2008 Softail Models Service Manual – PDF DOWNLOAD
DESCRIPTION:
2008 Softail Models Service Manual – PDF DOWNLOAD
ABOUT THIS MANUAL GENERAL
This electrical diagnostic 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 repair. Secondly, it will introduce to the professional Harley-Davidson Technician the latest field-tested and factory-approved diagnostic methods.We sincerely believe that this 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 Starting / Charging
2 Instruments
3 TSM/HFSM
4 Engine Management
A Appendix A Connector Repair
B Appendix B Wiring
C Appendix C Conversions
D Appendix D Glossary
E Appendix E TSM/TSSM (Japan/Korea
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.
PREPARATION FOR SERVICE
WARNING
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 disassembly, carefully read all relative 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 serviced and re-enable the system after service is completed
SERVICE BULLETINS
In addition to the information presented in this Service Manual, Harley-Davidson Motor Company will periodically issue Service Bulletins to Harley-Davidson dealers. Service Bulletins cover interim engineering changes and supplementary information. Consult the Service Bulletins to keep your product knowledge current and complete.
USE GENUINE REPLACEMENT PARTS
Do not use aftermarket parts and custom made front forks which can adversely affect performance and handling. Removing or altering factory installed parts can adversely affect performance and could result in death or serious injury. (00001a) To ensure satisfactory and lasting repairs, carefully follow the Service Manual instructions and use only genuine Harley- Davidson replacement parts. Behind the emblem bearing the words GENUINE HARLEY-DAVIDSON stand more than 100 years of design, research, manufacturing, testing and inspecting experience. This is your assurance that the parts you are using will fit right, operate properly and last longer
WARNINGS AND CAUTIONS Statements in this service manual preceded by the following words are of special significance
WARNING
indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. (00119a)
CAUTION
indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. (00139a
CAUTION
used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. (00140a
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.
WARNING
- protection when using hammers, arbor or hydraulic presses, gear pullers, spring compressors, slide hammers and similar tools. Flying parts could result in death or serious injury. (00496b) Some of these service operations require the use of tools specially designed for the purpose.
- These special tools should be used when and as recommended. It is important to note that some warnings against the use of specific service methods, which could damage the motorcycle or render it unsafe, are stated in this service manual.
- However, please remember that these warnings are not all-inclusive. Inadequate safety precautions 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 consequences 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
Read and follow warnings and directions on all products. Failure to follow warnings and directions can result in death or serious injury. (00470b) When reference is made in this manual to a specific brand name product, tool or instrument, an equivalent product, tool or instrument may be substituted. Kent-Moore Products All tools mentioned in this manual with an “HD”, “J” or “B” preface must be ordered through SPX Kent-Moore. For ordering
information or product returns, warranty or otherwise, visit www.spx.com. Loctite Sealing and Thread locking 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.
H-D MICHIGAN, INC.TRADEMARK INFORMATION Harley, Harley-Davidson, H-D, Bar & 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, V-Rod, VRSC, Wide Glide, and Harley-Davidson Genuine Motor Parts and Genuine Motor Accessories are among the trademarks of H-D Michigan, Inc.
CONTENTS
All photographs, illustrations and procedures may not necessarily 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.
TABLE OF CONTENTS:
2008 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
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