2008 Harley Davidson Softail Models Service Manual – PDF DOWNLOAD

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2008 Harley Davidson Softail Models Service Manual – PDF DOWNLOAD

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2008 Harley Davidson Softail Models Service Manual – PDF DOWNLOAD

ABOUT THIS MANUAL
GENERAL

• This Service Manual has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the Harley-Davidson product and assist in the performance of basic maintenance and repair.
• Secondly, it will introduce to the professional Harley-Davidson Technician the latest field-tested and factory-approved major repair methods. We sincerely believe that this Service Manual will make your association with Harley-Davidson products more pleasant and profitable.

HOW TO USE YOUR SERVICE MANUAL
Refer to the table below for the content layout of this manual.
NO. CHAPTER
1 Maintenance
2 Chassis
3 Engine
4 Fuel System
5 Starter
6 Drive
7 Transmission
8 Electrical
A Appendix A Connector Repair
B Appendix B Wiring
C Appendix C Conversions
D Appendix D Glossary

• Use the TABLE OF CONTENTS (which follows this FOREWORD) and the INDEX (at the back of this manual) to quickly locate subjects. Sections and topics in this manual are sequentially numbered for easy navigation.
• For example, a cross-reference shown as 2.1 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFICATIONS.
• 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.
• A number of acronyms and abbreviations are used in this document. See the D.1 GLOSSARY for a list of acronyms, abbreviations and definitions.

TABLE OF CONTENTS:

2008 Harley Davidson Softail Models Service Manual – PDF DOWNLOAD

COVER..............................................................  1
FOREWORD...........................................................  2
TABLE OF CONTENTS..................................................  4
1. MAINTENANCE..................................................... 16
	1.1 GENERAL.................................................... 18
		Servicing a New Motorcycle................................. 18
		Safe Operating Maintenance................................. 18
		Shop Practices............................................. 18
		Repair and Replacement Procedures.......................... 19
		Cleaning................................................... 20
		Tool Safety................................................ 20
	1.2 MAINTENANCE SCHEDULE....................................... 22
		General.................................................... 22
	1.3 FUEL AND OIL............................................... 26
		Fuel....................................................... 26
		Gasoline Blends............................................ 26
		Engine Lubrication......................................... 26
		Winter Lubrication......................................... 27
	1.4 BULB REQUIREMENTS.......................................... 28
		General.................................................... 28
	1.5 ENGINE OIL AND FILTER...................................... 29
		Checking and Adding Oil.................................... 29
		Changing Oil and Filter.................................... 29
	1.6 BRAKES..................................................... 31
		Fluid Inspection........................................... 31
		Rear Brake Pedal........................................... 31
	1.7 AIR CLEANER AND EXHAUST SYSTEM............................. 33
		Removal.................................................... 33
		Installation............................................... 34
		Exhaust System Leak Check.................................. 35
	1.8 TIRES AND WHEELS........................................... 36
		Tires...................................................... 36
		Tire Replacement........................................... 36
		Wheel Bearings............................................. 37
		Wheel Spokes............................................... 37
	1.9 PRIMARY CHAIN.............................................. 38
		General.................................................... 38
		Changing Primary Chaincase Lubricant....................... 38
	1.10 TRANSMISSION LUBRICANT.................................... 40
		Changing Transmission Lubricant............................ 40
	1.11 CLUTCH.................................................... 42
		Adjustment................................................. 42
	1.12 REAR BELT AND SPROCKETS................................... 44
		General.................................................... 44
		Cleaning................................................... 44
		Inspection................................................. 44
	1.13 REAR BELT DEFLECTION...................................... 46
		Inspection................................................. 46
		Adjustment................................................. 46
	1.14 THROTTLE CABLES........................................... 48
		Cable Inspection, Lubrication and Adjustment............... 48
	1.15 BLEEDING BRAKES........................................... 49
		General.................................................... 49
		Procedure.................................................. 49
	1.16 BRAKE PADS AND DISCS...................................... 50
		Inspection................................................. 50
		Brake Pad Replacement...................................... 50
	1.17 BATTERY MAINTENANCE....................................... 54
		General.................................................... 54
		Cleaning and Inspection.................................... 55
		Voltmeter Test............................................. 55
		Charging Battery........................................... 55
		Disconnection and Removal.................................. 56
		Storage.................................................... 57
		Installation and Connection................................ 58
	1.18 SUSPENSION ADJUSTMENTS.................................... 60
		Shock Absorbers: Softail Models............................ 60
	1.19 SPARK PLUGS............................................... 61
		Inspection................................................. 61
		Spark Plug Cable Inspection................................ 61
	1.20 STEERING HEAD BEARINGS: ALL BUT FLSTSB.................... 63
		Adjustment: FLST, FLSTC, FLSTF, FLSTN...................... 63
		Adjustment: FXST, FXSTB, FXSTC, FXCW/C..................... 64
		Lubrication................................................ 65
	1.21 STEERING HEAD BEARINGS: FLSTSB............................ 66
		General.................................................... 66
		Adjustment: FLSTSB......................................... 66
	1.22 ROCKER BEARINGS: FLSTSB................................... 68
		Inspection................................................. 68
	1.23 FRONT FORK OIL............................................ 70
		Replacing Fork Oil......................................... 70
	1.24 CABLE AND CHASSIS LUBRICATION............................. 71
		General.................................................... 71
		Cables and Hand Levers..................................... 71
		Jiffy Stand................................................ 71
		Steering Head Bearings..................................... 71
	1.25 HEADLAMP ALIGNMENT........................................ 72
		Inspection................................................. 72
		Adjustment................................................. 73
	1.26 CRITICAL FASTENERS........................................ 74
		Inspection................................................. 74
	1.27 ENGINE MOUNTS............................................. 75
		Inspection................................................. 75
	1.28 STORAGE................................................... 76
		General.................................................... 76
		Placing in Storage......................................... 76
		Removal from Storage....................................... 76
	1.29 TROUBLESHOOTING........................................... 78
		General.................................................... 78
		Engine..................................................... 78
		Lubrication System......................................... 79
		Electrical System.......................................... 80
		Transmission............................................... 80
		Handling................................................... 80
		Brakes..................................................... 80
2. CHASSIS......................................................... 82
	2.1 SPECIFICATIONS............................................. 84
		Specifications............................................. 84
	2.2 VEHICLE IDENTIFICATION NUMBER (V.I.N.)..................... 87
		Vehicle Identification Number.............................. 87
	2.3 FRONT WHEEL: ALL BUT FLSTSB................................ 89
		Removal.................................................... 89
		Disassembly................................................ 89
		Cleaning and Inspection.................................... 91
		Assembly................................................... 91
		Installation............................................... 92
	2.4 FRONT WHEEL: FLSTSB........................................ 93
		Removal.................................................... 93
		Disassembly................................................ 93
		Cleaning and Inspection.................................... 93
		Assembly................................................... 93
		Installation............................................... 94
	2.5 REAR WHEEL................................................. 95
		Removal.................................................... 95
		Disassembly................................................ 95
		Cleaning and Inspection.................................... 96
		Assembly................................................... 96
		Installation............................................... 97
	2.6 SEALED WHEEL BEARINGS...................................... 98
		Inspection................................................. 98
		Removal.................................................... 98
		Installation............................................... 99
	2.7 WHEEL LACING: 16 INCH RIM..................................101
		General....................................................101
		Procedure..................................................101
	2.8 WHEEL LACING: 17 INCH RIM..................................104
		General....................................................104
		Procedure..................................................104
	2.9 WHEEL LACING: 21 INCH RIM..................................107
		General....................................................107
		Procedure..................................................107
	2.10 TRUING LACED WHEELS.......................................110
		General....................................................110
		Lateral Truing.............................................110
		Radial Truing..............................................111
	2.11 CHECKING CAST WHEEL RUNOUT................................113
		General....................................................113
		Lateral Runout.............................................113
		Radial Runout..............................................113
	2.12 VEHICLE ALIGNMENT.........................................114
		Inspection.................................................114
	2.13 FRONT BRAKE MASTER CYLINDER...............................115
		General....................................................115
		Removal and Disassembly....................................115
		Cleaning and Inspection....................................117
		Assembly and Installation..................................117
	2.14 FRONT BRAKE CALIPER: ALL BUT FLSTSB.......................119
		Removal....................................................119
		Disassembly................................................119
		Cleaning, Inspection and Repair............................121
		Assembly...................................................122
		Installation...............................................122
	2.15 FRONT BRAKE CALIPER: FLSTSB...............................124
		Removal....................................................124
		Disassembly................................................125
		Cleaning and Inspection....................................126
		Assembly...................................................127
		Installation...............................................128
	2.16 REAR BRAKE MASTER CYLINDER................................130
		General....................................................130
		Removal....................................................130
		Installation...............................................130
		Disassembly................................................132
		Cleaning and Inspection....................................133
		Assembly...................................................133
	2.17 REAR BRAKE CALIPER........................................135
		Removal....................................................135
		Disassembly................................................135
		Cleaning, Inspection and Repair............................137
		Assembly...................................................138
		Installation...............................................138
	2.18 TIRES.....................................................140
		General....................................................140
		Removal....................................................140
		Cleaning, Inspection and Repair............................141
		Installation...............................................141
	2.19 FRONT FORK: TELESCOPIC....................................143
		General....................................................143
		Removal....................................................143
		Disassembly................................................143
		Cleaning and Inspection....................................143
		Assembly...................................................147
		Installation...............................................147
	2.20 FRONT FORK: SPRINGER......................................148
		General....................................................148
		Front Shock Absorber.......................................148
		Rigid Fork.................................................148
		Spring Fork................................................149
		Fork Rockers...............................................153
		Fork Stem Bearings.........................................154
	2.21 STEERING HEAD.............................................155
		Removal....................................................155
		Inspection.................................................156
		Disassembly................................................156
		Assembly...................................................157
		Installation...............................................158
	2.22 BELT GUARD AND DEBRIS DEFLECTOR...........................159
		Removal....................................................159
		Installation...............................................159
	2.23 REAR SHOCK ABSORBERS......................................160
		General....................................................160
		Removal....................................................160
		Installation...............................................160
	2.24 REAR FORK.................................................162
		Removal....................................................162
		Cleaning and Inspection....................................163
		Installation...............................................163
	2.25 THROTTLE CONTROL..........................................165
		Removal/Disassembly........................................165
		Cleaning and Inspection....................................165
		Assembly/Installation......................................165
		Cable Routing..............................................166
	2.26 CLUTCH CONTROL............................................167
		Removal....................................................167
		Installation...............................................167
	2.27 HANDLEBARS: ALL BUT FLSTF/FLSTSB/FXCW/FXCWC...............169
		Removal....................................................169
		Installation...............................................170
	2.28 HANDLEBARS: FLSTF.........................................171
		Removal....................................................171
		Installation...............................................172
	2.29 HANDLEBARS: FLSTSB........................................174
		Removal....................................................174
		Installation...............................................174
	2.30 HANDLEBARS: FXCW/FXCWC....................................176
		Removal....................................................176
		Installation...............................................177
	2.31 FRONT FENDER: ALL BUT FLSTSB..............................180
		Removal....................................................180
		Installation...............................................180
	2.32 FRONT FENDER: FLSTSB......................................181
		Removal....................................................181
		Installation...............................................182
	2.33 REAR FENDER: FLST/FLSTC...................................183
		Removal....................................................183
		Installation...............................................183
	2.34 REAR FENDER: FLSTF........................................185
		Removal....................................................185
		Installation...............................................185
	2.35 REAR FENDER: FXST/FXSTB/FXSTC/FLSTSB......................187
		Removal....................................................187
		Installation...............................................187
	2.36 REAR FENDER: FXCW/FXCWC...................................189
		Removal....................................................189
		Installation...............................................189
	2.37 REAR FENDER: FLSTN........................................191
		Removal....................................................191
		Disassembly................................................191
		Assembly...................................................193
		Installation...............................................193
	2.38 REAR FENDER WIRE CONDUIT..................................194
		Installation...............................................194
	2.39 JIFFY STAND...............................................196
		Cleaning...................................................196
		Sensor (HDI Models)........................................196
		Removal....................................................197
		Installation...............................................197
	2.40 FORK LOCK.................................................198
		Removal....................................................198
		Installation...............................................198
	2.41 SEAT AND STRAP RETENTION NUT..............................199
		Replacement................................................199
	2.42 SEAT: FXST/FXSTB..........................................200
		Removal and Installation...................................200
	2.43 SEAT: FXSTC...............................................201
		Removal and Installation...................................201
	2.44 SEAT: FXCW/FXCWC..........................................202
		Removal and Installation...................................202
	2.45 SEAT: FLSTN/FLSTF/FLST/FLSTC..............................204
		Removal and Installation...................................204
	2.46 SEAT: FLSTSB..............................................205
		Seat: FLSTSB...............................................205
	2.47 LUGGAGE RACK: FLSTN.......................................207
		Removal and Installation...................................207
	2.48 SADDLEBAGS: FLSTC.........................................208
		Removal....................................................208
		Installation...............................................208
	2.49 WINDSHIELD: FLSTC.........................................209
		Removal....................................................209
		Installation...............................................209
3. ENGINE..........................................................210
	3.1 SPECIFICATIONS.............................................212
		Specifications.............................................212
	3.2 SERVICE WEAR LIMITS........................................214
		General....................................................214
	3.3 ENGINE OIL FLOW............................................216
		Oil Feed...................................................216
		Top End....................................................217
		Bottom End.................................................218
		Chain Guide Bracket........................................220
		Oil Return.................................................220
	3.4 OIL PUMP OPERATION.........................................221
		General....................................................221
		Operation..................................................221
	3.5 BREATHER OPERATION.........................................223
		General....................................................223
	3.6 OIL PRESSURE...............................................224
		Oil Pressure Indicator Lamp................................224
		Checking Oil Pressure......................................224
	3.7 TROUBLESHOOTING............................................225
		Diagnosing Valve Train Noise...............................225
		Compression Test...........................................225
		Cylinder Leakdown Test.....................................225
		Diagnosing Smoking Engine or High Oil Consumption..........226
	3.8 HOW TO USE THIS SECTION....................................227
		Top End Repair.............................................227
		Bottom End Repair..........................................227
		Typical Symptoms...........................................227
	3.9 TOP END SERVICE............................................228
		Engine in Chassis..........................................228
		Engine Removed from Chassis................................229
	3.10 BOTTOM END SERVICE........................................230
		Engine in Chassis..........................................230
		Engine Removed From Chassis................................231
	3.11 STRIPPING MOTORCYCLE FOR SERVICE..........................232
		Procedure..................................................232
	3.12 ASSEMBLING MOTORCYCLE AFTER SERVICE.......................233
		Procedure..................................................233
	3.13 REMOVING ENGINE FROM CHASSIS..............................234
		Procedure..................................................234
	3.14 INSTALLING ENGINE IN CHASSIS..............................235
		Procedure..................................................235
	3.15 TOP END OVERHAUL: DISASSEMBLY.............................237
		General....................................................237
		Rocker Covers..............................................237
		Rocker Arm Support Plate...................................237
		Push Rods, Lifters and Covers..............................239
		Cylinder Head..............................................240
		Cylinder...................................................241
		Piston.....................................................241
	3.16 TOP END OVERHAUL: ASSEMBLY................................243
		General....................................................243
		Piston.....................................................243
		Cylinder...................................................244
		Cylinder Head..............................................246
		Push Rods, Lifters and Covers..............................249
		Rocker Arm Support Plate...................................250
		Breather Assembly..........................................251
	3.17 BOTTOM END OVERHAUL: DISASSEMBLY..........................253
		General....................................................253
		Cover and Cam Support Plate................................253
		Crankcase..................................................255
		Counterbalancer Assembly...................................256
	3.18 BOTTOM END OVERHAUL: ASSEMBLY.............................259
		General....................................................259
		Counterbalancer Assembly...................................259
		Crankcase..................................................262
		Cover and Cam Support Plate................................266
	3.19 BREATHER ASSEMBLY.........................................270
		Removal Overview...........................................270
		Disassembly................................................270
		Cleaning and Inspection....................................270
		Assembly...................................................270
		Installation Overview......................................270
	3.20 ROCKER ARM SUPPORT PLATE..................................271
		Removal Overview...........................................271
		Disassembly................................................271
		Cleaning and Inspection....................................271
		Assembly...................................................273
		Installation Overview......................................273
	3.21 PUSH RODS, LIFTERS AND COVERS.............................275
		Removal Overview...........................................275
		Disassembly................................................275
		Cleaning and Inspection....................................275
		Lifter Inspection..........................................276
		Assembly...................................................276
		Installation Overview......................................277
	3.22 CYLINDER HEAD.............................................278
		Removal Overview...........................................278
		Disassembly................................................278
		Cleaning...................................................279
		Inspection.................................................280
		Valve Guide Replacement....................................281
		Valve and Seat Refacing....................................285
		Assembly...................................................287
		Installation Overview......................................288
	3.23 CYLINDER..................................................289
		Removal Overview...........................................289
		Cleaning...................................................289
		Inspection.................................................290
		Deglazing Cylinder.........................................291
		Boring and Honing Cylinder.................................292
		Installation Overview......................................292
	3.24 PISTON....................................................293
		Removal Overview...........................................293
		Disassembly................................................293
		Cleaning...................................................293
		Inspection.................................................294
		Assembly...................................................295
		Installation Overview......................................297
	3.25 COVER AND CAM SUPPORT PLATE...............................298
		Removal Overview...........................................298
		Camshafts..................................................298
		Oil Pressure Relief Valve..................................300
		Cam Needle Bearings........................................300
		Cleaning and Inspection....................................303
		Installation Overview......................................304
	3.26 OIL PUMP..................................................305
		Removal Overview...........................................305
		Cleaning and Inspection....................................305
		Installation Overview......................................305
	3.27 CRANKCASE.................................................306
		Removal Overview...........................................306
		Right Crankcase Half.......................................306
		Left Crankcase Half........................................308
		Sprocket Shaft Bearing Inner Race..........................310
		Cylinder Studs.............................................312
		Pipe Plugs and Oil Fittings................................312
		Cleaning and Inspection....................................313
		Installation Overview......................................313
	3.28 FLYWHEEL AND CONNECTING RODS..............................314
		Removal Overview...........................................314
		Inspection.................................................314
		Installation Overview......................................314
	3.29 COUNTERBALANCER ASSEMBLY..................................315
		Removal Overview...........................................315
		Cleaning, Inspection, and Repair...........................315
		Installation Overview......................................318
	3.30 OIL TANK: ALL BUT FXCW/C..................................319
		Removal and Disassembly....................................319
		Installation...............................................322
	3.31 OIL TANK: FXCW/C..........................................323
		Removal and Disassembly....................................323
		Installation...............................................326
4. FUEL SYSTEM.....................................................328
	4.1 SPECIFICATIONS: FUEL SYSTEM................................330
		Specifications.............................................330
	4.2 ELECTRONIC FUEL INJECTION (EFI)............................331
		Troubleshooting............................................331
	4.3 IDLE SPEED.................................................332
		General....................................................332
	4.4 AIR CLEANER ASSEMBLY.......................................333
		Removal....................................................333
		Installation...............................................333
		Backplate Assembly: HDI Models.............................334
	4.5 FUEL TANK..................................................335
		General....................................................335
		Removal....................................................335
		Cleaning and Inspection....................................339
		Installation...............................................339
	4.6 THROTTLE POSITION SENSOR (TPS).............................341
		General....................................................341
		Removal....................................................341
		Installation...............................................341
	4.7 INTAKE AIR TEMPERATURE SENSOR (IAT)........................342
		General....................................................342
		Removal....................................................342
		Installation...............................................342
	4.8 ENGINE TEMPERATURE SENSOR (ET).............................343
		General....................................................343
		Removal....................................................343
		Installation...............................................343
	4.9 INDUCTION MODULE...........................................345
		Removal....................................................345
		Installation...............................................346
	4.10 IDLE AIR CONTROL (IAC)....................................347
		General....................................................347
		Removal....................................................347
		Installation...............................................347
	4.11 MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP)...................348
		General....................................................348
		Removal....................................................348
		Installation...............................................348
	4.12 OXYGEN SENSOR.............................................349
		General....................................................349
		Removal....................................................349
		Installation...............................................349
	4.13 FUEL INJECTORS............................................351
		General....................................................351
		Removal....................................................351
		Installation...............................................351
	4.14 FUEL PUMP AND FUEL GAUGE SENDING UNIT.....................353
		General....................................................353
		Removal....................................................353
		Disassembly/Assembly.......................................355
		Installation...............................................357
	4.15 FUEL PRESSURE TEST........................................359
		General....................................................359
		Testing....................................................359
	4.16 EXHAUST SYSTEM: ALL BUT FLSTF/FLSTN/FLSTSB................362
		Mufflers...................................................362
		System.....................................................362
	4.17 EXHAUST SYSTEM: FLSTF/FLSTN/FLSTSB........................364
		Mufflers...................................................364
		System.....................................................364
	4.18 INTAKE LEAK TEST..........................................366
		General....................................................366
		Leak Tester................................................366
		Procedure..................................................366
	4.19 EVAPORATIVE EMISSIONS CONTROL (CA MODELS).................368
		General....................................................368
		Charcoal Canister..........................................368
		Hose Routing/Replacement...................................369
5. STARTER.........................................................370
	5.1 SPECIFICATIONS: STARTER....................................372
		Specifications.............................................372
	5.2 STARTER....................................................374
		General....................................................374
		Removal....................................................374
		Installation...............................................374
		Testing....................................................374
		Field Coil Assembly........................................377
		Drive Assembly.............................................378
	5.3 STARTER SOLENOID...........................................379
		Solenoid Assembly..........................................379
		Solenoid Plunger...........................................379
		Solenoid Contacts..........................................379
6. DRIVE...........................................................382
	6.1 SPECIFICATIONS: DRIVE......................................384
		Specifications.............................................384
	6.2 PRIMARY CHAINCASE COVER....................................385
		General....................................................385
		Removal....................................................385
		Installation...............................................385
	6.3 DRIVE COMPONENTS...........................................386
		Removal....................................................386
		Installation...............................................388
	6.4 PRIMARY CHAINCASE HOUSING..................................392
		Removal....................................................392
		Inspection.................................................392
		Mainshaft Bearing and Lip Seal.............................392
		Mainshaft Bearing Inner Race...............................393
		Installation...............................................394
	6.5 CLUTCH.....................................................396
		Removal and Installation...................................396
		Clutch Pack Only...........................................396
		Clutch Pack and Bearing....................................398
	6.6 TRANSMISSION SPROCKET......................................401
		Removal....................................................401
		Cleaning and Inspection....................................402
		Installation...............................................402
	6.7 DRIVE BELT.................................................404
		Removal....................................................404
		Inspection.................................................404
		Installation...............................................404
7. TRANSMISSION....................................................406
	7.1 SPECIFICATIONS: TRANSMISSION...............................408
		Specifications.............................................408
		Service Wear Limits........................................408
	7.2 TRANSMISSION...............................................409
		Power Flow.................................................409
	7.3 SHIFTER LINKAGE............................................411
		Adjustment.................................................411
		Shifter Rod................................................411
	7.4 CLUTCH RELEASE COVER.......................................412
		Removal and Disassembly....................................412
		Cleaning and Inspection....................................412
		Assembly and Installation..................................413
	7.5 TRANSMISSION ASSEMBLY......................................414
		Removal....................................................414
		Disassembly................................................415
		Cleaning and Inspection....................................422
		Assembly...................................................422
		Installation...............................................425
	7.6 MAIN DRIVE GEAR AND BEARING................................427
		Removal....................................................427
		Cleaning and Inspection....................................428
		Installation...............................................430
	7.7 TRANSMISSION CASE..........................................434
		Removal....................................................434
		Installation...............................................434
		Disassembly................................................435
		Cleaning and Inspection....................................435
		Assembly...................................................436
8. ELECTRICAL......................................................438
	8.1 SPECIFICATIONS: ELECTRICAL.................................440
		Specifications.............................................440
	8.2 ELECTRICAL PANEL...........................................441
		General....................................................441
		Removal: All But FXCW/C....................................441
		Installation: All But FXCW/C...............................441
		Removal: FXCW/C............................................441
		Installation: FXCW/C.......................................442
	8.3 ELECTRONIC CONTROL MODULE (ECM)............................443
		General....................................................443
		Removal: All But FXCW/C....................................443
		Installation: All But FXCW/C...............................443
		Removal: FXCW/FXCWC........................................443
		Installation: FXCW/FXCWC...................................444
	8.4 VOLTAGE REGULATOR..........................................445
		General....................................................445
	8.5 FRONT ELECTRICAL CADDY.....................................446
		General....................................................446
		Disassembly................................................446
		Assembly...................................................446
	8.6 FUSES......................................................447
		General....................................................447
		Removal....................................................447
		Installation...............................................447
	8.7 RELAYS.....................................................448
		General....................................................448
		Removal....................................................448
		Installation...............................................448
	8.8 MAIN FUSE..................................................449
		Removal....................................................449
		Installation...............................................449
	8.9 IGNITION AND LIGHT SWITCH..................................450
		General....................................................450
		Removal and Installation: All But FXCW/C...................450
		Removal and Installation: FXCW/C...........................451
	8.10 BATTERY CABLES............................................452
		Routing Procedure..........................................452
	8.11 HEADLAMP..................................................454
		General....................................................454
		Removal and Installation...................................454
	8.12 TAIL LAMP: ALL BUT FLSTN..................................458
		General....................................................458
		Bulb Replacement...........................................458
		Base Replacement...........................................458
	8.13 TAIL LAMP: FLSTN..........................................460
		Bulb Replacement...........................................460
		Tail Lamp Replacement......................................460
	8.14 AUXILIARY LAMPS: FLST/FLSTC/FLSTN.........................462
		Auxiliary Lamp Bulb........................................462
		FLST and FLSTC Models......................................462
		FLSTN Models...............................................465
		Adjustment: FLST/FLSTC/FLSTN Models........................467
	8.15 TURN SIGNALS AND RUNNING LIGHTS...........................469
		Bulb Replacement: Bullet Style.............................469
		Bulb Replacement: Flat Lens Style..........................469
		Lamp Replacement...........................................469
	8.16 TURN SIGNAL AND SECURITY MODULE (TSM/TSSM/HFSM)...........474
		General....................................................474
		TSM/HFSM/TSSM Configuration................................474
		Removal....................................................474
		Installation...............................................474
	8.17 CRANK POSITION SENSOR (CKP)...............................475
		General....................................................475
		Removal....................................................475
		Installation...............................................475
	8.18 IGNITION COIL.............................................476
		Removal....................................................476
		Installation...............................................476
	8.19 SPARK PLUG CABLES.........................................478
		General....................................................478
		Removal....................................................478
		Installation...............................................478
	8.20 ALTERNATOR................................................479
		Removal....................................................479
		Cleaning and Inspection....................................479
		Installation...............................................479
	8.21 FUEL GAUGE................................................481
		General....................................................481
		Removal....................................................481
		Installation...............................................481
	8.22 INSTRUMENT CONSOLE: FXCW/C................................483
		Removal....................................................483
		Installation...............................................483
	8.23 SPEEDOMETER: ALL BUT FXCW/C...............................484
		Removal....................................................484
		Installation...............................................484
	8.24 SPEEDOMETER: FXCW/C.......................................485
		Removal....................................................485
		Installation...............................................485
	8.25 VEHICLE SPEED SENSOR (VSS)................................486
		General....................................................486
		Removal....................................................486
		Installation...............................................486
	8.26 INDICATOR LAMPS: ALL BUT FXCW/C...........................487
		General....................................................487
		Removal....................................................487
		Installation...............................................487
	8.27 INDICATOR LAMPS: FXCW/C...................................489
		Removal....................................................489
		Installation...............................................489
	8.28 NEUTRAL SWITCH............................................490
		General....................................................490
		Removal....................................................490
		Installation...............................................490
	8.29 OIL PRESSURE SWITCH.......................................491
		General....................................................491
		Removal....................................................491
		Installation...............................................491
	8.30 REAR STOPLIGHT SWITCH.....................................492
		General....................................................492
		Removal....................................................492
		Installation...............................................492
	8.31 HORN......................................................493
		Inspection.................................................493
		Removal and Installation: All But FXCW/C...................493
		Removal and Installation: FXCW/C...........................494
	8.32 ACTIVE EXHAUST............................................495
		General....................................................495
		Removal....................................................495
		Repair.....................................................495
		Installation...............................................495
	8.33 MAIN WIRING HARNESS.......................................496
		Removal....................................................496
		Installation...............................................497
	8.34 HANDLEBAR SWITCH ASSEMBLIES...............................499
		General....................................................499
		Repair Procedures..........................................499
	8.35 RIGHT HANDLEBAR SWITCH....................................500
		Removal....................................................500
		Installation...............................................500
		Switch Repair/Replacement..................................502
		Assembly...................................................504
	8.36 LEFT HANDLEBAR SWITCH.....................................506
		Removal....................................................506
		Installation...............................................506
		Switch Repair/Replacement..................................507
		Assembly...................................................508
A. APPENDIX A CONNECTOR REPAIR.....................................510
	A.1 AMP 1-PLACE CONNECTORS.....................................512
		AMP 1-Place Connector Repair...............................512
	A.2 AMP MULTILOCK CONNECTORS...................................514
		AMP Multilock Connector Repair.............................514
	A.3 AUTOFUSE ELECTRICAL CONNECTORS.............................518
		Autofuse Connector Repair..................................518
	A.4 DELPHI CONNECTORS..........................................519
		Delphi Connector Repair....................................519
	A.5 DELPHI MAXI FUSE HOUSING...................................521
		Delphi Maxi-Fuse Housing Repair............................521
	A.6 DEUTSCH ELECTRICAL CONNECTORS..............................523
		Deutsch Connector Repair...................................523
	A.7 DEUTSCH STANDARD TERMINAL REPAIR...........................527
		Deutsch Standard Terminal Crimps...........................527
	A.8 DEUTSCH SOLID BARREL MINI TERMINAL REPAIR..................528
		Deutsch Solid Barrel Terminal Crimps.......................528
	A.9 DEUTSCH MINI TERMINAL REPAIR...............................530
		Deutsch Mini Terminal Crimps...............................530
	A.10 MOLEX CONNECTORS..........................................531
		Molex Connector Repair.....................................531
		Crimp Terminal to Lead.....................................532
	A.11 PACKARD 150 METRI-PACK CONNECTORS.........................535
		150 Metri-Pack Connector Repair............................535
	A.12 PACKARD 280 METRI-PACK RELAY AND FUSE BLOCK CONNECTORS....537
		Fuse Block Repair..........................................537
	A.13 PACKARD 480 METRI-PACK CONNECTORS.........................538
		480 Metri-Pack Connector Repair............................538
	A.14 PACKARD 630 METRI-PACK CONNECTORS.........................539
		630 Metri-Pack Connector Repair............................539
	A.15 PACKARD METRI-PACK TERMINALS..............................540
		Metri-Pack Terminal Crimps.................................540
	A.16 PACKARD ECM CONNECTOR.....................................542
		Packard 100W Connector Repair..............................542
	A.17 PACKARD MICRO-64 CONNECTORS...............................544
		Packard Micro-64 Connector Repair..........................544
	A.18 SEALED SPLICE CONNECTORS..................................547
		Sealed Splice Connector Repair.............................547
B. APPENDIX B WIRING...............................................550
	B.1 CONNECTORS.................................................552
		Connector Locations........................................552
	B.2 WIRING DIAGRAMS............................................554
		Wiring Diagram Information.................................554
		2008 Softail Wiring Diagrams...............................555
C. APPENDIX C CONVERSIONS..........................................590
	C.1 METRIC CONVERSION..........................................592
		Conversion Table...........................................592
	C.2 FLUID CONVERSIONS..........................................593
		United States System.......................................593
		Metric System..............................................593
		British Imperial System....................................593
	C.3 TORQUE CONVERSIONS.........................................594
		United States System.......................................594
		Metric System..............................................594
D. APPENDIX D GLOSSARY.............................................596
	D.1 GLOSSARY...................................................598
		Acronyms and Abbreviations.................................598
TOOLS..............................................................602
TORQUE VALUES......................................................608
INDEX..............................................................620

2008 HARLEY DAVIDSON SOFTAIL MODELS SERVICE MANUAL – PDF DOWNLOAD:

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