harness connector 20 6 place Deu
71. i 22 22 f 7 N 167 Figure A 1 Inner Fairing Table A 1 FLHTP Wire Harness Connectors NO DESCRIPTION TYPE LOCATION 1 Main to interconnect harness 16 place Molex black Inner fairing right storage box support bracket 2 Main to interconnect harness 12 place Molex gray Inner fairing right fairing support brace 4 Accessory 4 place Deutsch Upper frame cross member under seat 2008 FLT Police Service Appendix A Wiring A 1 Table A 1 FLHTP Wire Harness Connectors NO DESCRIPTION TYPE LOCATION 5 MAXIFUSE 2 place Packard Under left side cover 7 Rear fender lights harness 8 place Multilock Top of rear fender under seat 12 Rear marker lights harness 3 place Multilock Inboard of left upper frame tube 13 Fuel tank harness 4 place Multilock Behind fuel tank under seat 15 Main to interconnect harness 4 place Packard Inner fairing front of right fairing bracket 18 Left rear turn signal 2 place Multilock Circuit board under tail lamp assembly 19 Right rear turn signal 2 place Multilock Circuit board under tail lamp assembly 21 Indicator lights 10 place Multilock Inner fairing above storage box 22 Interconnect to right handlebar switches 16 place Molex black Inner fairing fork stem nut lock plate left side 24 Interconnect to left handlebar switches 12 place M
72. ic Compression Release AGM Absorbed Glass Mat battery AMP Ampere AWG American Wire Gauge B Battery Voltage BAS Bank Angle Sensor BTDC Before Top Dead Center C Celsius Centigrade CA California CAL Calibration CC Cubic Centimeters CCA Cold Cranking Amps CKP Crankshaft Position cm Centimeter DC Direct Current DLC Data Link Connector DOM Domestic DTC Diagnostic Trouble Code DVOM Digital Volt Ohm Meter ECM Electronic Control Module ECT Engine Coolant Temperature EEPROM Electrically Erasable Programmable Read Only Memory EFI Electronic Fuel Injection ET Engine Temperature EVAP Evaporative Emissions Control System F Fahrenheit ft Ibs Foot Pounds fl oz Fluid Ounce g Gram GAL Gallon GAWR Gross Axle Weight Rating GND Ground electrical GVWR Gross Vehicle Weight Rating HDI Harley Davidson International H DSSS Harley Davidson Smart Security System HFSM Hands Free Security Module Hg Mercury IAC Idle Air Control 2008 FLT Police Service Appendix B Glossary B 1 Table B 1 Acronyms and Abbreviations ACRONYM OR ABBREVIATION DESCRIPTION IAT Intake Air Temperature ID Inside Diameter IGN Ignition Light Key Switch IM Instrument Module In Inch INJ PW Injector Pulse Width in lbs Inch Pounds Kg Kilogram Km Kilometer kPa Kilopascal km hr Kilometers Per Hour L L
73. in Harness 2 of 2 Main Harness 2 of 2 et00015 TSM TSSM HFSM Battery 1 1 B BN GY Ignition 2 2 f cy Turn Signal Serial Data 3 3 E LGN V Turn Signal Neutral Switch 4 4 TN Security Module ECM Start Relay Control 9 9k Clutch Switch 10 10 BK R EHEEEEEEEE Ground 12 12m BK GN Em gt gt 80A 30B 78A 78B 12V Run Stop Switch 72 72 W BK gt gt Serial Data 69 69 LGN V Right Hand Controls Engine Off Run Switch Start Switch 22A gt gt 22B Uni GYE 3 3 jm GY WBK 4 4 wek BK R y 6 6 BBKR 24A 24B Clutch Lockout Switch TN z BA s 3 21B mx 5 BK a a Left Hand Controls Neutral TN Bkm lt L Starting System MAXIFUSE 40 Ed p 7 j Z 11288 P m BK GN NE BK BK Red Battery Band BK lt lt 77B 77A 47A gt gt 478 Stator 40 Amp MAXIFUSE 1F Ignition 15A E GY a R BK A 2D Battery 15A 2C T 126A z En 11268 Y Za SG
74. in Ibs 6 8 10 9 Nm 1 1 SCHEDULED MAINTENANCE General Brake caliper pad pin 75 102 in Ibs 8 5 11 5 Nm 1 1 SCHEDULED MAINTENANCE General Chrome frame tube cover Phillips screw 25 40 in Ibs 2 8 4 5 Nm 2 5 AIR SEAT RESERVOIR Installation Clutch adjuster screw locknut 72 120 in lbs 8 1 13 6 Nm 1 1 SCHEDULED MAINTENANCE General Clutch inspection cover 84 108 in Ibs 9 5 12 2 Nm 1 1 SCHEDULED MAINTENANCE General Engine oil drain plug 14 21 ft Ibs 19 0 28 5 Nm 1 1 SCHEDULED MAINTENANCE General Handlebar switch housing screw 35 45 in Ibs 4 0 5 1 Nm 1 1 SCHEDULED MAINTENANCE General Headlamp door Phillips screw 9 18 in Ibs 1 0 2 0 Nm 2 7 TACHOMETER BRACKET FLHP E Installa tion Headlamp housing Phillips screws 9 18 in Ibs 1 0 2 0 Nm 2 7 TACHOMETER BRACKET FLHP E Installa FLHP E tion Headlamp nacelle chrome strip flange 15 20 in Ibs 1 7 2 3Nm 2 7 TACHOMETER BRACKET FLHP E Installa nut FLHP E tion Headlamp nacelle handlebar clamp 10 20 in Ibs 1 1 2 3Nm 2 7 TACHOMETER BRACKET FLHP E Installa shroud Phillips screw FLHP E tion License plate bracket to bottom support 15 20 ft lbs 20 3 27 1 Nm _ 2 5 AIR SEAT RESERVOIR Installation tube hex bolts Luggage rack to frame tube weldment 15 20 ft lbs 20 3 27 1 Nm 2 5 AIR SEAT RESERVOIR Installation T40 TORX screws Master cylinder reservoir cover screws 7 10 in Ibs 0 8 1 1 Nm 1 1 SCHEDULED MAINTENANCE General front Master cylinder reservoir cover screws 12 15 in Ibs 1
75. ing aligning the oblong hole in the bracket with the lower bracket weld nut Be sure that bracket is fully seated Tabs on each side are captured in slots cast into switch housing 9 Install Phillips screw with lockwasher to secure bracket inside housing CAUTION If routed incorrectly wires can be pinched by casting or handlebar resulting in switch failure 00542b 10 Loop switch wires so that spliced lengths are positioned directly over bracket screw 11 Capturing conduit about 1 4 inch 6 mm from end securely tighten cable strap to draw conduit to bracket Remove any excess cable strap material 12 On opposite side install second 7 inch cable strap cap turing conduit and wire splices Securely tighten cable strap to draw splices to conduit Remove any excess cable strap material 13 Route wire bundle to upper switch housing below and then forward of the main wire harness positioning conduit in channel next to angular arm of bracket Secure bundle to arm placing new cable strap 1 4 inch 6 mm from end of conduit Cut any excess cable strap material If necessary bend angular arm of bracket downward to firmly secure clutch interlock switch in installed position 14 See HANDLEBAR SWITCHES in the Touring Models Service Manual CLUTCH INTERLOCK SWITCH NOTE All Police models have a clutch interlock switch that prevents the motorcycle from starting even in NEUTRAL if the clutch lever is not pulled in Remov
76. irection and remove from hole in rear marker lights bracket 3 Place new marker light into hole in rear marker lights bracket and rotate in a clockwise direction to install 4 On inboard side of rear marker lights bracket gently push electrical connector onto prongs on marker light REMOVAL 1 Disconnect rear marker lights harness connector 12 3 place Multilock inboard of left upper frame tube 2 Carefully cut cable strap to release rear marker lights and pole lamp conduit from left side of bottom support tube 3 On inboard side of license plate bracket note that catches on rear marker lights bracket engage oblong holes in license plate bracket Using tip of flat blade screwdriver gently push top catch down and then bottom catch up to release from oblong hole Repeat step to release other side of rear marker lights bracket 4 Remove rear marker lights assembly from motorcycle INSTALLATION 1 Gently pull both electrical connectors from prongs to detach rear marker lights harness On inboard side of left upper frame tube mate pin and socket housings of rear marker lights harness connector 12 3 place Multilock Route free end of rear marker lights conduit rearward fol lowing inboard side of bottom support tube When conduit reaches air reservoir loop left side rear marker light con duit to outboard side while routing right side rear marker light conduit between top of bottom support tube and bottom o
77. itch 12V Run Stop Switch Power 72 72 W BK Starter Switch Black Black 22A gt gt 22B 1A 1B gt GY m 3 3 GYmm CY E 3 3 GY W BK 24 4 4 E W BK W BK 6 6 EW BK BKRE 6 6 IR BK R Clutch Gray Lockout 24A 24B Switch Ela Gray 2A 2B gt gt BK GN zm 12 12 Em BK GN Emm BK R 7 7 BK R BK R E 11 11 E BK R mmm 2 12 BK W12 12 I BK GN Bas Mid Left Hand Controls z m ANC os 3 BY se BK z Neutral E O 1 N Battery Red Band y m R 728A 1128B Sa ga GN z Starter mmm BK GN Ss BK Il Il Right Left GND 2 GN 648 1F Ignition 15A 1E GY R BK GY 2D Battery 15A oc R BN GY amp GN BK R TN GN LHGND 0 Stud GND 1A Dirty zx Em A 131 Neutral Switch 40A MAXIFUSE F Ch Lj U U Y 5B Charging System lt lt 77A gt gt 77B 46A 46B 40A MAXIFUSE IT Y 58 Left Dirty Powertrain GND Grounds Y IGNITION SWITCH LEGEND Z Ignition X INDICATES CONTINUITY 1 Switch BETWEEN LEAD WIRES 2 SWITCH IN POSITION INDICATED E 33A POSITION E gt RED RED GRAY BLACK LOCK X OFF X IGN X X X Lighting ACC x X Figure A 9 2008 FLHTP DOMESTIC and INTERNATIONAL Models Starti
78. iter LCD Liquid Crystal Display LED Light Emitting Diode mA Milliampere MAP Manifold Absolute Pressure ml milliliter mm millimeter MPH Miles Per Hour ms millisecond Nm Newton Meter N A Not Applicable no Number 02 Oxygen OD Outside Diameter OEM Original Equipment Manufacturer oz Ounce P amp A Parts and Accessories PN Part Number PSI Pounds per Square Inch RES Reserve RPM Revolutions Per Minute SCFH Cubic Feet per Hour at Standard Conditions TCA Throttle Control Actuator TDC Top Dead Center TGS Twist Grip Sensor TP Throttle Position TMAP Intake Air Temperature Manifold Absolute Pressure TSM Turn Signal Module TSSM Turn Signal Security Module V Volt VAC Volts of Alternating Current VDC Volts of Direct Current B 2 2008 FLT Police Service Appendix B Glossary Table B 1 Acronyms and Abbreviations ACRONYM OR ABBREVIATION DESCRIPTION VIN Vehicle Identification Number VSS Vehicle Speed Sensor 2008 FLT Police Service Appendix B Glossary B 3 NOTES B 4 2008 FLT Police Service Appendix B Glossary Tools Used in This Manual PART NUMBER TOOL NAME NOTES HD 33223 1 CYLINDER COMPRESSION GAUGE 8 5 AUTOMATIC COMPRESSION RELEASE Compres sion Test HD 34633 AIR SUSPENSION PUMP AND GAUGE 12 5 AIR SEAT RESERVOIR Installation HD 39787A RIVET TOOL 2 6 SADDLEBAGS Hinges HD 41404 B TEST CONNECTOR KIT 8 5 AUTOMATIC COMPRESSION RELEASE Dia gnostics HD 48498
79. ize 3 882 98 60 0 010 in oversize 3 887 98 73 Table 3 9 Connecting Rods ITEM REPLACE IF WEAR EXCEEDS INCHES MM Piston pin fit loose 0 001 0 025 Table 3 10 Crankshaft Sprocket Shaft Bearing ITEM REPLACE IF WEAR EXCEEDS INCHES MM Crankshaft runout Greater than Greater than 0 003 0 076 Bearing fit in crankcase 0 0038 0 0054 0 097 0 137 tight Bearing inner race on crankshaft tight Less than 0 0001 Less than 0 0254 Table 3 11 Valve Stem to Guide Clearance ITEM REPLACE IF WEAR EXCEEDS INCHES MM Intake 0 0035 0 089 Exhaust 0 0040 0 102 OIL COOLER OPERATION Pressurized oil flows through a hole in the oil filter mount into a passage in the oil cooler adapter The oil cooler adapter is mounted between the oil filter mount and the oil filter A thermostat inside the oil cooler adapter controls the flow of oil to the oil cooler The thermostat consists of a temperature sensitive element compressed between a spring and threaded plug See Figure 3 1 While the engine oil temperature is below 200 F 93 C the thermostat is open allowing most of the engine oil to pass from the supply port directly to the return port en route to the oil filter When the engine oil temperature reaches 200 F 93 C the thermostat closes and the entire flow is directed to the oil cooler through the supply hose The fins on the t
80. m 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 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 SYN3 Ultra Glide V Rod VRSC Wide Glide and Harley Davidson Genuine Motor Parts and Genuine Mot
81. m Table 3 4 Valve Spring Assembly Displacement 103 cu in 1690 cc ITEM PRESSURE DIMENSION Torque 102 ft lbs O 138 Nm Closed 165 lbs 75 kg 1 820 in 46 2 mm AM EI DEM Open 416 Ibs 189 kg 1 290 in 32 7 mm Free length n a 2 210 in 56 1 mm Table 3 2 Oiling System ITEM SPECIFICATION Table 3 5 Connecting Rods Pump Twin gerotor dual scavenge crank ITEM INCHES MM mounted and driven internal oil pump dry sump Piston pin fit loose 0 0003 0 0007 0 008 0 018 Pressure 30 38 psi 207 262 kN m at 2000 RPM and normal operating temperature of Table 3 6 Crankshaft Sprocket Shaft Bearing 230 F 110 C UT 2 ITEM INCHES MM Filtration 10 micron media filtered between pump j Bearing inner race on 0 0001 0 0010 0 0025 0 0254 and engine A crankshaft tight Cooling Thermostat controlled oil cooler 2008 FLT Police Service Engine 3 1 SERVICE WEAR LIMITS GENERAL Wear limits can be used as a guide when deciding whether to reuse engine parts Replace used parts whenever the following wear limits are exceeded Table 3 7 Cam Support Plate ITEM REPLACE IF WEAR EXCEEDS INCHES MM Cam chain tensioner 0 080 0 090 2 03 2 29 shoe Warpage 0 010 0 25 Crankshaft bushing fit 0 0008 0 001 0 0203 0 0254 3 2 2008 FLT Police Service Engine 3 2 Table 3 8 Cylinder Bore ITEM REPLACE IF WEAR EXCEEDS INCHES MM Standard 3 877 98 48 0 005 in overs
82. mpression test can determine the source of cylinder leakage Use CYLINDER COMPRESSION GAUGE Part No HD 33223 1 with a screw in type adapter NOTE The Twin Cam 103 Engine uses a 12 mm adapter with the compression gauge 1 Operate engine to normal operating temperature 2 Disconnect spark plug wires 3 Clean around plug base and remove front cylinder spark plug 4 Install compression tester to front cylinder per gauge instructions NOTE The test results will vary depending on whether the ACR is connected or not Refer to Table 8 2 for specifications 5 Shift transmission to neutral Crank engine continuously through 5 to 7 compression strokes 6 Record gauge readings at the end of the first and last compression strokes highest readings 7 Replace front spark plug and repeat test on rear cylinder 8 Refer to Table 8 2 Readings should be within specified range If readings are higher than normal suspect a compression release that is not functioning correctly If readings are low inject approximately 1 2 oz 15 ml engine oil into each cylinder and repeat the compression tests on both cylinders NOTE Readings that are considerably higher after injecting the oil indicate worn piston rings 2008 FLT Police Service Electrical 8 11 Table 8 2 Compression Specifications 3 If V GY wire is shorted to ground the ACRs will remain on for a time that exceeds the design parameters and the ACR solenoids will
83. nately tighten screws to 20 30 in Ibs 2 3 3 4 Nm 4 Slide two Phillips screws with external tooth lockwashers through holes in mounting plate pole lamp at top of lug gage rack engaging weld nuts at top of air reservoir bracket Alternately tighten screws to 20 30 in Ibs 2 3 3 4 Nm 5 Place luggage rack into position inboard of frame tubes 6 Install TA0 TORX screws with spacers on each side of motorcycle to secure ends of luggage rack to frame tube weldments Alternately tighten screws to 15 20 ft Ibs 20 3 27 1 Nm 7 Install two hex bolts to fasten license plate bracket to bottom support tube Alternately tighten screws to 15 20 ft lbs 20 3 27 1 Nm 8 Atinboard side of rear marker lights bracket connect left and right rear marker lights connectors 9 Install chrome frame tube cover on frame tube Install Phillips screw and tighten to 25 40 in Ibs 2 8 4 5 Nm Repeat step on opposite side of motorcycle 10 Install bolt with flat washer to install saddlebag front mounting bracket but do not tighten Repeat step on opposite side of motorcycle 11 Depress collar on compression fitting of air seat reservoir and insert air tube until it bottoms Gently tug on tube to verify that it is locked in place CAUTION Maximum air pressure for the seat is 100 psi 689 kPa Normal air pressure is 30 45 psi 207 310 kPa Do not operate with air pressure so low that system bottoms out on bumpy roads 00167a
84. nduit from the turn signal switch bracket 3 Remove the Phillips screw with lockwasher to release the turn signal switch bracket Remove the switch assembly from the housing 4 Remove the two T8 TORX screws and the Phillips screw with lockwasher to release the lower bracket Remove the bracket from the housing 5 Pull both switches from the housing 6 Cut the wires from the old switches as follows a Gray Black wire 1 1 2 in 38 mm b Orange Violet wires 1 7 8 in 48 mm c Green Red wire 1 1 4 in 32 mm NOTE Replacement pursuit auxiliary switch wires are cut to length and partially stripped Gray Black wire 2 in 51 mm Orange Violet wires 1 7 8 in 48 mm Green Red wire 1 3 4 in 45 mm 7 Connect wires of new switch See HANDLEBAR SWITCH ASSEMBLIES in the Touring Models Service Manual 8 Move keycap to the OFF position Install the switches in the housing with contacts facing the recessed area on the ramp Ribs cast in lower housing hold switches in position 8 8 2008 FLT Police Service Electrical The Auxiliary switch with the Gray Black lead is installed at the bottom while the Pursuit switch with the Green Red lead is at the top Route switch wires into corner space outside of the ribbed area NOTE If the keycap and ramp mechanism requires replacement install as follows Slide ramp upward to remove from keycap shaft Remove keycap from switch housing Install spring into hol
85. ng right fairing support brace 160 B 1 place Packard Upper frame cross member under seat 166 ABS module 20 place Molex Under right side cover 167 Front wheel speed sensor 2 place Amp Tyco Inner fairing below upper fork bracket left side 168 Rear wheel speed sensor 2 place Amp Tyco Under right side cover 176 Main to interconnect harness 6 place Deutsch Inner fairing outboard of right fairing bracket 178 Active intake solenoid 2 place Amp Tyco Back of air cleaner backplate 179 Active exhaust actuator 5 place Amp Tyco Domestic not used under right side cover HDI under right side cover behind elec trical bracket 201 ABS diode pack 4 place Deutsch Under right side cover 203F ACR solenoid 2 place Amp Tyco Between cylinders 203R ACR solenoid 2 place Amp Tyco Between cylinders 204 Twist Grip sensor 6 place Molex Inner fairing right support bracket 207 Stealth disable lighting circuit 3 place Molex black Inner fairing front of right fairing bracket 211 Throttle Control Actuator 6 place Molex Throttle body 2008 FLT Police Service Appendix A Wiring A 3 ed01652 22 24 31 20 73 20 207 NN 177 32 Figure A 2 Headlamp Nacelle FLHP E Table A 2 FLHP E Wire Harness Connectors NO DESCRIPTION TYPE LOCATION 4 Accessory 4 place Deutsch Upper frame cross member un
86. ng and Charging Figure A 9 Figure A 9 2008 FLHTP DOMESTIC and INTERNATIONAL Models Starting 2008 FLHTP DOMESTIC and INTERNATIONAL Models Starting and Charging and Charging et00089 Hands Free Security Module HFSM For Turn Signal amp Security Module TSM TSSM CAN Battery Ignition Serial Data Neutral Switch Left Turn Feed Right Turn Feed Right Turn Switch Input Left Turn Switch Input Start Relay Control Clutch Switch Alarm Signal Ground Receive Antenna Transmit Antenna A Transmit Antenna B i i GO i ACC i From Fairing i WO Harness 21A i 12345678910 Y 21B o ETIWEE BK g552so i c re i x Indicator i m Lamps i BN Right i BK ub Turn i i GN Y Oil O 1 AY Pressure i i TN i Neutral j om N MEN i wJsm High BK M D Beam i Left V e i El i BK 4 Turn i i i xac Boo 321 105B i 30A To Fairing i gt Harness N 105A 1 t i 2 i l i 3 AAA A a AA AAA REE NEEE Er ee 4 i i 5 6 7 i 8 i i 9 10 i i 11 i i 12 i i i Hands Free Antenna i 1 1 Y BK i 7 2 mon ON 1 1 Antenna A i 3 3 m BK BK 2 2 Antenna B i J lt lt gt gt 209B 209A
87. o 99642 97 6 ml Clutch cable Lubricant part number LUBIT 8 SUPER OIL Part No 94968 85TV 1 4 fl oz Handlebar switch housing screw torque 35 45 in Ibs 4 0 5 1 Nm 1 2 2008 FLT Police Service Maintenance Table 1 2 Quick Reference Maintenance Chart 2008 Police Models ITEM SERVICED SPECIFICATION DATA Spark plugs Type HD 6R12 Gap 0 038 0 043 in 0 97 1 09 mm Torque 12 18 ft lbs 16 3 24 4 Nm Front fork oil Amount See FRONT FORK in the Touring Service Manual Type and part number HYDRAULIC FORK OIL TYPE E Part No 99884 80 16 oz Battery Terminal bolt torque 60 96 in Ibs 6 8 10 9 Nm Top caddy clamp screw torque 15 20 ft lbs 20 27 Nm Table 1 3 Lubricants Greases Sealants ITEM PART NUMBER PACKAGE Anti Seize Lubricant 98960 97 1 oz squeeze tube CCI 20 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 qt bottle Transmission and Primary Chaincase Lubricant G40M Brake Grease 42820 04 squeeze packet Gray High Performance Sealant 99650 02 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 Su
88. olex gray Inner fairing left fairing support brace 30 TSM HFSM 12 place Deutsch Cavity in crossmember at rear of battery box under seat 31L Left front turn signal pursuit lamp 4 place Multilock Inner fairing outboard of left fairing bracket 31R Right front turn signal pursuit lamp 4 place Multilock Inner fairing right fairing support brace 32 Front fender tip lamp jumper harness 2 place Multilock black Inner fairing below upper fork bracket left side 33 Ignition light key switch 3 place Packard Inner fairing under storage box front of ignition switch housing 38 Headlamp Headlamp Connector Inner fairing back of headlamp 39 Speedometer 12 place Packard black Inner fairing back of speedometer 45 Rear fender tip lamp 3 place Multilock Circuit board under tail lamp assembly 46 Stator 3 place Lyall Bottom of voltage regulator left side 57 Siren PA speaker 2 place Deutsch Top rail of engine guard right side 59 Rear pole lamp 2 place Deutsch Under luggage rack left side 64 Fuse block Packard Under left side cover 65 VSS 3 place Delphi Top of transmission case under Starter 69 Pursuit flasher domestic only Relay connector Inner fairing front of soeedometer 70 Siren amplifier harness 12 place Deutsch black Inner fairing left fairing support brace 72 Siren amplifier 18 place Packard Top rail of saddlebag guard left side 77 Voltage regulator 2 place Lyall Bottom of volt
89. or 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 and without incurring obligation MAINTENANCE 1 1 SCHEDULED MAINTENANCE A teli nO O IR m M Sa Meg aT 1 1 CHASSIS 2 1 SPECIFICATIONS CHASSIS ELO BEES A ETT 2 1 2 2 VEHICLE IDENTIFICATION NUMBER V I N LOB A O 2 2 2 3 TIRES A ee AE E ere C RS aT eee E E EA 2 3 2 4 SEAT menant EP IM eco A ee e ao 2 4 Seal Retina 2 6 A OTT 2 6 Alt Spring Beplgcetiefib criar ri Ri 2 6 Feilen 2 6 IM SER nern 2 6 Seat Bracket Mount Replacement ss 2 7 FSI O 2 7 Melle een 2 7 2 5 AIR SEAT RESERVOIR PC A MM 2 8 Trete UI is caida 2 9 2 6 SADDLEBAGS nn 2 11 PM Danae dai aria 2 11 a Erel IIo n Ea E A E E E E E EA 2 11 Es ak ae 2 11 PORN ale nee 2 11 Lo een 2 11 alli P 2 11 PI VA s a sean tb ded Pru tha tipo a pM 2 11 tS Cell A A 2 12 ME E AE SEE TE AEE TT 2 12 Remova heann 2 12 DEVS ll A ia 2 12 TEMPE iaa id ios 2 12 PROTO Vl c miata 2 12 ISSN STO TT EET ORT 2 12 Knob and Spring ESI cisco 2 12 emn
90. osite side of motorcycle 5 At inboard side of rear marker lights bracket carefully pull left and right rear marker lights connectors 6 Remove two hex bolts to free license plate bracket from bottom support tube 7 Remove T40 TORX screws with spacers on each side of motorcycle to release ends of luggage rack from frame tube weldments 8 Raise luggage rack high enough to access air reservoir See Figure 2 7 9 Remove two Phillips screws with external tooth lock washers from mounting plate pole lamp at top of luggage rack to release air reservoir bracket 10 Remove two Phillips screws from license plate bracket to free rear of air reservoir bracket Be sure to hold reservoir as the last screw is removed or damage to fender paint can occur if assembly is dropped See Figure 2 8 11 Remove fittings and or air pressure gauge from reservoir if necessary sm04701 Figure 2 8 Air Seat Reservoir Assembly INSTALLATION PART NUMBER TOOL NAME HD 34633 AIR SUSPENSION PUMP AND GAUGE 1 Reassemble fittings and or air pressure gauge onto air reservoir if removed Orient parts as shown in Figure 2 8 Apply PIPE SEALANT WITH TEFLON to threads before assembly 2 Position air reservoir beneath luggage rack exercising caution to avoid scratching fender paint 3 Slide two Phillips screws through holes in license plate bracket engaging weld nuts at rear of air reservoir bracket Alter
91. perbonder 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 2008 FLT Police Service Maintenance 1 3 NOTES 1 4 2008 FLT Police Service Maintenance SUBJECT PAGE NO 2 1 SPECIFICATIONS CHASE ns el 2 2 VEHICLE IDENTIFICATION NUMBER khia N Ss A a 2 5 AIR SEAT RESERVOIR ii a sanan 2 6 SADDLEBAGS ss anne 2 7 TACHOMETER BRACKET T E NOTES GENERAL Table 2 3 Weights 2008 Police Models Table 2 1 Capacities 2008 Police Models ITEM FLHTP FLHP ITEM U S LITERS ERE RSs DR ke Fuel tank total 6 0 gal 22 7 ae 764 347 739 335 Low fuel warning lamp on 1 0 gal 3 8 GVWR 1200 544 1200 544 Oil tank with filter 4 0 U S at 3 8 GAWR front 500 227 500 227 Transmission 32 0 fl oz 0 95 approximate GAWR rear 827 375 827 375 Primary chaincase 38 0 fl oz 1 12 NOTE drained Gross vehicle weight rating GVWR maximum allowable Primary chaincase 45 0 fl oz 1 33 loaded vehicle weight and corresponding gross axle weight cover removed rating GAWR are printed on a label fixed to the bottom of the Table 2 2 Dimensions
92. place Multilock Circuit board under tail lamp assembly 108 Tachometer 12 place Packard gray Back of tachometer 117 Fuel gauge 4 place Multilock Below fuel tank left side 119 EFI fuses Fuse terminals Fuse block under right side cover 120 Oil pressure switch Post terminal Front Right Crankcase 121 Rear brake light switch Spade terminals Bottom of rear frame downtube right side 122 Horn Spade terminals Between cylinders left side 123 Starter relay Relay connector Fuse Block under left side cover 124 Brake light relay Relay connector Fuse Block under left side cover 126 Ignition keyswitch relay Relay connector Cavity in crossmember at rear of battery box under seat 128 Starter solenoid Spade terminals Top of starter 129 Harness grounds Ring terminals Upper frame cross member under seat 131 Neutral switch Post terminals Top of transmission right side 133 Jiffy Stand Sensor 3 place Molex black HDI Electrical caddie at bottom of lower frame crossmember Not used on Domestic 135 EFI system relay Relay connector Fuse block under right side cover 137 O2 sensor rear exhaust header 2 place Amp Tyco Under chrome starter cover 138 O2 sensor front exhaust header 2 place Amp Tyco Back of cross brace between front frame downtubes left side 141 Fuel level sender and fuel pump 4 place Packard Top of canopy under console 2008 FLT Police Service Appendix
93. re voltage at breakout box terminal 19 with breakout box disconnected from ECM Is voltage present Locate and repair short to voltage on V GY wire between terminal 2 on connector 203FB front or 203RB rear and ECM Measure resistance between terminal 1 and 2 on connector 203FA front or 203RA Is continuity present connector 78B terminal 19 7079 Reconnect breakout box and ECM and ACRs to the engine wiring harness Measure voltage at terminal 19 during cranking Is voltage 0 1 8 0 VDC and fluctuating while engine cranks Replace defective ACR solenoid 7077 Perform compression test only one spark plug can be removed at a time or ACR will be disabled Refer to COMPRESSION TEST Is compression 130 170 PSI 896 1 173 kN m2 0 with ACR connected and 200 220 PSI 1379 1517 kN m2 with ACR disconnected Replace ECM YES is not ACR rel Review symptoms Issue ated 8 14 2008 FLT Police Service Electrical Replace ACR on cylinder that is non functional 7077 7080 1001778 en SUBJECT PAGE NO AT EONNESTERE nn NE S A NOTES CONNECTORS CONNECTORS A 1 ed01651 31R K 2 bb 24 70 176 EN 31L 15 207
94. s 2 Install tether eyelet onto threaded boss 3 Apply a small dab of LOCTITE HIGH STRENGTH THREADLOCKER 262 red to threads of T15 TORX screw 4 Install screw into threaded boss and tighten to 20 25 in Ibs 2 3 2 8 Nm See Figure 2 12 5 Repeat this procedure to fasten opposite end of tether to second tether bracket sm04702 Tether bracket Rivet 4 T15 TORX screw Tether eyelet Wave spring meN Figure 2 12 Tether and Tether Bracket TETHER BRACKETS Removal 1 Remove tether See 2 6 SADDLEBAGS Tether 2 Drill out four rivets using a 3 16 inch drill bit 3 Remove tether bracket and backplate Installation 1 Slide new rivets through holes in backplate saddlebag saddlebag lid and tether bracket with the threaded boss on the outboard side 2 Install rivets See 2 6 SADDLEBAGS Hinges 3 Install tether See 2 6 SADDLEBAGS Tether KNOB AND SPRING LATCH Removal 1 Place multiple strips of masking tape on each side of knob to protect finished surfaces from scratches and other damage Using a large flat blade screwdriver alternately pry up each side of knob until free of post See upper frame of Figure 2 13 2 Remove knob seal and masking tape Remove any residual adhesive with 3M general Purpose adhesive remover Part No 051135 See lower frame of 3 Drill out two rivets using a 13 64 inch drill bit Remove spring latch See Installation 1 Hold sprin
95. s not ACR related Measure continuity between terminal 2 on connector 203FB front or 203RB rear and breakout box terminal 19 Is continuity present During the first 2 seconds after turning the key on while relay is energized or while cranking measure voltage at terminal 1 on connector 203FB front or 203RB rear Is battery voltage present Locate and repair open on Y GN wire between terminal 1 on connector 203FB front or 203RB rear and system relay 7077 Disconnect breakout box from ECM leaving harness connected to breakout box Measure continuity between terminal 19 on breakout box and ground Is continuity present YES Disconnect connector 203FB front and 203RB rear one at a time Is continuity to ground still resent Locate and repair short to ground on V GY wire between terminal 2 on connector 203FB front or 203RB rear and ECM connector 78B terminal 19 and replace both ACRs 7078 Replace grounded ACR 7077 Locate and repair open on V GY wire between terminal 2 on connector 203FB front or 203RB rear and ECM connector 78B terminal 19 7076 Go to ACR Diagnostics Part 2 of 2 fc01777_en 2008 FLT Police Service Electrical 8 13 ACR Diagnostics Part 2 of 2 Continued from ACR Diagnostics Part 1 of 2 Measu
96. ssembly carefully read all rel ative service information before repair work is started In 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 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 Supplement and the appropriate Service Manual Harley Davidson Motor Company will periodically issue Service Bul letins 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 AWARNING 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 mor
97. t pivot bolt and acorn nut 48 84 in Ibs 5 4 9 5 Nm 2 4 SEAT Seat Installation Seat stud flange nuts rear 96 144 in Ibs 10 9 16 3 Nm 2 4 SEAT Seat Installation Spark plugs 12 18 ft lbs 16 3 24 4 Nm 1 1 SCHEDULED MAINTENANCE General Spoke nipples 55 in Ibs 6 2 Nm 1 1 SCHEDULED MAINTENANCE General Tachometer bracket acorn nuts FLHP E 72 108 in Ibs 8 1 12 2 Nm 2 7 TACHOMETER BRACKET FLHP E Installa tion Top caddy clamp screw 15 20 ft lbs 20 27 Nm 1 1 SCHEDULED MAINTENANCE General Transmission drain plug 14 21 ft lbs 19 0 28 5 Nm 1 1 SCHEDULED MAINTENANCE General Transmission filler plug dipstick 25 75 in lbs 2 8 8 5 Nm 1 1 SCHEDULED MAINTENANCE General IV TORQUE VALUES A Automatic Compression Release ACR Compression Test l l iles esses 8 11 Diagnostics 4 nase er EN xu 8 12 General hares e ann 8 10 Installation 000000 8 10 Removal inicia oN arise 8 10 B Bulb Chart ra EUER DES ads 8 1 C Connector Locations 2 222222 seen en A 1 F Foreword Important General Information i l G Glossary Acronyms and AbbreviationS B 1 H Handlebar Switches Clutch Interlock Switch o o 8 7 Horn and Siren Yelp SwitCh 8 6 Pursuit and Auxiliary SwitCh 8 8 L Loctite aie ed re Li i I M Maintenance Periodic icf eek eo bie eto bee a 1 1 O Oil Cooler Cleaning and Inspecti0N
98. t switch high and low beams Turn left signal switch Horn siren yelp switch OF Penna Figure 8 5 Left Handlebar Switch Housing Installation 1 Install the switches in the housing with contacts facing tabs on ramp For best results install one switch at a time Ribs cast in lower housing hold switches in position The Horn switch with the Yellow Black lead pivot point towards rider is installed at the bottom while the Siren Yelp switch with the Brown Black lead pivot point towards the front is at the top Route switch wires in channel on the outboard side of the ribbed area 2 Install the keycap engaging slot with hook on ramp 3 Install lower bracket sliding pin through keycap and engaging hole in lower casting 4 Slide T8 TORX screws through holes in lower bracket and switches and thread into lower casting until snug 5 Install Phillips screw with lockwasher to secure lower bracket to threaded boss in housing Verify operation of Horn and Siren Yelp switches to ensure that both are spring returned 6 Install clutch interlock switch in bore of lower switch housing if loose 7 Insert tapered end of new 7 inch cable strap into round hole in turn signal switch bracket and then feed back through using the adjacent hole Reserve the oblong hole for the bracket screw NOTE Be sure that all splices are positioned above the turn signal switch bracket 8 Place the turn signal switch assembly into the hous
99. thout ABS 1 of 2 et00092 lt 73A P Lares 2 ja GY BN W 1 GY V 69A gt gt 69B Pursuit B Flasher 2 m GY V 3 GY BN gt 59B Pole Lamp 8K Bk LEONA gt 22B 9 GNR Right Hand Y BK ON Control BUR TSM TSSM HFSM Optional To ABS i Securit Front Turn Console Harness i y i Banery 13 J 3 Signals re Interconnect _ Start qa 40 Amp Voltage Ser Data 13 3 E ton ER e Tz Hs DY MAXIFUSE Regulator Neutral Switch 4 4 TN 1 3456 nummimm Y 56 EEE Left Turn Feed 5 5m Bi gala 20B W NIUN ie j EXA 1 2 Y Y Right Turn Feed 6 6 E BN EEEEEEEEN IE lz u u gt x xgzzzzzul loz 33 2z ft5 I Right Turn SW Input 7 7 EWBAN MEZ 5 z Ox e Lot Turn SW Input 8 8 E Wy anl E E 3 E g 5 2 a Yon d earn HH ES 5B Start Relay Control 9 9 TN GN Clutch Switch 10 10m BK R mmm Alarm Signal 11 11 ELGNEN Ground 12 12 BK GN mum e Spa wars urn oignal 30A 30B Turn Signal Security 80A cd L Module I E FIIIT a a l l Dues Bl o Y c nam on igi Y gt i i EBK GN a E ee E 15 IA l E ma 2 GN m um Ss BG EE EH UN m m mm NV m um BKR s a LGN V TN GN r GY ill eo i 3 er i L BENE ZBN Du 2A R a A z a EWBKi H Battery 15A o T 1373 7 EUE m y 13 BK D P QM e BN GY R CARAS fol BE GY LH
100. tomotive type ATO fuses are used ed01653 175 e e 1 Brakes Pursuit 15A 8 Fuel pump 15A 15 Brake light relay 2 Accessory 15A 9 EFI system relay 16 Headlamp 15A 3 P amp A 15A 10 Starter relay 17 Lighting 15A 4 Radio Siren 15A 11 P amp A ignition if equipped 2A 18 Spare 15A 5 Radio memory if equipped max 19 ABS if equipped 30A 15A 12 Instruments 15A 20 Spare 30A 6 Battery 15A 13 Ignition 15A 21 MAXIFUSE 40A 7 ECM power 15A 14 Engine control 15A Figure 8 2 Left Side Electrical Caddy 2008 FLT Police Service Electrical 8 3 Installation 1 Install fuse in fuse block For correct type and amperage rating refer to Figure 8 2 2 Install cover on fuse block 8 4 2008 FLT Police Service Electrical Align barbed studs in side cover with grommets in frame downtubes and push firmly into place no tools required Rotate siren amplifier mounting bracket downward Install wing nut style bolt to secure bracket to clamp on saddlebag guard Tighten top bolt if loosened Install left side saddlebag REAR MARKER LIGHTS 8 3 MARKER LIGHTS REPLACEMENT 1 On inboard side of rear marker lights bracket gently pull electrical connector from prongs on marker light 2 Rotate marker light in a counterclockwise d
101. tsch See Figure 2 16 4 Install two Phillips screws to fasten handlebar clamp shroud to the fork lock mechanism Install fork lock plate 5 Install headlamp connector at back of headlamp bulb 6 Align holes in headlamp housing with those in headlamp nacelle headlamp door bracket at bottom Install seven Phillips screws and alternately tighten to 9 18 in Ibs 1 0 2 0 Nm 2008 FLT Police Service Chassis 2 15 7 Fitthe square shaped portion of the headlamp door spring screw at bottom of headlamp door and tighten to 9 18 in into slot at top of headlamp housing and then snap the Ibs 1 0 2 0 Nm headlamp door chrome ring Into place Install Phillips nara windshield See WINDSHIELD FLHR C In the Touring Models Service Manual 2 16 2008 FLT Police Service Chassis SUBJECT PAGE NO SI SP ECIFIGAMONS ENGINE ee een 3 2 SERVICE WEAR LIMITS 3 2 NOTES SPECIFICATIONS ENGINE GENERAL 3 1 MANUFACTURING TOLERANCES Table 3 1 Engine 2008 Police Models Table 3 3 Valves ITEM SPECIFICATION ITEM IN MM Number of cylinders 2 Fit in guide exhaust 0 0015 0 0033 0 038 0 084 Type 4 cycle 45 degree Fit in guide intake 0 0008 0 0026 0 020 0 066 V Type air cooled Stem protrusion from 1 990 2 024 50 55 51 41 Compression ratio 9 6 1 cylinder head boss Bore 3 875 in 98 mm Stroke 4 375 in 111 m
102. ubes of the oil cooler dissipate heat before the flow returns to the oil cooler adapter through the return hose The engine oil then passes through the oil filter before returning to the crankcase NOTE For a complete description of the engine oil flow see GEN ERAL INFORMATION in the Touring Models Service Manual sm04710 1 Return fitting 2 Supply fitting 3 Thermostat Figure 3 1 Oil Cooler Adapter Flange nut 3 Flat washer 3 Mounting bracket Cil cooler 1 2 3 4 5 Supply hose 6 Return hose 7 Hose clamp 4 8 Oil cooler adapter 9 Oil filter adapter 10 Adhesive gasket Figure 3 2 Oil Cooler Assembly REMOVAL 1 Place a suitable drain pan beneath the oil cooler 2 See Figure 3 2 Remove three flange nuts with flat washers Raise oil cooler to free threaded studs from holes in mounting bracket 3 Usinga side cutters cut and remove clamps on oil cooler adapter side of supply and return hoses Pull hoses from fittings 4 Remove oil cooler from motorcycle 5 Using a side cutters cut and remove clamps on oil cooler side of supply and return hoses Pull hoses from fittings 2008 FLT Police Service Engine 3 3 6 Remove mounting bracket as follows a Remove voltage regulator and front electrical caddy See VOLTAGE REGULATOR in the Touring Models Service Manual b Lift mounting bracket off studs on lower frame cross member CLEANING AND IN
103. usc BIENES 2 12 A cA ERA LP 2 13 Spring Lateh Brsckel nen 2 13 A ER ER EFHVER MEA TE ARS REPE 2 13 Installatlen nase aaa 2 13 2 7 TACHOMETER BRACKET FLHP E HEM lara 2 14 A a 2 15 ENGINE 3 1 SPECIFICATIONS ENGINE A ee ebene 3 1 Manufacturing Tolerances anne 3 1 3 2 SERVICE WEAR LIMITS eo MT 3 2 3 3 OIL COOLER TODOS ON zc aret dire EU E Ga i Eae Eu EUR EM tre 3 3 ablic eC 3 3 Laid And IN caracas 3 4 Installation sn 3 4 Oil Cooler Adapter and Thermostat Replacement 3 4 Removal ciin E 3 4 A A E E E E 3 4 FUEL SYSTEM 4 1 FUEL SYSTEM BRS ING Coment cuan 4 1 ELECTRIC STARTER 5 1 ELECTRIC STARTER Na Unique COMO nt misa 5 1 DRIVE 6 1 DRIVE No JIEIQUE COM e 6 1 TRANSMISSION 7 1 TRANSMISSION No Unius CO u 7 1 ELECTRICAL 8 1 BULB CHART A E AE T E E E NA 8 1 8 2 SYSTEM FUSES AND RELAYS Busen FUSE S ee ee EROR Ads 8 3 Removal serrana R S 8 3 EENT E aia 8 4 8 3 REAR MARKER LIGHTS Marker Lights Replacement uiui iiceeieea 8 5 uiris suc RM ERU T 8 5 Installati i C A 8 5 8 4 HANDLEBAR SWITCHES Horn and Siren Yelp lucia 8 6 A n EVE RM Ed HMM 8 6 A see 8 6 Clutch Interlock Swilch essen ann 8 7 giri M 8 7 Stma cil 8 7 Pursuit and Auxiliary Swie R ee 8 8 REMOTA rin 8 8 A AE 8 8 8 5 AUTOMATIC COMPRESSION RELEASE ET E EA ees a eee 8 10 Rips e oO 8 10 TABLE OF C
104. vent lockups Tire inflation pressure that is significantly low also can have an adverse effect Table 2 7 Tire Data TIRE LOCATION SIZE MANUFACTURER S DESIGNATION TIRE PRESSURE COLD Front MT90B 16 72H Dunlop D402F PT 36 psi 248 kPa Rear MT90B 16 72H Dunlop D402 PT 36 40 psi 248 276 kPa All 2008 vehicles use only Dunlop Harley Davidson tires 2008 FLT Police Service Chassis 2 3 SEAT 2 4 GENERAL CAUTION Maximum air pressure for the seat is 100 psi 689 kPa Normal air pressure is 30 45 psi 207 310 kPa Do not operaie with air pressure so low that system bottoms out on bumpy roads 00167a NOTES Initially pressurize the seat air suspension system to 40 psi 275 8 kPa then add or remove pressure to the rider s comfort DO NOT operate motorcycle with system under inflated To check minimum air pressure have rider sit on seat and bounce to simulate riding conditions Visually check for any contact between air spring and frame components Add air as necessary See Figure 2 2 Removal and installation of retaining pin 1 requires that the air pressure be removed from the seat air suspension system The seat will no longer pivot up because the front of the seat will hit the fuel tank Retaining pin 1 should not be removed unless the seat is to be removed The seat does not adjust forward or rearward 2 4 2008 FLT Police Service Chassis
105. vet through holes in hinge saddlebag and backplate 2 Obtain RIVET TOOL Part No HD 39787A See Figure 2 11 3 Orient tool so that head of rivet is seated in depression of drive head Turn adjuster thumbscrew in or out of handle until both ends of rivet are captured 4 Slowly squeeze handle of tool to compress rivet Turn adjuster thumbscrew slightly in a clockwise direction and then squeeze handle again to further compress rivet Repeat step as necessary until rivet is fully installed NOTE Compress rivet in small increments only This method provides for best retention and alignment of parts and avoids possible damage to tool and painted surfaces of saddlebag 5 Repeat previous steps to install remaining rivets 6 Install lid onto saddlebag engaging upper and lower hinges 7 Compress new hinge pin rivet using a suitable rivet tool 8 Install tether See 2 6 SADDLEBAGS Tether TETHER Removal NOTE When the tether is removed use caution to keep lid from opening beyond its normal travel or damage to painted surfaces or hinges can occur 1 Remove T15 TORX screw from threaded boss on tether bracket See Figure 2 12 2 Remove tether eyelet and wave spring from threaded boss 2 12 2008 FLT Police Service Chassis 3 Repeat previous steps to remove opposite end of tether from second tether bracket Installation 1 With the concave side toward the tether bracket install wave spring onto threaded bos
106. wisted pair Figure A 3 Connector Wiring Diagram Symbols typical Table A 3 Wire Color Codes ALPHA CODE WIRE COLOR BE Blue BK Black BN Brown GN Green GY Grey LGN Light Green O Orange PK Pink R Red TN Tan V Violet W White Y Yellow 2008 FLT Police Service Appendix A Wiring A 7 WIRING DIAGRAMS Wiring Diagram List DIAGRAM LOCATION 2008 FLHTP DOMESTIC and INTERNATIONAL Models Main Harness without ABS 1 of 2 Figure A 4 2008 FLHTP DOMESTIC and INTERNATIONAL Models Main Harness with ABS 1 of 2 Figure A 5 2008 FLHTP DOMESTIC and INTERNATIONAL Models Main Harness 2 of 2 Figure A 6 2008 FLHTP DOMESTIC and INTERNATIONAL Models Interconnect Harness Figure A 7 2008 FLHTP DOMESTIC and INTERNATIONAL Models Pursuit Lamps Directional Lamps Tail Lamp and Figure A 8 Fender Tip Lamps 2008 FLHTP DOMESTIC and INTERNATIONAL Models Starting and Charging Figure A 9 2008 FLHTP DOMESTIC and INTERNATIONAL Models Handlebar Switches Indicator Lamps Fairing Figure A 10 Cap Switches and HFSM Antenna 2008 FLHTP DOMESTIC and INTERNATIONAL Models Anti Lock Brake System ABS Siren Amplifier Figure A 11 and Strobe Harness 2008 FLHP and FLHPE DOMESTIC and INTERNATIONAL Models Main Harness without ABS 1 of 2 Figure A 12 2008 FLHP and FLHPE DOMESTIC and INTERNATIONAL Models Main Harness with ABS 1 of 2 Figure A 13 2008
107. with a higher weight rating Since it has long been Harley Davidson policy not to mix different types of tires on the same vehicle we strongly recommend that both front and rear tires be replaced In order to alert the customer to this safety issue the following warning appears on a label fitted to the rear fender approximately 1 4 inch 6 4 mm behind the domestic seat mounting hole INIA IN Te This vehicle has tires with weight ratings for one person operation If this vehicle is modified to carry two people the tires must be changed See a Harley Davidson dealer for proper replacement tires Using improper tires can cause tire failure which could result in death or serious injury 00096a NOTE Use the tires recommended for civilian pleasure vehicles of the same year and model family AWARNING Harley Davidson front and rear tires are not the same Interchanging front and rear tires can cause tire failure which could result in death or serious injury 00026a Tire size manufacturer s description and inflation pressure are listed below NOTE ABS motorcycles must always use tires and wheels that are the same as the original equipment The ABS monitors the rotational speed of the wheels through individual wheel speed sensors Changing to different diameter wheels or different size tires can alter the rotational speed This can upset the calibration of the ABS and have an adverse effect on its ability to detect and pre

2008 FLT Police Models Service Manual Supplement

Contents

Download Pdf Manuals

Related Search

Related Contents