2008 Softail Models Service

Manual

©2008 H-D.
ALL RIGHTS RESERVED
99482-08A

Printed in the U.S.A.

VISIT THE HARLEY-DAVIDSON WEB SITE

http://www.harley-davidson.com
ABOUT THIS MANUAL
GENERAL gathered before work is started. Interrupting a job to locate
tools or parts is a distraction and causes needless delay.
This Service Manual has been prepared with two purposes in
mind. First, it will acquaint the user with the construction of the NOTES
Harley-Davidson product and assist in the performance of basic • To avoid unnecessary disassembly, carefully read all rel-
maintenance and repair. Secondly, it will introduce to the pro- ative service information before repair work is started.
fessional Harley-Davidson Technician the latest field-tested
• In figure legends, the number which follows the name of
and factory-approved major repair methods. We sincerely
a part indicates the quantity necessary for one complete
believe that this Service Manual will make your association
assembly.
with Harley-Davidson products more pleasant and profitable.
• When servicing a vehicle equipped with the Harley-
HOW TO USE YOUR SERVICE MANUAL Davidson Smart Security System (H-DSSS), you must
Refer to the table below for the content layout of this manual. first disarm the security system. Either keep the fob in
close proximity to the vehicle, or use Digital Technician to
NO. CHAPTER disable the security system while the vehicle is being ser-
viced and re-enable the system after service is completed.
1 Maintenance
2 Chassis SERVICE BULLETINS
3 Engine In addition to the information presented in this Service Manual,
Harley-Davidson Motor Company will periodically issue Service
4 Fuel System
Bulletins to Harley-Davidson dealers. Service Bulletins cover
5 Starter interim engineering changes and supplementary information.
6 Drive Consult the Service Bulletins to keep your product knowledge
current and complete.
7 Transmission
8 Electrical USE GENUINE REPLACEMENT PARTS
A Appendix A Connector Repair

FOREWORD
B Appendix B Wiring
C Appendix C Conversions Do not use aftermarket parts and custom made front forks
which can adversely affect performance and handling.
D Appendix D Glossary Removing or altering factory installed parts can adversely
affect performance and could result in death or serious
Use the TABLE OF CONTENTS (which follows this FORE- injury. (00001a)
WORD) and the INDEX (at the back of this manual) to quickly
locate subjects. Sections and topics in this manual are To ensure satisfactory and lasting repairs, carefully follow the
sequentially numbered for easy navigation. Service Manual instructions and use only genuine Harley-
Davidson replacement parts. Behind the emblem bearing the
For example, a cross-reference shown as 2.1 SPECIFICA- words GENUINE HARLEY-DAVIDSON stand more than 100
TIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFIC- years of design, research, manufacturing, testing and inspecting
ATIONS. experience.This is your assurance that the parts you are using
For quick and easy reference, all pages contain a section will fit right, operate properly and last longer.
number followed by a page number. For example, page 3-5
refers to page 5 in section 3.
WARNINGS AND CAUTIONS
A number of acronyms and abbreviations are used in this Statements in this service manual preceded by the following
document. See the D.1 GLOSSARY for a list of acronyms, words are of special significance.
abbreviations and definitions.

PREPARATION FOR SERVICE

WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury. (00119a)
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. CAUTION indicates a potentially hazardous situation
(00002a) which, if not avoided, may result in minor or moderate
injury. (00139a)
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 CAUTION used without the safety alert symbol indicates
that is excessively dirty should be cleaned before work starts. a potentially hazardous situation which, if not avoided,
Cleaning will occasionally uncover sources of trouble. Tools, may result in property damage. (00140a)
instruments and any parts needed for the job should be

I
 NOTE information or product returns, warranty or otherwise, visit
Refers to important information, and is placed in italic type. It www.spx.com.
is recommended that you take special notice of these items. Loctite Sealing and Threadlocking Products
Proper service and repair is important for the safe, reliable Some procedures in this manual call for the use of Loctite
operation of all mechanical products. The service procedures products. If you have any questions regarding Loctite product
recommended and described in this service manual are usage or retailer/wholesaler locations, please contact Loctite
effective methods for performing service operations. Corp. at www.loctite.com.

PRODUCT REGISTERED MARKS

Always wear proper eye protection when using hammers, Allen, Amp Multilock, Bluetooth, Brembo, Delphi, Deutsch,
arbor or hydraulic presses, gear pullers, spring com- Dunlop, Dynojet, Fluke, G.E. Versilube, Gunk, Hydroseal,
pressors, slide hammers and similar tools. Flying parts Hylomar, Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Mag-
could result in death or serious injury. (00496b) naflux, Marson Thread-Setter Tool Kit, MAXI fuse, Molex, MPZ,
Mulitilock, Novus, Packard, Pirelli, Permatex, Philips, PJ1,
Some of these service operations require the use of tools Pozidriv, Robinair, S100, Sems, Snap-on, Teflon, Threadlocker,
specially designed for the purpose. These special tools should Torca, Torco, TORX, Tufoil, Tyco, Ultratorch, Velcro, X-Acto,
be used when and as recommended. It is important to note and XM Satellite Radio are among the trademarks of their
that some warnings against the use of specific service methods, respective owners.
which could damage the motorcycle or render it unsafe, are
stated in this service manual. However, please remember that H-D MICHIGAN, INC. TRADEMARK
these warnings are not all-inclusive. Inadequate safety precau- INFORMATION
tions could result in death or serious injury.
Harley, Harley-Davidson, H-D, Bar & Shield, Digital Tech,
Since Harley-Davidson could not possibly know, evaluate or Digital Technician, Destroyer, Deuce, Dyna, Electra Glide,
advise the service trade of all possible ways in which service Evolution, Fat Boy, Glaze, Gloss, H-D, H-Dnet.com, HD, Harley,
might be performed, or of the possible hazardous con- Heritage Softail, Heritage Springer, Low Rider, Night Rod, Night
sequences of each method, we have not undertaken any such Train, Profile, Revolution, Road Glide, Road King, Rocker,
broad evaluation. Accordingly, anyone who uses a service Softail, Sportster, Sun Ray, Sunwash, Tech Link, Twin Cam
procedure or tool which is not recommended by Harley- 88, Twin Cam 88B, Twin Cam 96, Twin Cam 96B, Twin Cam
Davidson must first thoroughly satisfy himself that neither his 103, Twin Cam 103B, Twin Cam 110, Twin Cam 110B, Tour-
nor the operator's safety will be jeopardized as a result. Failure Pak, Screamin' Eagle, Softail, Super Guide, Super Premium,
to do so could result in death or serious injury. SYN3, Ultra Glide, V-Rod, VRSC, Wide Glide, and Harley-
Davidson Genuine Motor Parts and Genuine Motor Accessories
PRODUCT REFERENCES
are among the trademarks of H-D Michigan, Inc.

CONTENTS
Read and follow warnings and directions on all products. All photographs, illustrations and procedures may not neces-
Failure to follow warnings and directions can result in sarily depict the most current model or component, but are
death or serious injury. (00470b) based on the latest production information available at the time
of publication.
When reference is made in this manual to a specific brand
name product, tool or instrument, an equivalent product, tool Since product improvement is our continual goal, Harley-
or instrument may be substituted. Davidson reserves the right to change specifications, equipment
or designs at any time without notice and without incurring
Kent-Moore Products obligation.
All tools mentioned in this manual with an "HD", "J" or "B"
preface must be ordered through SPX Kent-Moore. For ordering

II FOREWORD
MAINTENANCE Pedal Lubrication.......................................................1-14
Pedal Pad..................................................................1-14

1.1 GENERAL 1.7 AIR CLEANER AND EXHAUST SYSTEM

Servicing a New Motorcycle...............................................1-1 Removal...........................................................................1-16
Safe Operating Maintenance..............................................1-1 Installation........................................................................1-17
Shop Practices...................................................................1-1 Exhaust System Leak Check............................................1-18
Repair Notes...............................................................1-1
Safety..........................................................................1-1 1.8 TIRES AND WHEELS
Removing Parts...........................................................1-1 Tires.................................................................................1-19
Cleaning......................................................................1-1 Tire Replacement.............................................................1-19
Disassembly and Assembly........................................1-2 Inspection..................................................................1-19
Checking Torques on Fasteners with Lock Patches.....1-2 When To Replace Tires.............................................1-19
Magnetic Parts Trays...................................................1-2 Wheel Bearings................................................................1-20
Repair and Replacement Procedures................................1-2 Wheel Spokes..................................................................1-20
Hardware and Threaded Parts....................................1-2
Threadlocking Agents..................................................1-2 1.9 PRIMARY CHAIN
Wiring, Hoses and Lines.............................................1-2
General.............................................................................1-21
Instruments and Gauges.............................................1-2
Changing Primary Chaincase Lubricant...........................1-21
Bearings......................................................................1-2
Bushings.....................................................................1-2 1.10 TRANSMISSION LUBRICANT
Gaskets.......................................................................1-2
Lip Type Seals.............................................................1-2 Changing Transmission Lubricant.....................................1-23
O-Rings (Preformed Packings)....................................1-3
Gears..........................................................................1-3
1.11 CLUTCH
Shafts..........................................................................1-3 Adjustment.......................................................................1-25
Part Replacement........................................................1-3
Exhaust System Leakage............................................1-3 1.12 REAR BELT AND SPROCKETS

TABLE OF CONTENTS
Cleaning.............................................................................1-3 General.............................................................................1-27
Part Protection............................................................1-3 Cleaning...........................................................................1-27
Cleaning Process........................................................1-3 Inspection.........................................................................1-27
Rust or Corrosion Removal.........................................1-3 Sprockets..................................................................1-27
Bearings......................................................................1-3 Rear Belt...................................................................1-27
Tool Safety..........................................................................1-3
Air Tools.......................................................................1-3 1.13 REAR BELT DEFLECTION
Wrenches....................................................................1-3 Inspection.........................................................................1-29
Pliers/Cutters/Pry bars................................................1-3 Adjustment.......................................................................1-29
Hammers.....................................................................1-4
Punches/Chisels..........................................................1-4 1.14 THROTTLE CABLES
Screwdrivers................................................................1-4
Ratchets and Handles.................................................1-4 Cable Inspection, Lubrication and Adjustment.................1-31
Sockets........................................................................1-4 Inspection and Lubrication........................................1-31
Storage Units...............................................................1-4 Adjustment................................................................1-31

1.2 MAINTENANCE SCHEDULE 1.15 BLEEDING BRAKES

General...............................................................................1-5 General.............................................................................1-32
Procedure.........................................................................1-32
1.3 FUEL AND OIL
1.16 BRAKE PADS AND DISCS
Fuel....................................................................................1-9
Gasoline Blends.................................................................1-9 Inspection.........................................................................1-33
Engine Lubrication..............................................................1-9 Brake Pads................................................................1-33
Winter Lubrication............................................................1-10 Brake Disc.................................................................1-33
Brake Pad Replacement...................................................1-33
1.4 BULB REQUIREMENTS Rear Brake Caliper....................................................1-33
Front Brake Caliper...................................................1-35
General.............................................................................1-11
1.17 BATTERY MAINTENANCE
1.5 ENGINE OIL AND FILTER
General.............................................................................1-37
Checking and Adding Oil..................................................1-12 Cleaning and Inspection...................................................1-38
Type of Oil.................................................................1-12 Voltmeter Test...................................................................1-38
Checking Oil Level.....................................................1-12 Voltmeter Test............................................................1-38
Changing Oil and Filter.....................................................1-12 Charging Battery..............................................................1-38
Safety Precautions....................................................1-38
1.6 BRAKES Using a Battery Charger............................................1-38
Fluid Inspection................................................................1-14 Disconnection and Removal.............................................1-39
Rear Brake Pedal.............................................................1-14 Storage.............................................................................1-40
Pedal Height..............................................................1-14 Installation and Connection..............................................1-41

III
TABLE OF CONTENTS
1.18 SUSPENSION ADJUSTMENTS Overheating...............................................................1-62
Valve Train Noise.......................................................1-62
Shock Absorbers: Softail Models......................................1-43
Excessive Vibration...................................................1-62
Adjustment................................................................1-43
Check Engine Light Illuminates During Operation.....1-62
Lubrication System...........................................................1-62
1.19 SPARK PLUGS
Oil Does Not Return To Oil Tank................................1-62
Inspection.........................................................................1-44 Engine Uses Too Much Oil Or Smokes Excessively...1-62
Spark Plug Cable Inspection............................................1-44 Engine Leaks Oil From Cases, Push Rods, Hoses,
Etc.............................................................................1-62
1.20 STEERING HEAD BEARINGS: ALL BUT Low Oil Pressure.......................................................1-63
FLSTSB High Oil Pressure......................................................1-63
Adjustment: FLST, FLSTC, FLSTF, FLSTN......................1-46 Electrical System..............................................................1-63
Bearing Adjustment (Fall-away)................................1-46 Alternator Does Not Charge......................................1-63
Adjustment: FXST, FXSTB, FXSTC, FXCW/C..................1-47 Alternator Charge Rate Is Below Normal..................1-63
Bearing Adjustment (Fall-away)................................1-47 Speedometer Operates Erratically............................1-63
Lubrication........................................................................1-48 Transmission.....................................................................1-63
Shifts Hard................................................................1-63
1.21 STEERING HEAD BEARINGS: FLSTSB Jumps Out Of Gear...................................................1-63
Clutch Slips...............................................................1-63
General.............................................................................1-49
Clutch Drags Or Does Not Release..........................1-63
Lubrication.................................................................1-49
Clutch Chatters..........................................................1-63
Adjustment: FLSTSB........................................................1-49
Handling...........................................................................1-63
Bearing Adjustment (Fall-away)................................1-49
Irregularities..............................................................1-63
1.22 ROCKER BEARINGS: FLSTSB Brakes..............................................................................1-63
Brake Does Not Hold Normally.................................1-63
Inspection.........................................................................1-51
CHASSIS
1.23 FRONT FORK OIL
Replacing Fork Oil............................................................1-53 2.1 SPECIFICATIONS
1.24 CABLE AND CHASSIS LUBRICATION Specifications.....................................................................2-1
Chassis Specifications................................................2-1
General.............................................................................1-54
Tire Specifications.......................................................2-2
Cables and Hand Levers..................................................1-54
Jiffy Stand.........................................................................1-54 2.2 VEHICLE IDENTIFICATION NUMBER
Steering Head Bearings...................................................1-54
(V.I.N.)
1.25 HEADLAMP ALIGNMENT Vehicle Identification Number.............................................2-4
Inspection.........................................................................1-55
Adjustment.......................................................................1-56 2.3 FRONT WHEEL: ALL BUT FLSTSB
Removal.............................................................................2-6
1.26 CRITICAL FASTENERS Disassembly.......................................................................2-6
Inspection.........................................................................1-57 Disc Wheel..................................................................2-6
Laced Wheel...............................................................2-6
1.27 ENGINE MOUNTS Cleaning and Inspection.....................................................2-8
Assembly............................................................................2-8
Inspection.........................................................................1-58
Disc Wheel..................................................................2-8
1.28 STORAGE Laced Wheel...............................................................2-8
Installation..........................................................................2-9
General.............................................................................1-59
Placing in Storage............................................................1-59 2.4 FRONT WHEEL: FLSTSB
Removal from Storage......................................................1-59
Removal...........................................................................2-10
1.29 TROUBLESHOOTING Disassembly.....................................................................2-10
Cleaning and Inspection...................................................2-10
General.............................................................................1-61 Assembly..........................................................................2-10
Engine..............................................................................1-61 Installation........................................................................2-11
Starter Motor Does Not Operate or Does Not Turn Engine
Over ..........................................................................1-61 2.5 REAR WHEEL
Engine Turns Over But Does Not Start .....................1-61
Removal...........................................................................2-12
Starts Hard................................................................1-61
Disassembly.....................................................................2-12
Starts But Runs Irregularly or Misses .......................1-61
Cleaning and Inspection...................................................2-13
A Spark Plug Fouls Repeatedly................................1-62
Assembly..........................................................................2-13
Pre-Ignition or Detonation (Knocks or Pings)............1-62
Installation........................................................................2-14

IV TABLE OF CONTENTS
 TABLE OF CONTENTS
2.6 SEALED WHEEL BEARINGS 2.17 REAR BRAKE CALIPER
Inspection.........................................................................2-15 Removal...........................................................................2-52
Removal...........................................................................2-15 Disassembly.....................................................................2-52
Installation........................................................................2-16 Cleaning, Inspection and Repair......................................2-54
Assembly..........................................................................2-55
2.7 WHEEL LACING: 16 INCH RIM Installation........................................................................2-55
General.............................................................................2-18
Procedure.........................................................................2-18 2.18 TIRES
General.............................................................................2-57
2.8 WHEEL LACING: 17 INCH RIM Removal...........................................................................2-57
General.............................................................................2-21 Cleaning, Inspection and Repair......................................2-58
Procedure.........................................................................2-21 Installation........................................................................2-58
Tube Type Tires.........................................................2-58
2.9 WHEEL LACING: 21 INCH RIM Tubeless Tires...........................................................2-59
General.............................................................................2-24
2.19 FRONT FORK: TELESCOPIC
Procedure.........................................................................2-24
General.............................................................................2-60
2.10 TRUING LACED WHEELS Removal...........................................................................2-60
Disassembly.....................................................................2-60
General.............................................................................2-27
Cleaning and Inspection...................................................2-60
Lateral Truing....................................................................2-27
Assembly..........................................................................2-64
Radial Truing.....................................................................2-28
Installation........................................................................2-64
2.11 CHECKING CAST WHEEL RUNOUT
2.20 FRONT FORK: SPRINGER
General.............................................................................2-30
General.............................................................................2-65
Lateral Runout..................................................................2-30
Front Shock Absorber.......................................................2-65
Radial Runout...................................................................2-30
Removal....................................................................2-65
2.12 VEHICLE ALIGNMENT Installation.................................................................2-65
Rigid Fork.........................................................................2-65
Inspection.........................................................................2-31 Removal....................................................................2-65
Installation.................................................................2-66
2.13 FRONT BRAKE MASTER CYLINDER Spring Fork.......................................................................2-66
General.............................................................................2-32 Disassembly..............................................................2-66
Removal and Disassembly...............................................2-32 Assembly...................................................................2-68
Cleaning and Inspection...................................................2-34 Fork Rockers....................................................................2-70
Assembly and Installation.................................................2-34 Removal....................................................................2-70
Installation.................................................................2-70
2.14 FRONT BRAKE CALIPER: ALL BUT Fork Stem Bearings..........................................................2-71
FLSTSB Removal and Installation...........................................2-71
Removal...........................................................................2-36
Disassembly.....................................................................2-36
2.21 STEERING HEAD
Cleaning, Inspection and Repair......................................2-38 Removal...........................................................................2-72
Assembly..........................................................................2-39 FLST, FLSTC, FLSTF, FLSTN Models......................2-72
Installation........................................................................2-39 FXST, FXSTC, FXSTB Models..................................2-72
FXCW/C Models........................................................2-72
2.15 FRONT BRAKE CALIPER: FLSTSB FLSTSB Models........................................................2-73
Removal...........................................................................2-41 Inspection.........................................................................2-73
Disassembly.....................................................................2-42 All Models..................................................................2-73
Cleaning and Inspection...................................................2-43 Disassembly.....................................................................2-73
Assembly..........................................................................2-44 Removing Lower Bearings From Fork Stem.............2-73
Installation........................................................................2-45 Steering Head Bearing Race Removal.....................2-74
Assembly..........................................................................2-74
2.16 REAR BRAKE MASTER CYLINDER Installation........................................................................2-75
FLST, FLSTC, FLSTF, FLSTN Models......................2-75
General.............................................................................2-47 FXST, FXSTC, FXSTB Models..................................2-75
Removal...........................................................................2-47 FXCW/C Models........................................................2-75
Installation........................................................................2-47 FLSTSB Models........................................................2-75
Disassembly.....................................................................2-49
Cleaning and Inspection...................................................2-50 2.22 BELT GUARD AND DEBRIS
Assembly..........................................................................2-50
DEFLECTOR
Removal...........................................................................2-76

TABLE OF CONTENTS V
TABLE OF CONTENTS
Belt Guard.................................................................2-76 2.35 REAR FENDER:
Debris Deflector........................................................2-76
Installation........................................................................2-76
FXST/FXSTB/FXSTC/FLSTSB
Belt Guard.................................................................2-76 Removal.........................................................................2-104
Debris Deflector........................................................2-76 Installation......................................................................2-104

2.23 REAR SHOCK ABSORBERS 2.36 REAR FENDER: FXCW/FXCWC

General.............................................................................2-77 Removal.........................................................................2-106
Removal...........................................................................2-77 Installation......................................................................2-106
Installation........................................................................2-77
2.37 REAR FENDER: FLSTN
2.24 REAR FORK Removal.........................................................................2-108
Removal...........................................................................2-79 Disassembly...................................................................2-108
Cleaning and Inspection...................................................2-80 Assembly........................................................................2-110
Installation........................................................................2-80 Installation......................................................................2-110

2.25 THROTTLE CONTROL 2.38 REAR FENDER WIRE CONDUIT

Removal/Disassembly......................................................2-82 Installation......................................................................2-111
Cleaning and Inspection...................................................2-82
Assembly/Installation........................................................2-82 2.39 JIFFY STAND
Cable Routing...................................................................2-83 Cleaning.........................................................................2-113
Sensor (HDI Models)......................................................2-113
2.26 CLUTCH CONTROL Removal.........................................................................2-114
Removal...........................................................................2-84 Installation......................................................................2-114
Installation........................................................................2-84
2.40 FORK LOCK
2.27 HANDLEBARS: ALL BUT Removal.........................................................................2-115
FLSTF/FLSTSB/FXCW/FXCWC Installation......................................................................2-115
Removal...........................................................................2-86
2.41 SEAT AND STRAP RETENTION NUT
Installation........................................................................2-87
Replacement..................................................................2-116
2.28 HANDLEBARS: FLSTF
2.42 SEAT: FXST/FXSTB
Removal...........................................................................2-88
Installation........................................................................2-89 Removal and Installation................................................2-117
Seat Strap...............................................................2-117
2.29 HANDLEBARS: FLSTSB Seat.........................................................................2-117
Removal...........................................................................2-91
2.43 SEAT: FXSTC
Installation........................................................................2-91
Removal and Installation................................................2-118
2.30 HANDLEBARS: FXCW/FXCWC Seat Strap...............................................................2-118
Seat.........................................................................2-118
Removal...........................................................................2-93
Installation........................................................................2-94
2.44 SEAT: FXCW/FXCWC
2.31 FRONT FENDER: ALL BUT FLSTSB Removal and Installation................................................2-119
Solo Seat: FXCW....................................................2-119
Removal...........................................................................2-97
Rider Seat: FXCWC................................................2-119
Installation........................................................................2-97
Passenger Seat Support: FXCWC..........................2-119
2.32 FRONT FENDER: FLSTSB
2.45 SEAT: FLSTN/FLSTF/FLST/FLSTC
Removal...........................................................................2-98
Removal and Installation................................................2-121
Installation........................................................................2-99

2.33 REAR FENDER: FLST/FLSTC 2.46 SEAT: FLSTSB

Seat: FLSTSB.................................................................2-122
Removal.........................................................................2-100
Removal..................................................................2-122
Installation......................................................................2-100
Installation...............................................................2-122
2.34 REAR FENDER: FLSTF Adjusting Seat Position...........................................2-122
Removal.........................................................................2-102 2.47 LUGGAGE RACK: FLSTN
Installation......................................................................2-102
Removal and Installation................................................2-124

VI TABLE OF CONTENTS
 TABLE OF CONTENTS
2.48 SADDLEBAGS: FLSTC 3.12 ASSEMBLING MOTORCYCLE AFTER
Removal.........................................................................2-125 SERVICE
Installation......................................................................2-125 Procedure.........................................................................3-22
2.49 WINDSHIELD: FLSTC 3.13 REMOVING ENGINE FROM CHASSIS
Removal.........................................................................2-126 Procedure.........................................................................3-23
Installation......................................................................2-126
3.14 INSTALLING ENGINE IN CHASSIS
ENGINE Procedure.........................................................................3-24

3.1 SPECIFICATIONS 3.15 TOP END OVERHAUL: DISASSEMBLY

Specifications.....................................................................3-1 General.............................................................................3-26
Rocker Covers..................................................................3-26
3.2 SERVICE WEAR LIMITS Rocker Arm Support Plate................................................3-26
General...............................................................................3-3 Push Rods, Lifters and Covers.........................................3-28
Cylinder Head...................................................................3-29
3.3 ENGINE OIL FLOW Cylinder............................................................................3-30
Oil Feed..............................................................................3-5 Piston...............................................................................3-30
Top End..............................................................................3-6
Bottom End.........................................................................3-7
3.16 TOP END OVERHAUL: ASSEMBLY
Chain Guide Bracket..........................................................3-9 General.............................................................................3-32
Oil Return...........................................................................3-9 Piston...............................................................................3-32
Cylinder............................................................................3-33
3.4 OIL PUMP OPERATION Cylinder Head...................................................................3-35
General.............................................................................3-10 Push Rods, Lifters and Covers.........................................3-38
Operation..........................................................................3-10 Rocker Arm Support Plate................................................3-39
Breather Assembly...........................................................3-40
3.5 BREATHER OPERATION
3.17 BOTTOM END OVERHAUL:
General.............................................................................3-12
DISASSEMBLY
3.6 OIL PRESSURE General.............................................................................3-42
Oil Pressure Indicator Lamp.............................................3-13 Cover and Cam Support Plate..........................................3-42
Checking Oil Pressure......................................................3-13 Prepare Engine.........................................................3-42
Cam Chain and Sprockets........................................3-42
3.7 TROUBLESHOOTING Cam Support Plate....................................................3-43
Crankcase........................................................................3-44
Diagnosing Valve Train Noise...........................................3-14
Counterbalancer Assembly..............................................3-45
Compression Test.............................................................3-14
Cylinder Leakdown Test....................................................3-14 3.18 BOTTOM END OVERHAUL: ASSEMBLY
Diagnosing Smoking Engine or High Oil Consumption.....3-15
Check Prior To Cylinder Head Removal....................3-15 General.............................................................................3-48
Check After Cylinder Head Removal.........................3-15 Counterbalancer Assembly..............................................3-48
Crankcase........................................................................3-51
3.8 HOW TO USE THIS SECTION Cover and Cam Support Plate..........................................3-55
Top End Repair.................................................................3-16 3.19 BREATHER ASSEMBLY
Bottom End Repair...........................................................3-16
Typical Symptoms.............................................................3-16 Removal Overview............................................................3-59
Disassembly.....................................................................3-59
3.9 TOP END SERVICE Cleaning and Inspection...................................................3-59
Assembly..........................................................................3-59
Engine in Chassis.............................................................3-17
Installation Overview........................................................3-59
Engine Removed from Chassis........................................3-18

3.10 BOTTOM END SERVICE 3.20 ROCKER ARM SUPPORT PLATE

Removal Overview............................................................3-60
Engine in Chassis.............................................................3-19
Disassembly.....................................................................3-60
Engine Removed From Chassis.......................................3-20
Cleaning and Inspection...................................................3-60
3.11 STRIPPING MOTORCYCLE FOR Inspection..................................................................3-60
Rocker Shaft Fit.........................................................3-60
SERVICE Rocker Arm Shaft to Bushing....................................3-61
Procedure.........................................................................3-21 Replace Rocker Arm Bushings.................................3-61
Assembly..........................................................................3-62

TABLE OF CONTENTS VII

TABLE OF CONTENTS
Installation Overview........................................................3-62 Installation Overview........................................................3-93

3.21 PUSH RODS, LIFTERS AND COVERS 3.26 OIL PUMP

Removal Overview............................................................3-64 Removal Overview............................................................3-94
Disassembly.....................................................................3-64 Cleaning and Inspection...................................................3-94
Cleaning and Inspection...................................................3-64 Installation Overview........................................................3-94
Lifter Inspection................................................................3-65
Assembly..........................................................................3-65 3.27 CRANKCASE
Installation Overview........................................................3-66 Removal Overview............................................................3-95
Right Crankcase Half........................................................3-95
3.22 CYLINDER HEAD Chain Guide Screen..................................................3-95
Removal Overview............................................................3-67 Crankshaft (Roller) Bearing Removal........................3-95
Disassembly.....................................................................3-67 Crankshaft (Roller) Bearing Installation.....................3-96
Cleaning...........................................................................3-68 Piston Jets Removal..................................................3-96
Inspection.........................................................................3-69 Piston Jets Installation...............................................3-96
Cylinder Head............................................................3-69 Left Crankcase Half..........................................................3-97
Valve Guides.............................................................3-69 Main Bearing Removal..............................................3-97
Valves........................................................................3-69 Main Bearing Installation...........................................3-98
Valve Springs............................................................3-69 Sprocket Shaft Bearing Inner Race..................................3-99
Tapered Keepers.......................................................3-70 Removal....................................................................3-99
Valve Seats...............................................................3-70 Installation...............................................................3-100
Valve Guide Replacement................................................3-70 Cylinder Studs................................................................3-101
Removal....................................................................3-70 Removal..................................................................3-101
Installation.................................................................3-71 Installation...............................................................3-101
Valve and Seat Refacing..................................................3-74 Pipe Plugs and Oil Fittings.............................................3-101
Assembly..........................................................................3-76 Removal/Installation................................................3-101
Installation Overview........................................................3-77 Cleaning and Inspection.................................................3-102
Installation Overview......................................................3-102
3.23 CYLINDER
Removal Overview............................................................3-78 3.28 FLYWHEEL AND CONNECTING RODS
Cleaning...........................................................................3-78 Removal Overview..........................................................3-103
Inspection.........................................................................3-79 Inspection.......................................................................3-103
Deglazing Cylinder...........................................................3-80 Installation Overview......................................................3-103
Boring and Honing Cylinder.............................................3-81
Installation Overview........................................................3-81 3.29 COUNTERBALANCER ASSEMBLY
Removal Overview..........................................................3-104
3.24 PISTON Cleaning, Inspection, and Repair...................................3-104
Removal Overview............................................................3-82 General....................................................................3-104
Disassembly.....................................................................3-82 Balance Shaft Removal...........................................3-104
Piston Rings..............................................................3-82 Balance Shaft Installation........................................3-105
Cleaning...........................................................................3-82 Balance Shaft Support Bearings Removal..............3-105
Inspection.........................................................................3-83 Balance Shaft Support Bearings Installation...........3-105
Assembly..........................................................................3-84 Front and Rear Balance Sprockets.........................3-106
Checking Piston Ring Gap........................................3-84 Hydraulic Tensioners...............................................3-106
Installing Piston Rings...............................................3-85 Chain Tensioner Guides..........................................3-107
Installation Overview........................................................3-86 Chain Guide Bracket...............................................3-107
Balance Chain.........................................................3-107
3.25 COVER AND CAM SUPPORT PLATE Installation Overview......................................................3-107
Removal Overview............................................................3-87
Camshafts........................................................................3-87 3.30 OIL TANK: ALL BUT FXCW/C
Removal....................................................................3-87 Removal and Disassembly.............................................3-108
Assembly...................................................................3-87 Oil Tank....................................................................3-108
Oil Pressure Relief Valve..................................................3-89 Oil Line Fittings/Retainers.......................................3-110
Removal....................................................................3-89 Installation......................................................................3-111
Installation.................................................................3-89
Inspection..................................................................3-89 3.31 OIL TANK: FXCW/C
Cam Needle Bearings......................................................3-89 Removal and Disassembly.............................................3-112
Removal....................................................................3-89 Oil Tank....................................................................3-112
Installation.................................................................3-91 Oil Line Fittings/Retainers.......................................3-114
Cleaning and Inspection...................................................3-92 Installation......................................................................3-115
Oil Pressure Valve.....................................................3-92
Cam Support Plate....................................................3-93

VIII TABLE OF CONTENTS

 TABLE OF CONTENTS
FUEL SYSTEM Installation........................................................................4-20

4.13 FUEL INJECTORS

4.1 SPECIFICATIONS: FUEL SYSTEM General.............................................................................4-22
Specifications.....................................................................4-1 Removal...........................................................................4-22
Installation........................................................................4-22
4.2 ELECTRONIC FUEL INJECTION (EFI)
Troubleshooting..................................................................4-2 4.14 FUEL PUMP AND FUEL GAUGE
SENDING UNIT
4.3 IDLE SPEED General.............................................................................4-24
General...............................................................................4-3 Removal...........................................................................4-24
Disassembly/Assembly.....................................................4-26
4.4 AIR CLEANER ASSEMBLY Fuel Filter..................................................................4-26
Removal.............................................................................4-4 Regulator...................................................................4-26
Installation..........................................................................4-4 Inlet sock...................................................................4-27
Backplate Assembly: HDI Models.......................................4-5 Fuel Pump.................................................................4-28
Installation........................................................................4-28
4.5 FUEL TANK
General...............................................................................4-6
4.15 FUEL PRESSURE TEST
Removal.............................................................................4-6 General.............................................................................4-30
Cleaning and Inspection...................................................4-10 Testing..............................................................................4-30
Installation........................................................................4-10
All But FXCW/C.........................................................4-10 4.16 EXHAUST SYSTEM: ALL BUT
FXCW/C....................................................................4-10 FLSTF/FLSTN/FLSTSB
4.6 THROTTLE POSITION SENSOR (TPS) Mufflers.............................................................................4-33
Removal....................................................................4-33
General.............................................................................4-12 Assembly...................................................................4-33
Removal...........................................................................4-12 System.............................................................................4-33
Installation........................................................................4-12 Removal....................................................................4-33
Installation.................................................................4-33
4.7 INTAKE AIR TEMPERATURE SENSOR
(IAT) 4.17 EXHAUST SYSTEM:
General.............................................................................4-13 FLSTF/FLSTN/FLSTSB
Removal...........................................................................4-13 Mufflers.............................................................................4-35
Installation........................................................................4-13 Removal....................................................................4-35
Assembly...................................................................4-35
4.8 ENGINE TEMPERATURE SENSOR (ET) System.............................................................................4-35
General.............................................................................4-14 Removal....................................................................4-35
Removal...........................................................................4-14 Installation.................................................................4-35
Installation........................................................................4-14
4.18 INTAKE LEAK TEST
4.9 INDUCTION MODULE General.............................................................................4-37
Removal...........................................................................4-16 Leak Tester.......................................................................4-37
Installation........................................................................4-17 Parts List...................................................................4-37
Tester Assembly........................................................4-37
4.10 IDLE AIR CONTROL (IAC) Tester Adjustment......................................................4-37
General.............................................................................4-18 Procedure.........................................................................4-37
Removal...........................................................................4-18
Installation........................................................................4-18 4.19 EVAPORATIVE EMISSIONS CONTROL
(CA MODELS)
4.11 MANIFOLD ABSOLUTE PRESSURE General.............................................................................4-39
SENSOR (MAP) Charcoal Canister.............................................................4-39
General.............................................................................4-19 Removal....................................................................4-39
Removal...........................................................................4-19 Installation.................................................................4-40
Installation........................................................................4-19 Hose Routing/Replacement..............................................4-40

4.12 OXYGEN SENSOR

General.............................................................................4-20
Removal...........................................................................4-20

TABLE OF CONTENTS IX
TABLE OF CONTENTS
STARTER Clutch Pack Only..............................................................6-13
Partial Disassembly...................................................6-13
Cleaning And Inspection...........................................6-13
5.1 SPECIFICATIONS: STARTER Assembly...................................................................6-14
Specifications.....................................................................5-1 Clutch Pack and Bearing..................................................6-15
Complete Disassembly..............................................6-15
5.2 STARTER Assembly...................................................................6-16
General...............................................................................5-3
Wiring Diagrams..........................................................5-3
6.6 TRANSMISSION SPROCKET
Removal.............................................................................5-3 Removal...........................................................................6-18
Installation..........................................................................5-3 Cleaning and Inspection...................................................6-19
Testing................................................................................5-3 Installation........................................................................6-19
Armature.....................................................................5-3
Brushes and Brush Holder..........................................5-5 6.7 DRIVE BELT
Field Coil Assembly............................................................5-6 Removal...........................................................................6-21
Disassembly................................................................5-6 Inspection.........................................................................6-21
Inspection....................................................................5-6 Installation........................................................................6-21
Assembly.....................................................................5-6
Drive Assembly...................................................................5-7 TRANSMISSION
Disassembly................................................................5-7
Inspection....................................................................5-7 7.1 SPECIFICATIONS: TRANSMISSION
Assembly.....................................................................5-7
Specifications.....................................................................7-1
5.3 STARTER SOLENOID Service Wear Limits............................................................7-1
Solenoid Assembly.............................................................5-8 7.2 TRANSMISSION
Disassembly................................................................5-8
Assembly.....................................................................5-8 Power Flow.........................................................................7-2
Solenoid Plunger................................................................5-8 Neutral.........................................................................7-2
Disassembly................................................................5-8 1st Gear......................................................................7-2
Assembly.....................................................................5-8 2nd Gear.....................................................................7-2
Solenoid Contacts..............................................................5-8 3rd Gear......................................................................7-2
Disassembly................................................................5-8 4th Gear......................................................................7-2
Assembly.....................................................................5-9 5th Gear......................................................................7-2
6th Gear......................................................................7-2
DRIVE
7.3 SHIFTER LINKAGE
6.1 SPECIFICATIONS: DRIVE Adjustment.........................................................................7-4
Shifter Rod.........................................................................7-4
Specifications.....................................................................6-1
7.4 CLUTCH RELEASE COVER
6.2 PRIMARY CHAINCASE COVER
Removal and Disassembly.................................................7-5
General...............................................................................6-2 Cleaning and Inspection.....................................................7-5
Removal.............................................................................6-2 Assembly and Installation...................................................7-6
Installation..........................................................................6-2
7.5 TRANSMISSION ASSEMBLY
6.3 DRIVE COMPONENTS
Removal.............................................................................7-7
Removal.............................................................................6-3 Disassembly.......................................................................7-8
Installation..........................................................................6-5 Shifter Cam/Shifter Forks............................................7-8
Mainshaft...................................................................7-10
6.4 PRIMARY CHAINCASE HOUSING Countershaft..............................................................7-13
Removal.............................................................................6-9 Replacing Side Door Bearings..................................7-14
Inspection...........................................................................6-9 Cleaning and Inspection...................................................7-15
Mainshaft Bearing and Lip Seal.........................................6-9 Assembly..........................................................................7-15
Removal......................................................................6-9 Installing Side Door Bearings....................................7-15
Installation...................................................................6-9 Countershaft..............................................................7-15
Mainshaft Bearing Inner Race..........................................6-10 Mainshaft...................................................................7-16
Removal....................................................................6-10 Shifter Cam/Shifter Forks..........................................7-16
Installation.................................................................6-10 Installation........................................................................7-18
Installation........................................................................6-11
7.6 MAIN DRIVE GEAR AND BEARING
6.5 CLUTCH Removal...........................................................................7-20
Removal and Installation..................................................6-13

X TABLE OF CONTENTS
 TABLE OF CONTENTS
Cleaning and Inspection...................................................7-21 Removal and Installation: All But FXCW/C.......................8-11
Needle Bearing Replacement...................................7-22 Removal and Installation: FXCW/C..................................8-12
Installation........................................................................7-23
Installing Main Drive Gear Bearing...........................7-23 8.10 BATTERY CABLES
Installing Main Drive Gear.........................................7-24 Routing Procedure...........................................................8-13
Installing Main Drive Gear Large Seal.......................7-24
8.11 HEADLAMP
7.7 TRANSMISSION CASE
General.............................................................................8-15
Removal...........................................................................7-27 Removal and Installation..................................................8-15
Installation........................................................................7-27 FXSTC Models..........................................................8-15
Disassembly.....................................................................7-28 FXCW/C Models........................................................8-15
Shifter Arm Assembly................................................7-28 FXST, FXSTB, and FLSTSB Models.........................8-15
Cleaning and Inspection...................................................7-28 FLST, FLSTC, FLSTF, and FLSTN Models...............8-15
Assembly..........................................................................7-29
Countershaft Needle Bearing Replacement..............7-29 8.12 TAIL LAMP: ALL BUT FLSTN
Shifter Pawl Lever Assembly.....................................7-29
General.............................................................................8-19
Bulb Replacement............................................................8-19
ELECTRICAL Base Replacement...........................................................8-19

8.1 SPECIFICATIONS: ELECTRICAL 8.13 TAIL LAMP: FLSTN

Specifications.....................................................................8-1 Bulb Replacement............................................................8-21
Tail Lamp Replacement....................................................8-21
8.2 ELECTRICAL PANEL
General...............................................................................8-2 8.14 AUXILIARY LAMPS:
Removal: All But FXCW/C..................................................8-2 FLST/FLSTC/FLSTN
Installation: All But FXCW/C...............................................8-2 Auxiliary Lamp Bulb..........................................................8-23
Removal: FXCW/C.............................................................8-2 Removal....................................................................8-23
Installation: FXCW/C..........................................................8-3 Installation.................................................................8-23
FLST and FLSTC Models.................................................8-23
8.3 ELECTRONIC CONTROL MODULE (ECM) Auxiliary Lamp Bracket Removal...............................8-23
General...............................................................................8-4 Auxiliary Lamp Bracket Installation...........................8-24
Removal: All But FXCW/C..................................................8-4 Auxiliary Lamp Housing Removal.............................8-24
Installation: All But FXCW/C...............................................8-4 Auxiliary Lamp Housing Installation..........................8-24
Removal: FXCW/FXCWC...................................................8-4 FLSTN Models.................................................................8-26
Installation: FXCW/FXCWC................................................8-5 Auxiliary Lamp Bracket Removal...............................8-26
Auxiliary Lamp Bracket Installation...........................8-26
8.4 VOLTAGE REGULATOR Auxiliary Lamp Housing Removal.............................8-27
General...............................................................................8-6 Auxiliary Lamp Housing Installation..........................8-27
Adjustment: FLST/FLSTC/FLSTN Models.......................8-28
8.5 FRONT ELECTRICAL CADDY
General...............................................................................8-7
8.15 TURN SIGNALS AND RUNNING LIGHTS
Disassembly.......................................................................8-7 Bulb Replacement: Bullet Style........................................8-30
Assembly............................................................................8-7 Bulb Replacement: Flat Lens Style..................................8-30
Lamp Replacement..........................................................8-30
8.6 FUSES All Models..................................................................8-30
General...............................................................................8-8 Front Turn Signals: All But FLST, FLSTC, FLSTN.....8-31
Removal.............................................................................8-8 Front Turn Signals: FLST, FLSTC, FLSTN.................8-32
Installation..........................................................................8-8 Rear Turn Signals: All But FXCW/C, FLSTN.............8-32
Rear Turn Signals: FXCW/C......................................8-32
8.7 RELAYS Rear Turn Signals: FLSTN.........................................8-34
General...............................................................................8-9 8.16 TURN SIGNAL AND SECURITY
Removal.............................................................................8-9
Installation..........................................................................8-9
MODULE (TSM/TSSM/HFSM)
General.............................................................................8-35
8.8 MAIN FUSE TSM/HFSM/TSSM Configuration.....................................8-35
Removal...........................................................................8-10 Removal...........................................................................8-35
Installation........................................................................8-10 Installation........................................................................8-35

8.9 IGNITION AND LIGHT SWITCH 8.17 CRANK POSITION SENSOR (CKP)
General.............................................................................8-11 General.............................................................................8-36

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TABLE OF CONTENTS
Removal...........................................................................8-36 Installation........................................................................8-52
Installation........................................................................8-36
8.30 REAR STOPLIGHT SWITCH
8.18 IGNITION COIL General.............................................................................8-53
Removal...........................................................................8-37 Removal...........................................................................8-53
All Except FXCW/C...................................................8-37 Installation........................................................................8-53
FXCW/C Only............................................................8-37
Installation........................................................................8-37 8.31 HORN
All Except FXCW/C...................................................8-37 Inspection.........................................................................8-54
FXCW/C Only............................................................8-37 Removal and Installation: All But FXCW/C.......................8-54
Removal and Installation: FXCW/C..................................8-55
8.19 SPARK PLUG CABLES
General.............................................................................8-39 8.32 ACTIVE EXHAUST
Removal...........................................................................8-39 General.............................................................................8-56
Installation........................................................................8-39 Removal...........................................................................8-56
Repair...............................................................................8-56
8.20 ALTERNATOR Installation........................................................................8-56
Removal...........................................................................8-40
Cleaning and Inspection...................................................8-40 8.33 MAIN WIRING HARNESS
Installation........................................................................8-40 Removal...........................................................................8-57
Installation........................................................................8-58
8.21 FUEL GAUGE
General.............................................................................8-42 8.34 HANDLEBAR SWITCH ASSEMBLIES
Removal...........................................................................8-42 General.............................................................................8-60
Installation........................................................................8-42 Repair Procedures...........................................................8-60

8.22 INSTRUMENT CONSOLE: FXCW/C 8.35 RIGHT HANDLEBAR SWITCH

Removal...........................................................................8-44 Removal...........................................................................8-61
Installation........................................................................8-44 Installation........................................................................8-61
Switch Repair/Replacement.............................................8-63
8.23 SPEEDOMETER: ALL BUT FXCW/C Upper Housing Repair...............................................8-63
Removal...........................................................................8-45 Lower Housing Repair...............................................8-64
Installation........................................................................8-45 Turn-Right Signal Switch...........................................8-64
Front Stoplight Switch...............................................8-64
8.24 SPEEDOMETER: FXCW/C Assembly..........................................................................8-65
Removal...........................................................................8-46
Installation........................................................................8-46 8.36 LEFT HANDLEBAR SWITCH
Removal...........................................................................8-67
8.25 VEHICLE SPEED SENSOR (VSS) Installation........................................................................8-67
General.............................................................................8-47 Switch Repair/Replacement.............................................8-68
Removal...........................................................................8-47 Upper Housing Repair...............................................8-68
Installation........................................................................8-47 Lower Housing Repair...............................................8-69
Turn-Left Signal Switch.............................................8-69
8.26 INDICATOR LAMPS: ALL BUT FXCW/C Clutch Interlock Switch..............................................8-69
Assembly..........................................................................8-69
General.............................................................................8-48
Removal...........................................................................8-48
Installation........................................................................8-48
APPENDIX A CONNECTOR REPAIR
8.27 INDICATOR LAMPS: FXCW/C A.1 AMP 1-PLACE CONNECTORS
Removal...........................................................................8-50 AMP 1-Place Connector Repair.........................................A-1
Installation........................................................................8-50 General.......................................................................A-1
Separating Pin and Socket Housings.........................A-1
8.28 NEUTRAL SWITCH Mating Pin and Socket Housings................................A-1
General.............................................................................8-51 Removing Socket Terminals........................................A-1
Removal...........................................................................8-51 Installing Socket Terminal...........................................A-1
Installation........................................................................8-51 Removing Pin Terminal...............................................A-1
Installing Pin Terminal.................................................A-2
8.29 OIL PRESSURE SWITCH
General.............................................................................8-52
A.2 AMP MULTILOCK CONNECTORS
Removal...........................................................................8-52 AMP Multilock Connector Repair.......................................A-3

XII TABLE OF CONTENTS

 TABLE OF CONTENTS
General.......................................................................A-3 Preparing Wire Leads for Crimping...........................A-19
Separating Pin and Socket Housings.........................A-3 Crimping a Mini Terminal to Wire Lead.....................A-19
Mating Pin and Socket Housings................................A-3 Inspecting Crimps.....................................................A-19
Removing Terminals from Housing.............................A-3
Inserting Terminals into Housing.................................A-4 A.10 MOLEX CONNECTORS
Preparing Wire Leads for Crimping.............................A-4 Molex Connector Repair..................................................A-20
Crimping Terminals to Leads......................................A-5 Separating Pin and Socket Housings.......................A-20
Inspecting Crimped Terminals.....................................A-6 Mating Pin and Socket Housings..............................A-20
Removing Terminals.................................................A-20
A.3 AUTOFUSE ELECTRICAL Installing Terminals...................................................A-20
CONNECTORS Crimp Terminal to Lead....................................................A-21
Autofuse Connector Repair................................................A-7 Prepare Lead............................................................A-21
General.......................................................................A-7 Prepare Tool..............................................................A-21
Disassembly................................................................A-7 Position Terminal in the Punch/Die...........................A-22
Assembly....................................................................A-7 Insert Stripped Lead.................................................A-22
Crimp Terminal to Lead.............................................A-22
A.4 DELPHI CONNECTORS Inspect Crimp............................................................A-23
Delphi Connector Repair....................................................A-8 A.11 PACKARD 150 METRI-PACK
General.......................................................................A-8
Separating Pin and Socket Housings.........................A-8 CONNECTORS
Mating Pin and Socket Housings................................A-8 150 Metri-Pack Connector Repair....................................A-24
Removing Socket Terminals........................................A-8 General.....................................................................A-24
Installing Socket Terminals..........................................A-8 Separating Pin and Socket Housings.......................A-24
Mating Pin and Socket Housings..............................A-24
A.5 DELPHI MAXI FUSE HOUSING Removing Socket Terminal.......................................A-24
Delphi Maxi-Fuse Housing Repair...................................A-10 Inserting Socket Terminal..........................................A-24
General.....................................................................A-10
Removing Maxi-Fuse................................................A-10 A.12 PACKARD 280 METRI-PACK RELAY
Installing Maxi-Fuse..................................................A-10 AND FUSE BLOCK CONNECTORS
Removing Socket Terminals......................................A-10 Fuse Block Repair............................................................A-26
Installing Socket Terminals........................................A-10 Removing Socket Terminals......................................A-26
Installing Socket Terminals........................................A-26
A.6 DEUTSCH ELECTRICAL CONNECTORS Crimping Terminals...................................................A-26
Deutsch Connector Repair...............................................A-12
General.....................................................................A-12 A.13 PACKARD 480 METRI-PACK
Separating Pin and Socket Housings.......................A-12 CONNECTORS
Mating Pin and Socket Housings..............................A-12
Removing Socket Terminals......................................A-12 480 Metri-Pack Connector Repair....................................A-27
Installing Socket Terminals........................................A-12 General.....................................................................A-27
Removing Pin Terminals...........................................A-14 Separating Pin and Socket Housings.......................A-27
Installing Pin Terminals.............................................A-14 Mating Pin and Socket Housings..............................A-27
Crimping Terminals...................................................A-15 Removing Socket Terminals......................................A-27
Installing Socket Terminals........................................A-27
A.7 DEUTSCH STANDARD TERMINAL
A.14 PACKARD 630 METRI-PACK
REPAIR
CONNECTORS
Deutsch Standard Terminal Crimps.................................A-16
Preparing Wire Leads for Crimping...........................A-16 630 Metri-Pack Connector Repair....................................A-28
Crimping Terminal to Lead........................................A-16 General.....................................................................A-28
Inspecting Crimps.....................................................A-16 Separating Pin and Socket Housings.......................A-28
Mating Pin and Socket Housings..............................A-28
A.8 DEUTSCH SOLID BARREL MINI Removing Socket Terminal.......................................A-28
Installing Socket Terminal.........................................A-28
TERMINAL REPAIR
Deutsch Solid Barrel Terminal Crimps.............................A-17 A.15 PACKARD METRI-PACK TERMINALS
Preparing Wire Leads For Crimping.........................A-17 Metri-Pack Terminal Crimps.............................................A-29
Adjusting Crimper Tool..............................................A-17 Matching Terminal To Crimper..................................A-29
Crimping a Barrel Contact To Wire Lead...................A-17 Preparing Wire Lead.................................................A-29
Inspecting Crimps.....................................................A-17 Crimping Wire Core..................................................A-29
Crimping Insulation/Seal...........................................A-29
A.9 DEUTSCH MINI TERMINAL REPAIR Inspecting Crimps.....................................................A-30
Deutsch Mini Terminal Crimps.........................................A-19

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TABLE OF CONTENTS
A.16 PACKARD ECM CONNECTOR B.2 WIRING DIAGRAMS
Packard 100W Connector Repair.....................................A-31 Wiring Diagram Information...............................................B-3
General.....................................................................A-31 Wire Color Codes........................................................B-3
Separating Socket Housing From ECM....................A-31 Wiring Diagram Symbols............................................B-3
Mating Socket Housing To ECM...............................A-31 2008 Softail Wiring Diagrams.............................................B-4
Removing Socket Terminal.......................................A-31
Installing Socket Terminal.........................................A-31 APPENDIX C CONVERSIONS
Crimping Terminals...................................................A-31

A.17 PACKARD MICRO-64 CONNECTORS C.1 METRIC CONVERSION

Conversion Table................................................................C-1
Packard Micro-64 Connector Repair................................A-33
General.....................................................................A-33 C.2 FLUID CONVERSIONS
Separating Pin and Socket Housings.......................A-33
Mating Pin and Socket Housings..............................A-33 United States System........................................................C-2
Removing Terminal...................................................A-33 Metric System....................................................................C-2
Installing Terminal.....................................................A-33 British Imperial System......................................................C-2
Preparing Wire Leads for Crimping...........................A-34
Crimping Terminals...................................................A-34
C.3 TORQUE CONVERSIONS
Inspecting Crimps.....................................................A-34 United States System........................................................C-3
Metric System....................................................................C-3
A.18 SEALED SPLICE CONNECTORS
Sealed Splice Connector Repair......................................A-36 APPENDIX D GLOSSARY
General.....................................................................A-36
Preparing Wire Leads...............................................A-36 D.1 GLOSSARY
Splicing Wire Leads..................................................A-36 Acronyms and Abbreviations.............................................D-1
Inspecting Seals.......................................................A-36

APPENDIX B WIRING REFERENCE MATERIAL

TOOLS...........................................................I
B.1 CONNECTORS
Connector Locations..........................................................B-1 TORQUE VALUES......................................VII
Function/Location.......................................................B-1
Place and Color..........................................................B-1 INDEX........................................................XIX
Connector Number......................................................B-1
Repair Instructions......................................................B-1

XIV TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
1.1 GENERAL.................................................................................................................................1-1
1.2 MAINTENANCE SCHEDULE....................................................................................................1-5
1.3 FUEL AND OIL..........................................................................................................................1-9
1.4 BULB REQUIREMENTS.........................................................................................................1-11
1.5 ENGINE OIL AND FILTER......................................................................................................1-12
1.6 BRAKES..................................................................................................................................1-14
1.7 AIR CLEANER AND EXHAUST SYSTEM..............................................................................1-16
1.8 TIRES AND WHEELS..............................................................................................................1-19
1.9 PRIMARY CHAIN....................................................................................................................1-21
1.10 TRANSMISSION LUBRICANT..............................................................................................1-23
1.11 CLUTCH................................................................................................................................1-25
1.12 REAR BELT AND SPROCKETS...........................................................................................1-27
1.13 REAR BELT DEFLECTION...................................................................................................1-29
1.14 THROTTLE CABLES.............................................................................................................1-31
1.15 BLEEDING BRAKES.............................................................................................................1-32
1.16 BRAKE PADS AND DISCS...................................................................................................1-33
1.17 BATTERY MAINTENANCE...................................................................................................1-37
1.18 SUSPENSION ADJUSTMENTS...........................................................................................1-43
1.19 SPARK PLUGS......................................................................................................................1-44
1.20 STEERING HEAD BEARINGS: ALL BUT FLSTSB...............................................................1-46

MAINTENANCE
1.21 STEERING HEAD BEARINGS: FLSTSB..............................................................................1-49
1.22 ROCKER BEARINGS: FLSTSB............................................................................................1-51
1.23 FRONT FORK OIL................................................................................................................1-53
1.24 CABLE AND CHASSIS LUBRICATION.................................................................................1-54
1.25 HEADLAMP ALIGNMENT.....................................................................................................1-55
1.26 CRITICAL FASTENERS........................................................................................................1-57
1.27 ENGINE MOUNTS................................................................................................................1-58
1.28 STORAGE.............................................................................................................................1-59
1.29 TROUBLESHOOTING...........................................................................................................1-61
NOTES
GENERAL 1.1
SERVICING A NEW MOTORCYCLE Safety
Safety is always the most important consideration when per-
forming any job. Be sure you have a complete understanding
of the task to be performed. Use common sense. Use the
Perform the service and maintenance operations as proper tools. Protect yourself and bystanders with approved
indicated in the regular service interval table. Lack of eye protection. Don't just do the job - do the job safely.
regular maintenance at the recommended intervals can
affect the safe operation of your motorcycle, which could Removing Parts
result in death or serious injury. (00010a)
Always consider the weight of a part when lifting. Use a hoist
Service operations to be performed before customer delivery whenever necessary. Do not lift heavy parts by hand. A hoist
are specified in the applicable model year PREDELIVERY AND and adjustable lifting beam or sling are needed to remove some
SET-UP MANUAL. parts. The lengths of chains or cables from the hoist to the part
should be equal and parallel and should be positioned directly
The performance of new motorcycle initial service is required
over the center of the part. Be sure that no obstructions will
to keep warranty in force and to ensure proper emissions sys-
interfere with the lifting operation. Never leave a part suspended
tems operation. See 1.2 MAINTENANCE SCHEDULE.
in mid-air.
SAFE OPERATING MAINTENANCE
NOTES
• Do not attempt to retighten engine head bolts. Retightening Be sure to check capacity rating and condition of hoists,
can cause engine damage. slings, chains and cables before use. Exceeding capacity
ratings or using lifting devices that are in poor condition
• During the initial break-in period, use only Harley-Davidson
can lead to an accident, which could result in death or
20W50 engine oil. Failure to use the recommended oil will
serious injury. (00466c)
result in improper break-in of the engine cylinders and
piston rings. Always use blocking or proper stands to support the part that
has been hoisted. If a part cannot be removed, verify that all
A careful check of certain equipment is necessary after periods
bolts and attaching hardware have been removed. Check to
of storage, and frequently between regular service intervals,
see if any parts are in the way of the part being removed.
to determine if additional maintenance is required.
When removing hoses, wiring or tubes, always tag each part
Check:
to ensure proper installation.
1. Tires for abrasions, cuts and correct pressure.
Cleaning
2. Secondary drive belt for proper tension and condition.
If you intend to reuse parts, follow good shop practice and
3. Brakes, steering and throttle for responsiveness. thoroughly clean the parts before assembly. Keep all dirt out
of parts; the unit will perform better and last longer. Seals, filters
4. Brake fluid level and condition. Hydraulic lines and fittings
and covers are used in this vehicle to keep out environmental
for leaks. Also, check brake pads and rotors for wear.
dirt and dust. These items must be kept in good condition to
5. Cables for fraying, crimping and free operation. ensure satisfactory operation.
6. Engine oil and transmission fluid levels. When you are instructed in a step to clean fastener threads or
threaded holes, proceed as follows: Clean all LOCTITE material
7. Headlamp, auxiliary lamp, tail lamp, brake lamp, horn and from fastener threads and threaded holes. Use a wire brush
turn signal operation. to clean fastener threads. Use a thread chaser or other suitable
tool to clean threaded holes. Use PJ-1 cleaner or equivalent
SHOP PRACTICES to remove all traces of oil and contaminants from threads. Blow
Repair Notes out all threaded holes with low pressure compressed air.

General maintenance practices are given in this section. Clean and inspect all parts as they are removed. Be sure all
holes and passages are clean and open. After cleaning, cover
NOTES all parts with clean lint-free cloth, paper or other material. Be
• Repair = Disassembly/Assembly. sure the part is clean when it is installed.
• Replacement = Substitute a new part for existing com- Always clean around lines or covers before they are removed.
ponent. Plug, tape or cap holes and openings to keep out dirt, dust and
debris.
All special tools and torque values are noted at the point of
use. Always verify cleanliness of blind holes before assembly.
Tightening a screw with dirt, water or oil in the hole can cause
All required parts or materials can be found in the appropriate
castings to crack or break.
PARTS CATALOG.

2008 Softail Service: Maintenance 1-1

Disassembly and Assembly Wiring, Hoses and Lines
Always assemble or disassemble one part at a time. Do not Hoses, clamps, electrical wiring, electrical switches or fuel lines
work on two assemblies simultaneously. Be sure to make all if they do not meet specifications.
necessary adjustments. Recheck your work when finished. Be
sure that everything is done. Instruments and Gauges
Operate the vehicle to perform any final check or adjustments. Replace broken or defective instruments and gauges. Replace
If all is correct, the vehicle is ready to go back to the customer. dials and glass that are so scratched or discolored that reading
is difficult.
Checking Torques on Fasteners with Lock
Bearings
Patches
Anti-friction bearings must be handled in a special way. To
To check the torque on a fastener that has a lock patch: keep out dirt and abrasives, cover the bearings as soon as
1. Set the torque wrench for the lowest setting in the specified they are removed from the package.
torque range. Wash bearings in a non-flammable cleaning solution. Knock
2. Attempt to tighten fastener to set torque. If fastener does out packed lubricant inside by tapping the bearing against a
not move and lowest setting is satisfied (torque wrench wooden block. Wash bearings again. Cover bearings with clean
clicks), then the proper torque has been maintained. material after setting them down to dry. Never use compressed
air to dry bearings.
Magnetic Parts Trays Coat bearings with clean oil. Wrap bearings in clean paper.
Magnetic parts trays are becoming common in the service
When bearings are installed against shoulders, be sure that
facility because they are convenient and can keep parts from
the chamfered side of the bearing always faces the shoulder.
becoming lost during a repair procedure.
Lubricate bearings and all metal contact surfaces before
However, hardened steel parts can become magnetized when pressing into place. Only apply pressure on the part of the
held in magnetic parts trays. Metal fragments that would bearing that makes direct contact with the mating part. Install
ordinarily be washed away in the oil and trapped in the oil filter bearings with numbered side facing out.
or magnetic drain plug during vehicle operation could be cap-
Always use the proper tools and fixtures for removing and
tured by magnetized parts in the engine, potentially causing
installing bearings.
accelerated engine wear and damage.
Bearings do not usually need to be removed. Only remove
Parts that will be returned to service inside the vehicle's
bearings if necessary.
powertrain such as gears, thrust washers and especially
bearings should never be kept in magnetic parts trays. Bushings
REPAIR AND REPLACEMENT Do not remove a bushing unless damaged, excessively worn
PROCEDURES or loose in its bore. Press out bushings that must be replaced.
When pressing or driving bushings, be sure to apply pressure
Hardware and Threaded Parts in line with the bushing bore. Use a bearing/bushing driver or
Install helical thread inserts when inside threads in castings a bar with a smooth, flat end. Never use a hammer to drive
are stripped, damaged or not capable of withstanding specified bushings.
torque. Inspect the bushing and the mated part for oil holes. Be sure
Replace bolts, nuts, studs, washers, spacers and small all oil holes are properly aligned.
common hardware if missing or in any way damaged. Clean
up or repair minor thread damage with a suitable tap or die.
Gaskets
Always discard gaskets after removal. Replace with new gas-
Replace all damaged or missing lubrication fittings.
kets. Never use the same gasket twice. Be sure that gasket
Use Teflon pipe sealant or LOCTITE 565 THREAD SEALANT holes match up with holes in the mating part. But be aware
on pipe fitting threads. that sections of a gasket may be used to seal passages.
Threadlocking Agents If a gasket must be made, be sure to cut holes that match up
with the mating part. Serious damage can occur if any flange
Always follow specific service manual procedures when working
holes are blocked by the gasket. Use material that is the right
with fasteners containing preapplied threadlocking agents when
type and thickness.
fastener replacement is recommended. When re-using
fasteners containing threadlocking agents, be sure to com- Lip Type Seals
pletely remove all existing threadlocking agent from fastener
Lip seals are used to seal oil or grease and are usually installed
threads with a wire brush or wire wheel. Also, be sure to
with the sealing lip facing the contained lubricant. Seal orient-
remove residual threadlocking agent from fastener hole using
ation, however, may vary under different applications.
an appropriate thread chasing device and compressed air when
using new or existing fasteners. Always use the recommended Seals should not be removed unless necessary. Only remove
threadlocking agent for your specific procedure. seals if required to gain access to other parts or if seal damage
or wear dictates replacement.
Leaking oil or grease usually means that a seal is damaged.
Replace leaking seals to prevent overheated bearings.

1-2 2008 Softail Service: Maintenance

Always discard seals after removal. Do not use the same seal Bearings
twice.
Remove shields and seals from bearings before cleaning.
O-Rings (Preformed Packings) Clean bearings with permanent shields and seals in solution.
Always discard o-rings after removal. Replace with new o-rings.
To prevent leaks, lubricate the o-rings before installation. Apply
the same type of lubricant as that being sealed. Be sure that
Using compressed air to "spin dry" bearings can cause
all gasket, o-ring and seal mating surfaces are thoroughly clean
bearing to fly apart, which could result in death or serious
before installation.
injury. (00505b)
Gears Clean open bearings by soaking them in a petroleum cleaning
Always check gears for damaged or worn teeth. solution. Never use a solution that contains chlorine.
Remove burrs and rough spots with a honing stone or crocus Let bearings stand and dry. Do not dry with compressed air.
cloth before installation. Do not spin bearings while they are drying.
Lubricate mating surfaces before pressing gears on shafts. TOOL SAFETY
Shafts Air Tools
If a shaft does not come out easily, check that all nuts, bolts • Always use approved eye protection equipment when
or retaining rings have been removed. Check to see if other performing any task using air-operated tools.
parts are in the way before using force.
• On all power tools, use only recommended accessories
Shafts fitted to tapered splines should be very tight. If shafts with proper capacity ratings.
are not tight, disassemble and inspect tapered splines. Discard
parts that are worn. Be sure tapered splines are clean, dry and • Do not exceed air pressure ratings of any power tools.
free of burrs before putting them in place. Press mating parts • Bits should be placed against work surface before air
together tightly. hammers are operated.
Clean all rust from the machined surfaces of new parts. • Disconnect the air supply line to an air hammer before
Part Replacement attaching a bit.

Always replace worn or damaged parts with new parts. • Never point an air tool at yourself or another person.
• Protect bystanders with approved eye protection.
Exhaust System Leakage
In the event of an exhaust system leak at a muffler or header Wrenches
pipe connection location, disassemble and clean all mating • Never use an extension on a wrench handle.
surfaces. Replace any damaged components. If leak still exists,
disassemble and repair the leak by applying a bead of Harley- • If possible, always pull on a wrench handle and adjust
Davidson High-Performance Sealant (Part No. 99650-02) (or your stance to prevent a fall if something lets go.
an equivalent 02 Sensor/Catalyst-safe alternative). Reassemble • Never cock a wrench.
components, wipe off any excess sealant and allow adequate
curing time following sealant product instructions before oper- • Never use a hammer on any wrench other than a
ating vehicle. STRIKING FACE wrench.
• Discard any wrench with broken or battered points.
CLEANING
• Never use a pipe wrench to bend, raise or lift a pipe.
Part Protection
Before cleaning, protect rubber parts (such as hoses, boots
Pliers/Cutters/Pry bars
and electrical insulation) from cleaning solutions. Use a grease- • Plastic- or vinyl-covered pliers handles are not intended
proof barrier material. Remove the rubber part if it cannot be to act as insulation. Do not use on live electrical circuits.
properly protected.
• Do not use pliers or cutters for cutting hardened wire
Cleaning Process unless they were designed for that purpose.

Any cleaning method may be used as long as it does not result • Always cut at right angles.
in parts damage. Thorough cleaning is necessary for proper • Do not use any pry bar as a chisel, punch or hammer.
parts inspection. Strip rusted paint areas to bare metal before
priming and repainting.

Rust or Corrosion Removal

Remove rust and corrosion with a wire brush, abrasive cloth,
sand blasting, vapor blasting or rust remover. Use buffing
crocus cloth on highly polished parts that are rusted.

2008 Softail Service: Maintenance 1-3

Hammers Ratchets and Handles
• Never strike a hammer against a hardened object, such • Periodically clean and lubricate ratchet mechanisms with
as another hammer. a light grade oil. Do not replace parts individually; ratchets
should be rebuilt with the entire contents of service kit.
• Always grasp a hammer handle firmly, close to the end.
• Never hammer or put a pipe extension on a ratchet or
• Strike the object with the full face of the hammer.
handle for added leverage.
• Never work with a hammer which has a loose head.
• Always support the ratchet head when using socket
• Discard hammer if face is chipped or mushroomed. extensions, but do not put your hand on the head or you
may interfere with the action of its reversing mechanism.
• Wear approved eye protection when using striking tools.
• When breaking loose a fastener, apply a small amount of
• Protect bystanders with approved eye protection.
pressure as a test to be sure the ratchet's gear wheel is
Punches/Chisels engaged with the pawl.

• Never use a punch or chisel with a chipped or mush- Sockets

roomed end; dress mushroomed chisels and punches with
• Never use hand sockets on power or impact wrenches.
a file.
• Select the right size socket for the job.
• Hold a chisel or a punch with a tool holder if possible.
• Never cock any wrench or socket.
• When using a chisel on a small piece, clamp the piece
firmly in a vise and chip toward the stationary jaw. • Select only impact sockets for use with air or electric
impact wrenches.
• Wear approved eye protection when using these tools.
• Replace sockets showing cracks or wear.
• Protect bystanders with approved eye protection.
• Keep sockets clean.
Screwdrivers
• Always use approved eye protection when using power
• Do not use a screwdriver for prying, punching, chiseling, or impact sockets.
scoring or scraping.
• Use the right type of screwdriver for the job; match the tip
Storage Units
to the fastener. • Do not open more than one loaded drawer at a time. Close
each drawer before opening up another.
• Do not interchange POZIDRIV, PHILLIPS or REED AND
PRINCE screwdrivers. • Close lids and lock drawers and doors before moving
storage units.
• Screwdriver handles are not intended to act as insulation.
Do not use on live electrical circuits. • Do not pull on a tool cabinet; push it in front of you.
• Do not use a screwdriver with rounded edges because it • Set the brakes on the locking casters after the cabinet has
will slip. Redress with a file. been rolled to your workspace.

1-4 2008 Softail Service: Maintenance

MAINTENANCE SCHEDULE 1.2
GENERAL If more detailed information is needed, turn to the sections
which follow for step-by-step instructions.
The table below lists the periodic maintenance requirements
for Softail model motorcycles. If you are familiar with the pro- Also, throughout this manual, you will be instructed to use
cedures, just refer to the table for the recommended service various lubricants, greases and sealants. Refer to Table 1-3.
interval. If necessary, see the quick reference table (Table 1-2) for the correct part numbers of these items.
for the required specifications.

Table 1-1. Regular Service Intervals: 2008 Softail Models

ITEM SERVICED PROCEDURE 1000 MI. 5000 MI. 10,000 MI. 15,000 MI. 20,000 MI. 25,000 MI. NOTES
1600 KM 8000 KM 16,000 KM 24,000 KM 32,000 KM 40,000 KM

Engine oil and filter Replace X X X X X X

Oil lines and brake system Inspect for leaks X X X X X X 1
Air cleaner Inspect, service as required X X X X X X
Tires Check pressure, inspect tread X X X X X X
Wheel spokes Check tightness X X X 1, 4
Primary chaincase lubricant Replace X X X
Transmission lubricant Replace X X
Clutch Check adjustment X X X X X X 1
Rear belt and sprockets Inspect, adjust belt X X X X X X 1
Throttle, brake, and clutch controls Check, adjust and lubricate X X X X X X 1
Jiffy stand Inspect and lubricate X X X 1
Fuel lines and fittings Inspect for leaks X X X X X X 1
Fuel filter in fuel tank Replace X 1
Brake fluid Check levels and condition X X X X X X 6
Brake pads and discs Inspect for wear X X X X X X
Spark plugs Inspect X X X X X X
Replace X
Electrical equipment and switches Check operation X X X X X X
Engine idle speed Check adjustment X X X X X X 1
Front fork oil Replace Replace at 50,000 miles (80,000 kilometers). 1
Steering head bearings Adjust X X X 1
(Softail models)
Lubricate X X 2
Steering head bearings Adjust Adjust and lubricate every 2500 miles (4000 kilometers). 1, 5
(Springer models)
Windshield bushings Inspect X X 1
Springer rocker bearings Adjust X X X 1, 7
Critical fasteners Check tightness X X X 1
Battery Check battery and clean connections 3
Exhaust system Inspect for leaks, cracks, and loose X X X X X X 3
or missing fasteners or heat shields
Road test Verify component and system func- X X X X X X
tions
NOTES: 1. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are
mechanically qualified.
2. Disassemble, lubricate and inspect every 30,000 miles (48,000 kilometers).
3. Perform annually.
4. Not all vehicles are equipped with spoke wheels. Consult appropriate topic in service manual.
5. Disassemble, lubricate and inspect every 20,000 miles (32,000 kilometers).
6. Change D.O.T. 4 fluid and flush brake system every two years.
7. Adjust at 500 miles (800 kilometers).

2008 Softail Service: Maintenance 1-5

 Table 1-2. Softail Quick Reference Maintenance Chart

ITEM SERVICED SPECIFICATION DATA

Engine oil and filter Drain plug torque 14-21 ft-lbs (19-28 Nm)
Oil capacity 3.0 qt (2.85 L)
Filter Hand tighten 1/2-3/4 turn after gasket contact
Chrome filter part number 63798-99
Black filter part number 63731-99
Primary chain lubricant Lubricant capacity 32 oz (0.95 L) wet
40 oz (1.18 L) dry
Primary chaincase drain plug torque 14-21 ft-lbs (19-28 Nm)
Clutch adjustment Free play at adjuster screw 1/2-1 turn
Adjuster screw locknut torque 72-120 in-lbs (8-14 Nm)
Free play at hand lever 1/16-1/8 in. (1.6-3.2 mm)
Clutch inspection cover torque 84-108 in-lbs (10-12 Nm)
Transmission lubricant Lubricant level Dipstick at FULL with motorcycle on jiffy stand and
filler plug resting on threads
Lubricant capacity 32 oz (0.95 L)
Transmission drain plug torque 14-21 ft-lbs (19-28 Nm)
Filler plug torque 25-75 in-lbs (3-9 Nm)
Spark plugs Type HD-6R12
Gap 0.038-0.043 in. (0.97-1.09 mm)
Torque 12-18 ft-lbs (16-24 Nm)
Engine idle speed Idle speed 950-1050 RPM
Front fork oil Type HYDRAULIC FORK OIL (TYPE E)
Part No. 99884-80 (16 oz)
Battery Lubricant ELECTRICAL CONTACT LUBRICANT
Part No. 99861-02 (1 oz)
Battery terminal torque 60-72 in-lbs (6.8-8.1 Nm)

1-6 2008 Softail Service: Maintenance

 Table 1-2. Softail Quick Reference Maintenance Chart

ITEM SERVICED SPECIFICATION DATA

Tire condition and pres- Pressure for solo rider FLST, FLSTC, FLSTN Models:
sure Front: 36 psi (248 kPa)
Rear: 36 psi (248 kPa)
FXST, FXSTC, FXSTB Models:
Front: 30 psi (207 kPa)
Rear: 38 psi (262 kPa)
FLSTF, FLSTSB Models:
Front: 36 psi (248 kPa)
Rear: 38 psi (262 kPa)
FXCW/C Models:
Front: 30 psi (207 kPa)
Rear: 38 psi (262 kPa)
Pressure for rider and passenger FLST, FLSTC, FLSTN Models:
Front: 36 psi (248 kPa)
Rear: 40 psi (276 kPa)
FXST, FXSTC, FXSTB Models:
Front: 30 psi (207 kPa)
Rear: 42 psi (290 kPa)
FLSTF Models:
Front: 36 psi (248 kPa)
Rear: 42 psi (290 kPa)
FXCWC Models:
Front: 30 psi (207 kPa)
Rear: 42 psi (290 kPa)
Wear Replace tire if 1/32 in. (0.8 mm) or less of tread
pattern remains
Wheel spokes Spoke nipple torque Steel laced wheel:
55 in-lbs (6.2 Nm)
Chrome aluminum laced wheel:
55 in-lbs (6.2 Nm)
Steering head bearings Lubricant for neck fitting SPECIAL PURPOSE GREASE
Part No. 99857-97 (14oz cartridge)
Brake fluid reservoir level DOT 4 hydraulic brake fluid part number 99953-99A (12 oz)
Proper fluid level 1/4 ± 1/8 in. (6.35 ± 3.18 mm) from top
Master cylinder reservoir cover torque 6-8 in-lbs (0.7-0.9 Nm)
Brake pad linings and Minimum brake pad thickness 0.04 in. (1.02 mm)
discs Minimum brake disc thickness See stamp on side of disc
Drive belt Upward measurement force applied at midpoint of 10 lb (4.5 kg)
bottom off belt strand
With motorcycle on Jiffy Stand without rider or FLSTN, FXCW/C: 1/4-5/16 in. (6.4-7.9 mm)
luggage FXST, FLST, FLSTC, FLSTF, FXSTB,
FXSTC: 9/16-5/8 in. (14.3-15.9 mm)
Vehicle upright with rear wheel in air FLSTN, FXCW/C: 5/16-3/8 in. (7.9-9.5 mm)
FXST, FLST, FLSTC, FLSTF, FXSTB,
FXSTC: 11/16-3/4 in. (17.5-19.1 mm)
Air cleaner Air cleaner cover bracket screw torque 40-60 in-lbs (4.5-6.8 Nm)
Air cleaner cover screw torque 36-60 in-lbs (4.1-6.8 Nm)
Adhesive for air cleaner cover screw LOCTITE THREADLOCKER 243
Part No. 99642-97 (6 ml)

2008 Softail Service: Maintenance 1-7

 Table 1-2. Softail Quick Reference Maintenance Chart

ITEM SERVICED SPECIFICATION DATA

Clutch and throttle Lubricant SUPER OIL
cables Part No. 94968-85TV (1/4 fl oz)
Handlebar clamp screw torque 12-15 ft-lbs (16.3-20.3 Nm)
Handlebar switch housing screw torque 35-45 in-lbs (4-5 Nm)

Table 1-3. Lubricants, Greases, Sealants

ITEM PART NUMBER PACKAGE

Anti-Seize Lubricant 98960-97 1 oz squeeze tube
CCI #20 Brake Grease 42830-05 (included in master cylinder squeeze packet
rebuild kit)
D.O.T. 4 Brake Fluid 99953-99A 12 oz. bottle
Electrical Contact Lubricant 99861-02 1 oz squeeze tube
Genuine Harley-Davidson Formula+ 99851-05 1 qt bottle
Transmission and Primary Chaincase
Lubricant
G40M Brake Grease 42820-04 squeeze packet
Gray High Performance Sealant 99650-02 1.9 oz squeeze tube
HYLOMAR Gasket and Thread Sealant 99653-85 3.5 oz tube
Loctite Pipe Sealant With Teflon 565 99818-97 6 ml squeeze tube
Loctite Prism Primer (770)
Loctite Prism Superbonder (411)
Loctite Superbonder 420 Adhesive
Loctite Threadlocker 243 (blue) 99642-97 6 ml squeeze tube
Loctite Threadlocker 262 (red) 94759-99 6 ml squeeze tube
Loctite Threadlocker 272 98618-03 10 ml bottle
Special Purpose Grease 99857-97 14 oz. cartridge
Super Oil 94968-85TV 1/4 fl. oz
Type "E" Hydraulic Fork Oil 99884-80 16 oz bottle

1-8 2008 Softail Service: Maintenance

FUEL AND OIL 1.3
FUEL and as much as 15% MTBE. Gasoline/MTBE blends can
be used in your motorcycle.
Refer to Table 1-4. Always use a good quality unleaded gas-
oline. Octane ratings are usually found on the pump. • ETHANOL is a mixture of 10% ethanol (Grain alcohol) and
90% unleaded gasoline. Gasoline/ethanol blends can be
used in your motorcycle if the ethanol content does not
exceed 10%.
Avoid spills. Slowly remove filler cap. Do not fill above • REFORMULATED OR OXYGENATED GASOLINES
bottom of filler neck insert, leaving air space for fuel (RFG): Reformulated gasoline is a term used to describe
expansion. Secure filler cap after refueling. Gasoline is gasoline blends that are specifically designed to burn
extremely flammable and highly explosive, which could cleaner than other types of gasoline, leaving fewer tailpipe
result in death or serious injury. (00028a) emissions. They are also formulated to evaporate less
when you are filling your tank. Reformulated gasolines
use additives to oxygenate the gas. Your motorcycle will
run normally using this type of gas and Harley-Davidson
Use care when refueling. Pressurized air in fuel tank can recommends you use it when possible, as an aid to cleaner
force gasoline to escape through filler tube. Gasoline is air in our environment.
extremely flammable and highly explosive, which could
result in death or serious injury. (00029a) • Do not use race gas or octane boosters. Use of these fuels
will damage the fuel system.
Modern service station pumps dispense a high flow of gasoline
into a motorcycle fuel tank making air entrapment and pressur- Some gasoline blends might adversely affect the starting,
ization a possibility. driveability or fuel efficiency of the motorcycle. If any of these
problems are experienced, try a different brand of gasoline or
gasoline with a higher octane blend.
Table 1-4. Octane Ratings

SPECIFICATION RATING
ENGINE LUBRICATION
Pump Octane (R+M)/2 91 (95 RON)

GASOLINE BLENDS Do not switch lubricant brands indiscriminately because

Your motorcycle was designed to get the best performance some lubricants interact chemically when mixed. Use of
and efficiency using unleaded gasoline. Most gasoline is inferior lubricants can damage the engine. (00184a)
blended with alcohol and/or ether to create oxygenated blends. Engine oil is a major factor in the performance and service life
The type and amount of alcohol or ether added to the fuel is of the engine. Always use the proper grade of oil for the lowest
important. temperature expected before the next scheduled oil change.
Refer to Table 1-5. Your authorized dealer has the proper oil
to suit your requirements.

Do not use gasoline that contains methanol. Doing so can If it is necessary to add oil and Harley-Davidson oil is not
result in fuel system component failure, engine damage available, use an oil certified for diesel engines. Acceptable
and/or equipment malfunction. (00148a) diesel engine oil designations include: CF-4, CG-4, CH-4 and
CI-4.
• Gasoline containing METHYL TERTIARY BUTYL ETHER
(MTBE): Gasoline/MTBE blends are a mixture of gasoline The preferred viscosities for the diesel engine oils in des-
cending order are: 20W50, 15W40 and 10W40.
At the first opportunity, see an authorized dealer to change
back to 100 percent Harley-Davidson oil.

Table 1-5. Recommended Engine Oils

H-D TYPE VISCOSITY H-D RATING LOWEST AMBIENT COLD WEATHER

TEMPERATURE STARTS BELOW 50° F
(10° C)
H-D Multi-grade SAE 10W40 HD 360 Below 40° F (4° C) Excellent
H-D Multi-grade SAE 20W50 HD 360 Above 40° F (4° C) Good
H-D Regular Heavy SAE 50 HD 360 Above 60° F (16° C) Poor
H-D Extra Heavy SAE 60 HD 360 Above 80° F (27° C) Poor

2008 Softail Service: Maintenance 1-9

WINTER LUBRICATION Water vapor is a normal by-product of combustion in any
engine. During cold weather operation, some of the water vapor
In colder climates, the engine oil should be changed often. If condenses to liquid form on the cool metal surfaces inside the
motorcycle is used frequently for short trips, less than 15 engine. In freezing weather this water will become slush or ice
miles (24 kilometers), in ambient temperatures below 60° and, if allowed to accumulate too long, may block the oil lines
F (16° C), oil change intervals should be reduced to 1500 and cause damage to the engine.
miles (2400 kilometers). Motorcycles used only for short runs
must have a thorough tank flush-out before new oil is put in. If the engine is run frequently and allowed to thoroughly warm
The tank flush-out should be performed by an authorized dealer up, most of this water will become vapor again and will be
or qualified technician. blown out through the crankcase breather.

NOTE If the engine is not run frequently and allowed to thoroughly

warm up, this water will accumulate, mix with the engine oil
The further below freezing the temperature drops, the shorter and form a sludge that is harmful to the engine.
the oil change interval should be.

1-10 2008 Softail Service: Maintenance

BULB REQUIREMENTS 1.4
GENERAL NOTES
• See Softail models parts catalog for part numbers.
Refer to Table 1-6. This table gives the location and bulb
requirements for all Harley-Davidson Softail motorcycles. • All Softail model speedometers, tachometers indicator
lamps and odometers are illuminated with LEDs.
• All FXCW/C model rear turn signal lamps are illuminated
with LEDs.
• LEDs are non-repairable. Entire assembly must be
replaced if LED fails.

Table 1-6. Bulb Chart: 2008 Softail Models

LAMP DESCRIPTION BULBS CURRENT DRAW HARLEY-DAVIDSON

(ALL LAMPS 12 VOLT) REQUIRED (AMPERAGE) PART NUMBER
FL FX FL FX
MODELS MODELS MODELS MODELS
Headlamp high beam/low beam 1 4.7 4.3 68329-03 68329-03
position lamp international 1 0.32 53436-97
Tail and stop lamp tail lamp 1 0.59 68167-04
(all models except FLSTN, stop lamp 1 2.10 68167-04
FXCW, FXCWC)
tail lamp international 1 0.59 68167-04
stop lamp international 1 2.10 68167-04
Tail and stop lamp tail lamp 1 0.59 68168-89A
(FLSTN) stop lamp 1 2.10 68168-89A
tail lamp international 1 0.59 68169-90A
stop lamp international 1 2.10 68169-90A
Rear turn signal, tail/stop Illuminated with LEDs. Replace entire assembly upon failure.
lamp (FXCW, FXCWC)
Turn signal lamp (all models front/running 2 2.25 0.59 68168-89A
except rear lamps on front international 2 1.75 68163-84
FXCW, FXCWC)
rear 2 2.25 68572-64B
rear international 2 1.75 68163-84
Auxiliary lamps FLST/FLSTC/FLSTN 2 2.50 68351-05
Fog lamp international 2 2.92 68847-98
Fender tip lamp FLST/FLSTC 2 0.10 68193-95
Instrument panel lamps Illuminated with LEDs. Replace entire assembly upon failure.

2008 Softail Service: Maintenance 1-11

ENGINE OIL AND FILTER 1.5
CHECKING AND ADDING OIL
sm03039
See Figure 1-1. Checking engine oil level:
• As part of the pre-ride inspection.
• At every scheduled service interval.

Type of Oil
Refer to Table 1-5. Use the proper grade of oil for the lowest
temperature expected before the next oil change. See 1.3 FUEL
AND OIL for specific information regarding winter needs.
If it is necessary to add oil and Harley-Davidson oil is not
available, use an oil certified for diesel engines. Acceptable
diesel engine oil designations include CF-4, CG-4, CH-4, and
CI-4. The preferred viscosities for the diesel engine oils, in
descending order, are 20W-50, 15W-40 and 10W-40. At the
first opportunity, see a Harley-Davidson dealer to change back Figure 1-2. Oil Tank Dipstick Upper Groove
to 100 percent Harley-Davidson oil.

Checking Oil Level CHANGING OIL AND FILTER

PART NUMBER TOOL NAME
HD-42311 OIL FILTER WRENCH
Oil level cannot be accurately measured on a cold engine.
For pre-ride inspection, with motorcycle leaning on jiffy HD-44067 OIL FILTER WRENCH
stand on level ground, oil should register on dipstick
between arrows when engine is cold. Do not add oil to NOTES
bring the level to the FULL mark on a COLD engine. • If the motorcycle is ridden hard, under dusty conditions,
(00185a) or in cold weather, the oil and filter should be changed
more often.
Ride motorcycle until engine is warmed up to operating temper-
ature, then do the following. • All Softail models are shipped from the factory with SAE
20W50 Harley-Davidson 360 Motor Oil.
1. Idle motorcycle on jiffy stand for 1-2 minutes.
• All Softail models come equipped from the factory with a
2. Shut motorcycle off and leave motorcycle resting on jiffy
premium 5 micron synthetic media oil filter, Part No.
stand.
63798-99 (Chrome) or 63731-99 (Black). These are the
3. See Figure 1-2. Check oil level on dipstick. If necessary, only recommended replacement filters.
add oil until oil registers at upper groove on dipstick. Do
1. Ride motorcycle until engine is warmed up to normal
not overfill oil tank.
operating temperature.
2. See Figure 1-1. Remove the engine oil filler plug/dipstick
sm03037 by pulling steadily while moving plug back and forth.
3. See Figure 1-3. Remove the engine oil drain plug with o-
ring (2). Allow oil to drain into a suitable container.

Use Harley-Davidson oil filter wrench for filter removal.

This tool can prevent damage to crankshaft position
sensor and/or sensor cable. (00192b)
4. See Figure 1-4. Remove the oil filter using the OIL FILTER
WRENCH (Part No. HD-42311) or OIL FILTER
WRENCH (Part No. HD-44067). Clean the oil filter
mounting surface of any old gasket material.
Figure 1-1. Checking Oil Tank Level 5. See Figure 1-5. Lube the gasket on new oil filter with
engine oil and install new filter. Hand tighten oil filter 1/2
to 3/4 turn after gasket contacts filter mounting surface.
DO NOT use oil filter wrench for oil filter installation.

1-12 2008 Softail Service: Maintenance