2008 FXDSE2 Model Service Manual Supplement

99525-08
©2007 H-D.
 IMPORTANT NOTICE

Harley-Davidson motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards
and U.S.A. Environmental Protection Agency regulations effective on the date of manufacture.

To maintain the safety, dependability, and emission and noise control performance, it is essential that
the procedures, specifications and service instructions in this manual are followed.

Any substitution, alteration or adjustment of emission system and noise control components outside of
factory specifications may be prohibited by law.

Harley-Davidson Motor Company

2008 FXDSE2 Model Service
Manual Supplement

©2007 H-D.
ALL RIGHTS RESERVED
99525-08

Printed in the U.S.A.

VISIT THE HARLEY-DAVIDSON WEB SITE

http://www.harley-davidson.com
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2008 FXDSE2 Model Service Manual Supplement (99525-08)

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NOTES
ABOUT THIS MANUAL
GENERAL PREPARATION FOR SERVICE
This Service Manual Supplement has been designed to be
used with the current Service Manual and has been prepared
with two purposes in mind. First, it will acquaint the user with
Stop the engine when refueling or servicing the fuel
the construction of the Harley-Davidson product and assist in
system. Do not smoke or allow open flame or sparks near
the performance of basic maintenance and repair. Secondly,
gasoline. Gasoline is extremely flammable and highly
it will introduce to the professional Harley-Davidson Technician
explosive, which could result in death or serious injury.
the latest field-tested and factory-approved major repair
(00002a)
methods. We sincerely believe that this Service Manual Sup-
plement will make your association with Harley-Davidson Good preparation is very important for efficient service work.
products more pleasant and profitable. 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
NOTE
reduce the incidence of misplaced tools and parts. A motorcycle
This Service Manual Supplement provides information unique that is excessively dirty should be cleaned before work starts.
to this model motorcycle. Any information not presented in this Cleaning will occasionally uncover sources of trouble. Tools,
supplement can be found in the appropriate Service Manual instruments and any parts needed for the job should be
or Electrical Diagnostic Manual. gathered before work is started. Interrupting a job to locate
tools or parts is a distraction and causes needless delay.
HOW TO USE YOUR SERVICE MANUAL
SUPPLEMENT NOTES
• To avoid unnecessary disassembly, carefully read all rel-
Use the TABLE OF CONTENTS (which follows this FORE- ative service information before repair work is started.
WORD) and the INDEX (at the back of this manual) to quickly
locate subjects. Sections and topics in this manual are • In figure legends, the number which follows the name of
sequentially numbered for easy navigation. a part indicates the quantity necessary for one complete
assembly.
NO. CHAPTER
• When servicing a vehicle equipped with the Harley-
1 Maintenance Davidson Smart Security System (H-DSSS), you must

FOREWORD
2 Chassis first disarm the security system. Either keep the fob in
close proximity to the vehicle, or use Digital Technician to
3 Engine disable the security system while the vehicle is being ser-
4 Fuel System viced and re-enable the system after service is completed.
5 Electric Starter SERVICE BULLETINS
6 Drive
In addition to the information presented in this Service Manual
7 Transmission Supplement and the appropriate Service Manual, Harley-
8 Electrical Davidson Motor Company will periodically issue Service Bul-
letins to Harley-Davidson dealers. Service Bulletins cover
A Appendix A Wiring interim engineering changes and supplementary information.
B Appendix B Glossary Consult the Service Bulletins to keep your product knowledge
current and complete.
For example, a cross-reference shown as 2.1 SPECIFICA-
TIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFIC- USE GENUINE REPLACEMENT PARTS
ATIONS.
If the subject you seek is not in this supplement, refer to the
corresponding section in the appropriate Service Manual. Do not use aftermarket parts and custom made front forks
Check the title page located in the front of each section to find which can adversely affect performance and handling.
the subject. Removing or altering factory installed parts can adversely
For quick and easy reference, all pages contain a section affect performance and could result in death or serious
number followed by a page number. For example, page 3-5 injury. (00001a)
refers to page 5 in section 3. To ensure satisfactory and lasting repairs, carefully follow the
In figure legends, the number following the name of a part Service Manual instructions and use only genuine Harley-
indicates the quantity necessary for one complete assembly. Davidson replacement parts. Behind the emblem bearing the
words GENUINE HARLEY-DAVIDSON stand more than 100
years of design, research, manufacturing, testing and inspecting
experience.This is your assurance that the parts you are using
will fit right, operate properly and last longer.

WARNINGS AND CAUTIONS

Statements in this service manual preceded by the following
words are of special significance.

I
 When reference is made in this manual to a specific brand
name product, tool or instrument, an equivalent product, tool
or instrument may be substituted.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious Kent-Moore Products
injury. (00119a)
All tools mentioned in this manual with an "HD", "J" or "B"
preface must be ordered through SPX Kent-Moore. For ordering
information or product returns, warranty or otherwise, visit
CAUTION indicates a potentially hazardous situation www.spx.com.
which, if not avoided, may result in minor or moderate Loctite Sealing and Threadlocking Products
injury. (00139a)
Some procedures in this manual call for the use of Loctite
products. If you have any questions regarding Loctite product
usage or retailer/wholesaler locations, please contact Loctite
CAUTION used without the safety alert symbol indicates Corp. at www.loctite.com.
a potentially hazardous situation which, if not avoided,
PRODUCT REGISTERED MARKS
may result in property damage. (00140a)
Allen, Amp Multilock, Bluetooth, Brembo, Delphi, Deutsch,
NOTE Dunlop, Dynojet, Fluke, G.E. Versilube, Gunk, Hydroseal,
Refers to important information, and is placed in italic type. It Hylomar, Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Mag-
is recommended that you take special notice of these items. naflux, Marson Thread-Setter Tool Kit, MAXI fuse, Molex, MPZ,
Mulitilock, Novus, Packard, Pirelli, Permatex, Philips, PJ1,
Proper service and repair is important for the safe, reliable Pozidriv, Robinair, S100, Sems, Snap-on, Teflon, Threadlocker,
operation of all mechanical products. The service procedures Torca, Torco, TORX, Tufoil, Tyco, Ultratorch, Velcro, X-Acto,
recommended and described in this service manual are and XM Satellite Radio are among the trademarks of their
effective methods for performing service operations. respective owners.

H-D MICHIGAN, INC. TRADEMARK

INFORMATION
Always wear proper eye protection when using hammers,
arbor or hydraulic presses, gear pullers, spring com- Harley, Harley-Davidson, H-D, Bar & Shield, Digital Tech,
pressors, slide hammers and similar tools. Flying parts Digital Technician, Destroyer, Deuce, Dyna, Electra Glide,
could result in death or serious injury. (00496b) Evolution, Fat Boy, Glaze, Gloss, H-D, H-Dnet.com, HD, Harley,
Heritage Softail, Heritage Springer, Low Rider, Night Rod, Night
Some of these service operations require the use of tools Train, Profile, Revolution, Road Glide, Road King, Rocker,
specially designed for the purpose. These special tools should Softail, Sportster, Sun Ray, Sunwash, Tech Link, Twin Cam
be used when and as recommended. It is important to note 88, Twin Cam 88B, Twin Cam 96, Twin Cam 96B, Twin Cam
that some warnings against the use of specific service methods, 103, Twin Cam 103B, Twin Cam 110, Twin Cam 110B, Tour-
which could damage the motorcycle or render it unsafe, are Pak, Screamin' Eagle, Softail, Super Guide, Super Premium,
stated in this service manual. However, please remember that SYN3, Ultra Glide, V-Rod, VRSC, Wide Glide, and Harley-
these warnings are not all-inclusive. Inadequate safety precau- Davidson Genuine Motor Parts and Genuine Motor Accessories
tions could result in death or serious injury. are among the trademarks of H-D Michigan, Inc.
Since Harley-Davidson could not possibly know, evaluate or
advise the service trade of all possible ways in which service CONTENTS
might be performed, or of the possible hazardous con- All photographs, illustrations and procedures may not neces-
sequences of each method, we have not undertaken any such sarily depict the most current model or component, but are
broad evaluation. Accordingly, anyone who uses a service based on the latest production information available at the time
procedure or tool which is not recommended by Harley- of publication.
Davidson must first thoroughly satisfy himself that neither his
nor the operator's safety will be jeopardized as a result. Failure Since product improvement is our continual goal, Harley-
to do so could result in death or serious injury. Davidson reserves the right to change specifications, equipment
or designs at any time without notice and without incurring
PRODUCT REFERENCES obligation.

Read and follow warnings and directions on all products.

Failure to follow warnings and directions can result in
death or serious injury. (00470b)

II FOREWORD
MAINTENANCE Cleaning and Inspection.....................................................2-8
Disassembly.....................................................................2-10
Steering Head Bearing Race Removal ....................2-10
1.1 SCHEDULED MAINTENANCE Assembly..........................................................................2-11
General...............................................................................1-1 Installation........................................................................2-11

1.2 HEADLAMP ALIGNMENT 2.7 FRONT FORK

Inspection...........................................................................1-2 General.............................................................................2-12
Removal...........................................................................2-12
1.3 AIR FILTER (DOM) Disassembly.....................................................................2-12
Removal.............................................................................1-4 Cleaning and Inspection...................................................2-13
Cleaning.............................................................................1-4 Assembly..........................................................................2-14
Installation..........................................................................1-4 Installation........................................................................2-14

1.4 AIR FILTER (HDI) 2.8 REAR AXLE COVERS

Removal.............................................................................1-5 Removal...........................................................................2-16
Cleaning.............................................................................1-5 Installation........................................................................2-16
Installation..........................................................................1-5
2.9 REAR FORK PIVOT COVERS
1.5 HYDRAULIC CLUTCH FLUID Removal...........................................................................2-17
General...............................................................................1-6 Installation........................................................................2-17
Clutch Fluid Level...............................................................1-6
2.10 LICENSE PLATE BRACKET
1.6 BLEEDING CLUTCH FLUID LINE General.............................................................................2-18
Draining and Filling.............................................................1-7 Removal: Domestic...........................................................2-18
Bleed Clutch Master Cylinder.............................................1-8 Installation: Domestic.......................................................2-18
Bleed Fluid Line and Actuator............................................1-8 Removal: HDI...................................................................2-18

TABLE OF CONTENTS
Return Motorcycle to Service.............................................1-8 Installation: HDI................................................................2-18

1.7 ENGINE LUBRICATION SYSTEM 2.11 REAR FENDER

General...............................................................................1-9 General.............................................................................2-19

CHASSIS 2.12 REAR SHOCKS

General.............................................................................2-20
Removal...........................................................................2-20
2.1 SPECIFICATIONS: CHASSIS Inspection.........................................................................2-20
General...............................................................................2-1 Installation........................................................................2-20
Preload Adjustment..........................................................2-20
2.2 VEHICLE IDENTIFICATION NUMBER
(V.I.N.) 2.13 REAR WHEEL
Vehicle Identification Number (V.I.N.): FXDSE2.................2-2 General.............................................................................2-22
General........................................................................2-2 Preliminary Inspection - Brake Disc..........................2-22
Abbreviated V.I.N.........................................................2-2 Preliminary Inspection - Wheel/Tire..........................2-22
Removal...........................................................................2-23
2.3 FRONT AXLE COVER Disassembly.....................................................................2-23
Removal.............................................................................2-3 Cleaning and Inspection...................................................2-23
Installation..........................................................................2-3 Assembly..........................................................................2-23
Installation........................................................................2-23
2.4 FRONT FENDER
2.14 SEAT
Removal.............................................................................2-4
Installation..........................................................................2-4 Removal...........................................................................2-25
Installation........................................................................2-25
2.5 FRONT WHEEL
2.15 FRONT SPOILER
General...............................................................................2-5
Preliminary Inspection - Brake Disc............................2-5 Removal...........................................................................2-26
Preliminary Inspection - Wheel/Tire............................2-5 Installation........................................................................2-27
Removal.............................................................................2-5
Disassembly.......................................................................2-6
2.16 BELT GUARD AND DEBRIS
Cleaning and Inspection.....................................................2-6 DEFLECTOR
Assembly............................................................................2-6 Removal...........................................................................2-28
Installation..........................................................................2-6 Installation........................................................................2-28

2.6 STEERING HEAD

General...............................................................................2-8
Removal.............................................................................2-8

III
TABLE OF CONTENTS
2.17 FORK TUBE AND STEERING NUT 3.2 SERVICE WEAR LIMITS
COVERS General...............................................................................3-3
Removal...........................................................................2-29
Steering Nut Cover....................................................2-29
3.3 CYLINDER HEAD
Fork Covers...............................................................2-29 General...............................................................................3-5
Installation........................................................................2-29 Removal.............................................................................3-5
Steering Nut Cover....................................................2-29 Determining Service...........................................................3-5
Fork Covers...............................................................2-29 Disassembly.......................................................................3-5
Cleaning.............................................................................3-6
2.18 FOOTPEGS AND FORWARD Inspection...........................................................................3-8
CONTROLS Cylinder Head..............................................................3-8
Valve Guides...............................................................3-8
Removal...........................................................................2-30 Valves..........................................................................3-8
Footpeg Assembly.....................................................2-30 Valve Springs..............................................................3-8
Left Footpeg/Pedal Bracket.......................................2-30 Tapered Keepers.........................................................3-8
Right Footpeg/Pedal Bracket.....................................2-31 Valve Seats.................................................................3-8
Passenger Footpeg Bracket......................................2-31 Replacing Valve Guides......................................................3-9
Installation........................................................................2-31 Removal......................................................................3-9
Footpeg Assembly.....................................................2-31 Installation.................................................................3-10
Left Footpeg/Pedal Bracket.......................................2-32 Assembly..........................................................................3-13
Right Footpeg/Pedal Bracket.....................................2-32 Installation........................................................................3-15
Passenger Footpeg Bracket......................................2-32
3.4 PISTONS
2.19 HANDGRIPS AND HAND CONTROLS
General.............................................................................3-16
General.............................................................................2-33 Measuring Piston..............................................................3-16
Throttle and Brake Controls..............................................2-33
Removal....................................................................2-33 3.5 BORING AND HONING CYLINDERS
Installation.................................................................2-33
Clutch Handgrip and Controls..........................................2-35 Inspection.........................................................................3-17
Removal....................................................................2-35 Cylinder Bore Finished Size.............................................3-18
Installation.................................................................2-35 Piston Orientation.............................................................3-19

2.20 HANDLEBARS 3.6 CRANKCASE ASSEMBLY

Removal...........................................................................2-37 General.............................................................................3-20
Installation........................................................................2-38 Assembly..........................................................................3-20

2.21 CLUTCH MASTER CYLINDER AND FUEL SYSTEM

RESERVOIR
4.1 FUEL SYSTEM
General.............................................................................2-40
Removal...........................................................................2-40 No Unique Content.............................................................4-1
Disassembly.....................................................................2-41
Assembly..........................................................................2-42 ELECTRIC STARTER
Installation........................................................................2-42
5.1 SPECIFICATIONS: STARTER
2.22 CLUTCH HAND LEVER
General...............................................................................5-1
Removal...........................................................................2-44
Installation........................................................................2-44 DRIVE
2.23 CLUTCH FLUID LINE
6.1 CLUTCH RELEASE BEARING AND
Replacement....................................................................2-45
Removal....................................................................2-45 PUSHROD
Installation.................................................................2-45 General...............................................................................6-1
Removal.............................................................................6-1
ENGINE Installation..........................................................................6-1
Measure Release Plate Movement.............................6-1
3.1 SPECIFICATIONS: ENGINE Install Clutch Inspection Cover....................................6-1

General...............................................................................3-1
Manufacturing Tolerances...................................................3-1

IV TABLE OF CONTENTS
 TABLE OF CONTENTS
TRANSMISSION 8.5 REAR TURN SIGNALS
Bulb Replacement..............................................................8-8
7.1 SPECIFICATIONS: TRANSMISSION Removal.............................................................................8-8
Installation..........................................................................8-8
General...............................................................................7-1
8.6 AUTOMATIC COMPRESSION RELEASE
7.2 CLUTCH RELEASE COVER
General...............................................................................8-9
Removal.............................................................................7-2
Removal.............................................................................8-9
Installation..........................................................................7-2
Installation..........................................................................8-9
Fill and Bleed......................................................................7-3
Compression Test.............................................................8-10
Diagnostics.......................................................................8-11
7.3 SECONDARY CLUTCH ACTUATOR
Diagnostic Tips..........................................................8-11
Replacement......................................................................7-4 Diagnostic Notes.......................................................8-11

ELECTRICAL APPENDIX A WIRING

8.1 SPECIFICATIONS: ELECTRICAL A.1 WIRING DIAGRAM INFORMATION
General...............................................................................8-1 Wiring Diagram Information...............................................A-1
Wire Color Codes........................................................A-1
8.2 FUEL GAUGE Wiring Diagram Symbols............................................A-1
Cleaning.............................................................................8-2 Wiring Diagrams.................................................................A-2
Removal.............................................................................8-2
Repair.................................................................................8-2 APPENDIX B GLOSSARY
Installation..........................................................................8-3

8.3 TACHOMETER B.1 GLOSSARY

Acronyms and Abbreviations..............................................B-1
Removal.............................................................................8-4
Installation..........................................................................8-4 REFERENCE MATERIAL
8.4 FRONT TURN SIGNALS
Bulb Replacement..............................................................8-5
TOOLS...........................................................I
Removal.............................................................................8-5
Installation..........................................................................8-6
TORQUE VALUES.......................................III
INDEX.........................................................VII

TABLE OF CONTENTS V
NOTES

VI TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
1.1 SCHEDULED MAINTENANCE.................................................................................................1-1
1.2 HEADLAMP ALIGNMENT.........................................................................................................1-2
1.3 AIR FILTER (DOM)....................................................................................................................1-4
1.4 AIR FILTER (HDI)......................................................................................................................1-5
1.5 HYDRAULIC CLUTCH FLUID...................................................................................................1-6
1.6 BLEEDING CLUTCH FLUID LINE............................................................................................1-7
1.7 ENGINE LUBRICATION SYSTEM............................................................................................1-9

MAINTENANCE
NOTES
SCHEDULED MAINTENANCE 1.1
GENERAL
NOTE
SCREAMIN' EAGLE DYNA has SYN3 SYNTHETIC MOTOR-
CYCLE LUBRICANT in engine, transmission and primary
chaincase.

Table 1-1. Regular Service Intervals: 2008 FXDSE2 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

Air cleaner Inspect, service as required X X X X X X
Tires Check pressure, inspect tread X X X X X X
Primary chaincase lubricant Replace X X X
Transmission lubricant Replace X X
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 pump filter Replace X 1
Brake fluid Check levels and condition X X X X X X 4
Brake pads and discs Inspect for wear X X X X 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
Front fork oil Replace 1, 5
Steering head bearings Adjust X X X 1, 2
Rear fork bearings Inspect every 30,000 miles (48,000 kilometers) 1
Critical fasteners Check tightness X X X 1
Engine mounts and stabilizer links Inspect 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. Replace D.O.T. 4 HYDRAULIC BRAKE FLUID and flush system every two (2) years.
5. Disassemble, lubricate and inspect every 50,000 miles (80,000 kilometers).

2008 FXDSE2 Service: Maintenance 1-1

HEADLAMP ALIGNMENT 1.2
INSPECTION
om00692

The automatic-on headlamp feature provides increased

visibility of the rider to other motorists. Be sure headlamp
is on at all times. Poor visibility of rider to other motorists
can result in death or serious injury. (00030b)
Check headlamp for proper height and lateral alignment: 2
• When new owner takes delivery of motorcycle.
• When there is a change in load (adding luggage, etc.).
1. Verify correct front and rear tire pressure. See TIRES AND 1
WHEELS in the Service Manual.
2. Place motorcycle on level floor (or pavement) in an area 1. 25 feet (7.6 meters)
with minimum light. 2. 35 inches (0.9 meters)
3. See Figure 1-1. Position motorcycle 25 ft (7.6 m) away Figure 1-1. Checking Headlamp Alignment: Dyna Models
from a screen or wall. Measure vertical distance from
center of headlamp to floor, and draw a horizontal line on
screen or wall at same height above floor.
4. Load vehicle with rider, passenger (if normally present) sm02228

and any cargo. Weight will compress vehicle suspension

slightly.
5. Stand motorcycle upright with both tires resting on floor
and with front wheel held in straight alignment (directly
forward).
6. See Figure 1-2. Turn ignition switch ON. Set handlebar
headlamp switch to HI beam position.
7. Check light beam for alignment.
a. Main beam, which is a broad, flat pattern of light,
should be centered equally above and below hori-
zontal line.
b. Main beam of light should also be directed straight
ahead. Properly adjusted headlamps project an equal
area of light to right and left of center.
c. Adjust headlamp alignment if necessary by loosening
headlamp alignment fasteners and tilting headlamp Figure 1-2. Headlamp Switch High Beam Setting
up or down, left or right to compensate.
d. Tighten headlamp alignment fasteners to 25-30 ft-
lbs (34-41 Nm).

1-2 2008 FXDSE2 Service: Maintenance

sm04441

Figure 1-3. Headlamp Alignment Fastener Locations

2008 FXDSE2 Service: Maintenance 1-3

AIR FILTER (DOM) 1.3
REMOVAL 2. Allow filter to either air dry or blow it dry, from inside, with
low pressure air. Do not use air cleaner filter oil on Harley-
1. See Figure 1-4. Remove medallion screws (1) and Davidson paper/wire mesh air filter element.
medallion (2).
3. Hold filter element up to a strong light source. If light is
2. Remove cover screw (3) and air cleaner cover (4). uniformly visible through element, it is sufficiently clean.
3. Remove fasteners (5) and filter element (6) from backplate 4. See Figure 1-4. Inspect gasket/seal (7) and replace with
(8). new one if damaged. Place adhesive side of seal toward
filter element.
CLEANING
1. Wash paper/wire mesh air filter element and breather INSTALLATION
tubes in lukewarm water with a mild detergent. Do not 1. See Figure 1-4. Install filter element (6) on backplate (8)
strike filter element on a hard surface to dislodge dirt. and secure with screws (5). Tighten screws to 40-60 in-
lbs (4.5-6.8 Nm).
2. Apply a drop of LOCTITE THREADLOCKER 243 (blue)
Compressed air can pierce the skin and flying debris from to threads of air cleaner cover screw (3).
compressed air could cause serious eye injury. Wear 3. Install air cleaner cover. Tighten cover screw to 60-90 in-
safety glasses when working with compressed air. Never lbs (6.8-10.2 Nm).
use your hand to check for air leaks or to determine air
flow rates. (00061a) 4. Install medallion (2) and tighten medallion screws (1) to
20-30 in-lbs (2.3-3.9 Nm).

sm04442
8
6

5
4

2 3

1
7

1. Medallion screw (5) 5. Screws (3)

2. Medallion 6. Filter element
3. Cover screw 7. Gasket and seal
4. Cover 8. Backplate
Figure 1-4. Air Cleaner Assembly (Domestic)

1-4 2008 FXDSE2 Service: Maintenance

AIR FILTER (HDI) 1.4
REMOVAL 2. Allow filter to either air dry or blow it dry, from inside, with
low pressure air. Do not use air cleaner filter oil on Harley-
1. See Figure 1-5. Remove insert screws (1) and insert (2). Davidson paper/wire mesh air filter element.
2. Remove cover screw (3) and air cleaner cover (4). 3. Hold filter element up to a strong light source. If light is
3. Remove screws (5), bracket (6) and filter element (7). uniformly visible through element, it is sufficiently clean.

4. Gently pull both rubber breather tubes (8) from screws in 4. Inspect gasket/seal and replace with new one if damaged.
backplate.
INSTALLATION
5. Inspect rubber breather tubes for tears, cuts, holes or other
1. Press two rubber breather tubes over screws on backplate.
damage. Replace if required.
2. See Figure 1-5. Fit breather tubes (8) into holes in air filter
CLEANING and position the filter on backplate.
1. Wash paper/wire mesh air filter element and breather 3. Place bracket (6) on air filter. Align adapter holes to air
tubes in lukewarm water with a mild detergent. Do not filter holes. Install screws (5) through bracket and air filter.
strike filter element on a hard surface to dislodge dirt. Alternately tighten to 40-60 in-lbs (4.5-6.8 Nm).
4. Apply a drop of LOCTITE THREADLOCKER 243 (blue)
to threads of cover screw (3).
Compressed air can pierce the skin and flying debris from 5. Install air cleaner cover. Tighten cover screw to 36-60 in-
compressed air could cause serious eye injury. Wear lbs (4.1-6.8 Nm).
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air 6. Install insert (2) and insert screws (1). Tighten to 27-32
flow rates. (00061a) in-lbs (3.0-3.6 Nm).

sm04443

5
2

4
1
3
1. Insert screws (2) 5. Screws (3)
2. Insert 6. Bracket
3. Cover screw 7. Air filter
4. Air cleaner cover 8. Breather tube (2)
Figure 1-5. Air Cleaner Assembly (HDI)

2008 FXDSE2 Service: Maintenance 1-5

HYDRAULIC CLUTCH FLUID 1.5
GENERAL
The clutch is hydraulically actuated. The hand lever actuated
master cylinder creates pressure in the clutch fluid line that Do not allow dirt or debris to enter the master cylinder
activates a secondary clutch actuator mounted in the clutch reservoir. Dirt or debris in the reservoir can cause improper
release cover. The secondary clutch actuator piston extends operation and equipment damage. (00205c)
and contacts a pushrod to disengage the clutch. 1. Stand motorcycle upright. Turn handlebars to level reser-
voir.
2. Remove two screws, clutch master cylinder/reservoir cover
D.O.T. 4 hydraulic brake fluid is used in the hydraulic and cover gasket.
clutch. Do not use other types of fluids as they are not NOTE
compatible and could cause equipment damage. (00353a) Clutch fluid volume in reservoir actually increases with clutch
wear. Do NOT overfill reservoir.
3. See Figure 1-6. If fluid level is below FILL LEVEL on ledge
D.O.T. 4 brake fluid will damage painted and body panel in reservoir, add D.O.T. 4 HYDRAULIC BRAKE FLUID
surfaces it comes in contact with. Always use caution and (Part No. 99953-99A) to raise fluid level. Do not exceed
protect surfaces from spills whenever brake work is per- FILL LEVEL.
formed. Failure to comply can result in cosmetic damage. 4. Carefully place cover gasket and cover on clutch master
(00239b) cylinder/reservoir.
• Do not wipe any spilled brake fluid off of finished surfaces.
5. Secure cover with two screws. Tighten screws to 6-8 in-
Always flush the affected components with water (not
lbs (0.7-0.9 Nm).
soapy).

sm03945

Direct contact of D.O.T. 4 brake fluid with eyes can cause

irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

CLUTCH FLUID LEVEL

Even though a clear sight glass in the reservoir cover indicates
low clutch fluid, remove the reservoir cover to check fluid level.

Figure 1-6. Fill Level

1-6 2008 FXDSE2 Service: Maintenance

BLEEDING CLUTCH FLUID LINE 1.6
DRAINING AND FILLING 9. Fill clutch master cylinder/reservoir with D.O.T. 4
HYDRAULIC BRAKE FLUID (Part No. 99953-99A). Initial
fluid level should not exceed FILL LEVEL with reservoir
in a level position.
Be sure no clutch fluid gets on tires, wheels or brakes NOTE
when adding fluid. Traction can be adversely affected, The shelf life of a bottle of unopened D.O.T. 4 HYDRAULIC
which could result in loss of control and death or serious BRAKE FLUID is one year. The shelf life of an uncontaminated
injury. (00294a) bottle that has been resealed is one week.
10. Bleed master cylinder. See 1.6 BLEEDING CLUTCH
FLUID LINE, Bleed Clutch Master Cylinder.
Direct contact of D.O.T. 4 brake fluid with eyes can cause 11. Bleed clutch fluid line and secondary actuator. See
irritation. Avoid eye contact. In case of eye contact flush 1.6 BLEEDING CLUTCH FLUID LINE, Bleed Fluid Line
with large amounts of water and get medical attention. and Actuator.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF sm03946
CHILDREN. (00240a)

D.O.T. 4 brake fluid will damage painted and body panel

surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)
• Do not wipe any spilled brake fluid off of finished surfaces.
Always flush the affected components with water (not
soapy).

Figure 1-7. Actuator Bleeder Valve

Do not allow dirt or debris to enter the master cylinder
reservoir. Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)
sm03947
1. Cover exhaust with towel and place a suitable pan under
clutch release cover to catch excess clutch fluid.
2. See Figure 1-7. Remove plastic cap and loosen bleeder
valve.
3. Run hose from bleeder valve to pan.
4. Loosen the clutch master cylinder/reservoir cover.
5. Allow clutch fluid to drain into pan. 2
6. See Figure 1-8. Remove flare nut (1) on outside of the
clutch release cover. Discard o-ring and drain fluid line (2)
into pan. 1
NOTE
Dispose of clutch fluid in accordance with local regulations.
7. Hand tighten valve and replace cap.
8. Install clutch line flare nut with a new o-ring and tighten 1. Flare nut
to 72-120 in-lbs (8.1-13.6 Nm). 2. Clutch fluid line

NOTE Figure 1-8. Clutch Fluid Line and Flare Nut

When filling an empty clutch fluid line, a Snap-on Basic Vacuum
Brake Bleeder with a fitting that mates to the secondary actu-
ator bleeder valve can be used to initially draw the fluid down
the clutch line.

2008 FXDSE2 Service: Maintenance 1-7

BLEED CLUTCH MASTER CYLINDER 4. Fill reservoir to FILL LEVEL and repeat the previous step
three times or more until only a steady flow of clutch fluid
NOTE escapes banjo fitting and fluid level in reservoir is at FILL
Clutch fluid volume in reservoir actually increases with clutch LEVEL with motorcycle in an upright position.
wear. Do NOT overfill clutch reservoir.
BLEED FLUID LINE AND ACTUATOR
1. Stand motorcycle upright. Turn handlebars to level reser-
voir. 1. While holding reservoir cover in place:
a. Pump clutch hand lever 5 times.
2. Add D.O.T. 4 HYDRAULIC BRAKE FLUID (Part No.
99953-99A) to clutch master cylinder/reservoir. Initial fluid b. Hold clutch hand lever against handlebar.
level should not exceed FILL LEVEL with reservoir in a
c. Run hose from bleeder valve to suitable container.
level position.
d. Loosen actuator bleeder valve.
NOTE
The shelf life of a bottle of unopened D.O.T. 4 HYDRAULIC e. Watch bleeder valve for air bubbles.
BRAKE FLUID is one year. The shelf life of an uncontaminated f. Tighten bleeder valve.
bottle that has been resealed is one week.
g. Release clutch hand lever.

NOTE
Clutch fluid volume in reservoir actually increases with clutch
D.O.T. 4 brake fluid will damage painted and body panel
wear. Do NOT overfill clutch reservoir.
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per- 2. With reservoir level, fill reservoir to FILL LEVEL and repeat
formed. Failure to comply can result in cosmetic damage. the previous step three times or more until only a steady
(00239b) flow of clutch fluid escapes bleeder valve and fluid level
in reservoir is at FILL LEVEL with motorcycle in an upright
• Do not wipe any spilled brake fluid off of finished surfaces.
position.
Always flush the affected components with water (not
soapy). RETURN MOTORCYCLE TO SERVICE
NOTE 1. Test pressure by squeezing clutch hand lever.
Loosen banjo bolt only enough to allow air bubbles to escape. 2. Tighten fasteners as follows:
Clutch fluid under pressure can squirt a steady stream several a. Clutch master cylinder banjo bolt to 21-25 ft-lbs (28.5-
feet. 33.9 Nm).
3. While holding reservoir cover in place:
b. Clutch line flare nut to 72-120 in-lbs (8.1-13.6 Nm).
a. Pump clutch hand lever 5 times.
c. Actuator bleeder valve to 12-15 in-lbs (1.4-1.7 Nm).
b. Hold clutch hand lever against handlebar.
d. Reservoir cover screws to 6-8 in-lbs (0.7-0.9 Nm).
c. Hold shop towel under fitting and loosen master cyl-
inder banjo bolt. 3. Remove hose from bleeder valve and replace protective
cap.
d. Watch banjo fitting for air bubbles.
4. Test ride motorcycle. Incorrect pressure or fluid level can
e. Retighten banjo fitting.
cause:
f. Release hand lever. a. Dragging clutch.
b. Hard shifting.

1-8 2008 FXDSE2 Service: Maintenance

ENGINE LUBRICATION SYSTEM 1.7
GENERAL
The engine of this model is initially filled with Screamin' Eagle
SYN3 Synthetic Motorcycle Lubricant. Do not switch lubricant brands indiscriminately because
some lubricants interact chemically when mixed. Use of
If oil needs to be added to the engine to bring the fill level to inferior lubricants can damage the engine. (00184a)
FULL on the dipstick and SYN3 is not available, the first choice
would be to add H-D 360 SAE 20W50 to the SYN3 for engine If it is necessary to add oil and the recommended Harley-
lubrication. Although H-D 360 is compatible with SYN3, we Davidson lubricant is not available, use an oil certified for diesel
suggest the mixture of the fluids be changed as soon as pos- engines.
sible. At the first opportunity, see a Harley-Davidson dealer to change
If H-D 360 is not available, the second choice would be to add back to 100 percent Harley-Davidson oil.
an acceptable diesel engine oil. We again suggest the mixture Acceptable diesel engine oil designations include:
of the fluids be changed as soon as possible. DO NOT add
diesel engine oil to the primary chaincase or transmission. • CF-4

Refer to Table 1-2. To switch lubricant to H-D 360, completely • CG-4

drain the SYN3 before filling with H-D 360. A residual amount • CH-4
of fluid will remain. It is not required to flush out the residual
fluid. • CI-4
The preferred viscosities for the diesel engine oils, in des-
cending order are:

Prolonged or repeated contact with used motor oil may • 20W50

be harmful to skin and could cause skin cancer. Promptly • 15W40
wash affected areas with soap and water. (00358b)
• 10W40

If swallowed, do not induce vomiting. Contact a physician

immediately. In case of contact with eyes, immediateley
flush with water. Contact a physician if irritation persists.
(00357b)

Table 1-2. Recommended Oil Grades

HARLEY- VISCOSITY HARLEY- LOWEST COLD

DAVIDSON TYPE DAVIDSON AMBIENT WEATHER
RATING TEMPERATURE STARTS
BELOW
50°F (10°C)
Screamin' Eagle® SYN3 Synthetic Motorcycle SAE 20W50 HD 360 Above 40°F (4°C) Excellent
Lubricant
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 FXDSE2 Service: Maintenance 1-9

NOTES

1-10 2008 FXDSE2 Service: Maintenance

SUBJECT............................................................................................................................PAGE NO.
2.1 SPECIFICATIONS: CHASSIS...................................................................................................2-1
2.2 VEHICLE IDENTIFICATION NUMBER (V.I.N.)..........................................................................2-2
2.3 FRONT AXLE COVER..............................................................................................................2-3
2.4 FRONT FENDER......................................................................................................................2-4
2.5 FRONT WHEEL.........................................................................................................................2-5
2.6 STEERING HEAD.....................................................................................................................2-8
2.7 FRONT FORK.........................................................................................................................2-12
2.8 REAR AXLE COVERS............................................................................................................2-16
2.9 REAR FORK PIVOT COVERS................................................................................................2-17
2.10 LICENSE PLATE BRACKET.................................................................................................2-18
2.11 REAR FENDER.....................................................................................................................2-19
2.12 REAR SHOCKS....................................................................................................................2-20
2.13 REAR WHEEL.......................................................................................................................2-22
2.14 SEAT......................................................................................................................................2-25
2.15 FRONT SPOILER..................................................................................................................2-26
2.16 BELT GUARD AND DEBRIS DEFLECTOR...........................................................................2-28
2.17 FORK TUBE AND STEERING NUT COVERS......................................................................2-29
2.18 FOOTPEGS AND FORWARD CONTROLS..........................................................................2-30
2.19 HANDGRIPS AND HAND CONTROLS................................................................................2-33
2.20 HANDLEBARS......................................................................................................................2-37
2.21 CLUTCH MASTER CYLINDER AND RESERVOIR..............................................................2-40
2.22 CLUTCH HAND LEVER........................................................................................................2-44

CHASSIS
2.23 CLUTCH FLUID LINE............................................................................................................2-45
NOTES
SPECIFICATIONS: CHASSIS 2.1
GENERAL
Table 2-5. Tire Sizes: 2008 FXDSE2

Table 2-1. Dimensions: 2008 FXDSE2 MOUNT SIZE NUMBER

Front 21 in. D402F MH90-21
ITEM IN. MM
Rear 17 in. D407 170/60R17 78H
Wheel base 63.5 1614
2008 motorcycles use Dunlop Harley-Davidson tires only.
Overall length 92.4 2346
Overall width 37.0 941
Road clearance 4.6 117
Overall height 45.6 1159 Do not inflate tire beyond maximum pressure as specified
on sidewall. Over inflated tires can blow out, which could
Saddle height* 26.5 673 result in death or serious injury. (00027a)
*With 180 lb. (82 kg) rider on seat
Table 2-6. Tire Pressures: 2008 FXDSE2
Table 2-2. Weights: 2008 FXDSE2 LOAD TIRE PRESSURE (COLD)
ITEM LB. KG FRONT REAR
Weight as shipped from 678 308 PSI kPa PSI kPa
factory
Solo rider 30 206 38 262
GVWR 1085 492
Rider and passenger 30 206 42 290
GAWR front 390 177
GAWR rear 695 315

NOTE Match tires, tubes, air valves and caps to the correct wheel
rim. Contact a Harley-Davidson dealer. Mismatching can
Gross Vehicle Weight Rating (GVWR) (maximum allowable
result in damage to the tire bead, allow tire slippage on
loaded vehicle weight) and corresponding Gross Axle Weight
the rim or cause tire failure, which could result in death
Ratings (GAWR) are given on a label located on left front frame
or serious injury. (00023a)
cross tube.
NOTE
Table 2-3. Capacities: 2008 FXDSE2 See TIRES AND WHEELS in the the Dyna Service Manual for
ITEM U.S. LITERS important information regarding tires.
Fuel tank (total) 5.0 gal 18.9
Oil tank with filter 3.5 qt. 3.3
Transmission (approximate) 32 oz. 0.95 Use only Harley-Davidson approved tires. See a Harley-
Davidson dealer. Using non-approved tires can adversely
Primary chaincase (approx- 32 oz. 0.95 affect stability, which could result in death or serious
imate) injury. (00024a)
Low fuel warning light on 1.0 gal 3.8 • Use tubeless tires on all Harley-Davidson disc wheels.
• Do not use inner tubes in radial tires.
Table 2-4. Wheel, Brake Disc and Tire Runout
• Always use correct size tires. Tire sizes are molded on
RUNOUT MM IN tire sidewall.
Wheel - rim lateral 0.76 0.030
Wheel - rim radial 0.76 0.030
Front brake disc - 0.3 0.012
lateral
Rear brake disc - 0.3 0.012
lateral
Tire - lateral 1.52 0.060
Tire - radial 2.29 0.090

2008 FXDSE2 Service: Chassis 2-1

VEHICLE IDENTIFICATION NUMBER (V.I.N.) 2.2
VEHICLE IDENTIFICATION NUMBER (V.I.N.):
om01121
FXDSE2
General
See Figure 2-1. A full 17-digit serial or Vehicle Identification
Number (V.I.N.) is stamped on the right side of the steering
head and on a label located on the right front frame down tube.
See Figure 2-2 for the complete V.I.N. as it appears on the
steering head. For a description of each item in the V.I.N., refer
to Table 2-7.

Abbreviated V.I.N.
An abbreviated V.I.N. showing the vehicle model, engine type,
model year, and sequential number is stamped on the left side
of the crankcase below the engine cylinders.
Example: PS88950000
NOTE
Always give the full 17-digit Vehicle Identification Number when
ordering parts or making any inquiry about your motorcycle. Figure 2-1. V.I.N. Stamping Location: FXDSE2

om01044

1 2 3 4 5 6 7 8 9 10

1 HD 1 PS 8 1 3 8 K 950000
Figure 2-2. Typical Harley-Davidson V.I.N.: 2008 FXDSE2 Models

Table 2-7. Harley-Davidson V.I.N. Breakdown: 2008 FXDSE2 Models

POSITION DESCRIPTION POSSIBLE VALUES

1 Market designation 1=Originally manufactured for sale within the United States
5=Originally manufactured for sale outside of the United States
2 Manufacturer HD=Harley-Davidson
3 Motorcycle type 1=Heavyweight motorcycle (901 cc or larger)
4 Model PS=FXDSE2 Screamin' Eagle® Dyna™
5 Engine type 8=110 cu. in. (1800 cc) air cooled, fuel injected
6 Introduction date 1=Regular
2=Mid-year
3=California/regular
4=Cosmetic changes and/or special introductory date
5=California/cosmetic changes and/or special introductory date
6=California/mid-year
7 V.I.N. check digit Can be 0-9 or X
8 Model year 8=2008
9 Assembly plant K=Kansas City, MO U.S.A.
10 Sequential number varies

2-2 2008 FXDSE2 Service: Chassis

FRONT AXLE COVER 2.3
REMOVAL INSTALLATION
1. See Figure 2-3. Thread a #6-32 screw into axle cover. NOTE
2. Using a rocking and pulling motion, remove front axle Be sure o-rings are installed on axle cover before installation,
cover from axle. otherwise cover can dislodge from fork assembly.
Orient cover contour over axle end and firmly push axle cover
into place until seated.
sm04446

Figure 2-3. Axle Cover

2008 FXDSE2 Service: Chassis 2-3

FRONT FENDER 2.4
REMOVAL INSTALLATION
Remove mounting screws and gently remove fender from fork Gently align fender with mounting pads on front fork assembly
assembly to avoid scratching paint. to avoid scratching paint and install mounting screws. Tighten
mounting screws to 15-21 ft-lbs (20.3-28.5 Nm).
sm04447

Figure 2-4. Front Fender Mounting Screw Locations

2-4 2008 FXDSE2 Service: Chassis

FRONT WHEEL 2.5
GENERAL 3. If scored, warped, or excessively worn, replace disc.

Maximum tire mileage and good handling qualities are directly Preliminary Inspection - Wheel/Tire
related to wheel and tire care. Wheels and tires should be
1. Block motorcycle underneath frame so front wheel is raised
inspected regularly for wear. If handling problems occur, check
off of ground.
TROUBLESHOOTING in the Dyna Service Manual for possible
causes. 2. Inspect tire for wear and wear pattern. Replace tire as
necessary.
Preliminary Inspection - Brake Disc
3. Inspect air valve. Replace as necessary.
1. Measure brake disc thickness for excessive wear. Min-
imum acceptable thickness is stamped on side of disc. 4. Inspect wheel bearing end play and service bearings if
necessary. If end play is 0.002 in. (0.051 mm) or more,
2. If warped, replace disc. Maximum allowable lateral runout replace wheel bearings. See SEALED WHEEL BEARINGS
of a floating brake disc is 0.012 in. (0.3 mm). in the Dyna Service Manual.

sm04448
9

8
7
5

2
6
4

2
1

1. Spacer (2) 4. Screw (5) 7. Wheel

2. Bearing (2) 5. Air valve hole 8. Brake disc
3. Inner spacer 6. Hub cover 9. Screw (5)
Figure 2-5. Front Wheel Components

REMOVAL 3. Remove brake caliper assembly according to the Dyna

Service Manual procedure.
1. Block motorcycle underneath frame so front wheel is off
of ground. 4. Support caliper using a rubber bungee cord. Be careful
not to scratch fender or fork slider finish.

NOTE
To prevent accidental vehicle start-up, which could cause Do not operate front brake lever with front wheel removed or
death or serious injury, remove main fuse before pro- caliper piston may be forced out of piston bore. Reseating
ceeding. (00251b) piston requires disassembly of caliper.

2. Remove Maxi-Fuse.

2008 FXDSE2 Service: Chassis 2-5

DISASSEMBLY 4. Inspect brake pads. Minimum brake pad thickness is 0.06
in. (1.6 mm). See BRAKE PADS AND DISCS in the Dyna
NOTE Service Manual.
See TIRES in the Dyna Service Manual to service tire or valve
stem assembly. ASSEMBLY
1. See Figure 2-6. Remove front axle cover (1) using a #6-
32 screw. Loosen right side set screw (4) and remove axle
(2). Be sure that brake fluid or other lubricants do not contact
NOTE brake pads or discs. Such contact can adversely affect
Do not remove left side axle set screw or left side axle insert braking ability, which could cause loss of control, resulting
unless necessary. in death or serious injury. (00290a)

2. If necessary, remove left side set screw (5) and axle insert NOTE
(3).
Always install first of two bearings on side with lettering on
wheel hub (primary side).
sm04449 1. If sealed wheel bearings must be serviced, always replace
bearings as a complete set. See SEALED WHEEL
BEARINGS in the Dyna Service Manual.

1
Do not inflate tire beyond maximum pressure as specified
2 on sidewall. Over inflated tires can blow out, which could
4 result in death or serious injury. (00027a)
3
5 2. If necessary, mount tire, valve stem and balance wheel
assembly as required. See TIRES in the Dyna Service
1. Front axle cover Manual.
2. Front axle
3. Verify that wheel and tire are true. See TIRES and
3. Axle insert
CHECKING CAST WHEEL RUNOUT in the Dyna Service
4. Right side set screw
Manual.
5. Left side set screw
4. See Figure 2-5. If removed, install brake disc on left side
Figure 2-6. Front Axle Assembly
of wheel, using five new screws (9). Tighten screws to 16-
24 ft-lbs (21.7-32.5 Nm). Verify that brake disc is clean.
3. See Figure 2-5. Remove spacers (1) from left and right 5. If removed, install hub cover (6). Tighten screws to 16-24
sides and remove wheel (7) from motorcycle. ft-lbs (21.7-32.5 Nm).
4. If tire replacement is necessary, remove tire and valve 6. After wheel is balanced, apply a liberal coat of LOCTITE
stem. See TIRES in the Dyna Service Manual. ANTI-SEIZE LUBRICANT to the bore of both bearing
5. If wheel bearing replacement is necessary, press out races.
sealed wheel bearings (2). See SEALED WHEEL BEAR-
INSTALLATION
INGS in the Dyna Service Manual.
1. See Figure 2-6. If removed, install axle insert (3) into left
6. If removing brake disc (8), remove five bolts (9) securing
side fork assembly.
brake disc to wheel.
2. Apply a drop of LOCTITE 243 to the threads of set screw
CLEANING AND INSPECTION (5). Ensure flat on insert (3) is aligned with set screw hole
1. Thoroughly clean all parts in solvent. and install set screw. Tighten to 50-55 ft-lbs (68-75 Nm).

2. Inspect all parts for damage or excessive wear. NOTE

Ensure threaded axle insert (3) is installed in left fork.
3. Apply a liberal coat of LOCTITE ANTI-SEIZE LUBRICANT
to axle.
Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could 4. Install front wheel assembly, spacers and thread axle into
result in death or serious injury. (00111a) left fork assembly insert. Tighten axle to 65-70 ft-lbs (88-
95 Nm).
3. Inspect brake discs. Measure disc thickness for excessive
wear. Minimum acceptable thickness is stamped on side 5. Apply LOCTITE 243 to threads of axle set screw (4) and
of disc. Also replace discs if warped or badly scored. See install into bottom of fork assembly. Tighten set screw to
BRAKE PADS AND DISCS in appropriate Dyna Service 50-55 ft-lbs (68-75 Nm).
Manual. 6. Install axle cover in right side fork assembly and press
firmly in place.

2-6 2008 FXDSE2 Service: Chassis

Be sure that brake fluid or other lubricants do not contact Whenever a wheel is installed and before moving the
brake pads or discs. Such contact can adversely affect motorcycle, pump brakes to build brake system pressure.
braking ability, which could cause loss of control, resulting Insufficient pressure can adversely affect brake perform-
in death or serious injury. (00290a) ance, which could result in death or serious injury.
(00284a)
7. Install brake caliper to left side fork assembly.
a. Loosely install long caliper mounting bolt through top 8. Pump brake hand lever to move pistons out until they
hole in caliper and into top hole on fork leg. contact both brake pads. Verify piston location against
pads.
b. Install short mounting bolt through bottom hole in
caliper and into bottom hole on fork leg. Tighten 9. Install Maxi-Fuse.
bottom mounting bolt to 28-38 ft-lbs (38-52 Nm).
c. Final tighten top mounting bolt to 28-38 ft-lbs (38-52
Nm). After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)
10. Test brake system.

2008 FXDSE2 Service: Chassis 2-7

STEERING HEAD 2.6
GENERAL 5. See Figure 2-7. Remove fork stem cover (8). Bend lock-
washer (6) tab away from fork stem nut (7). Remove stem
The FXDSE2 model motorcycle uses an inverted-type fork that nut.
is unique from conventional forks. Follow instructions below to
remove and install front fork/steering head as an assembly. 6. Pull upper fork bracket and handlebar assembly free from
fork stem and gently lay assembly on protected gas tank
REMOVAL of motorcycle.
7. Remove adjusting nut (5) and lower fork bracket from
steering head. Remove upper dust shield.
To prevent accidental vehicle start-up, which could cause CLEANING AND INSPECTION
death or serious injury, remove main fuse before pro-
ceeding. (00251b) 1. Check upper and lower bearing races in steering head. If
they are pitted or grooved, replace bearings and races in
1. Remove Maxi-Fuse.
sets.
2. Remove fork assemblies. See 2.7 FRONT FORK.
3. Remove headlamp and bracket. See HEADLAMP in the
Dyna Service Manual. Replace both bearing assemblies even if one assembly
4. Remove brake hose bracket from bottom of lower fork appeares to be good. Mismatched bearings can lead to
bracket. excessive wear and premature replacement. (00532b)
2. Check roughness of bearings by turning them in the races
yet installed in steering head. Replace bearings if they do
not turn freely and smoothly.

2-8 2008 FXDSE2 Service: Chassis

sm04450
8
9
7
6 9

3
4
5
13

10

11

3
12

1. Fork assembly, left side 8. Fork stem cover and set screw
2. Fork assembly, right side 9. Fork assembly cap
3. Screws (8) 10. Bearings
4. Fork bracket, upper 11. Lower dust shield
5. Adjusting nut 12. Fork bracket and stem, lower
6. Lockwasher 13. Upper dust shield
7. Fork stem nut
Figure 2-7. Front Fork and Steering Head Assembly

2008 FXDSE2 Service: Chassis 2-9

DISASSEMBLY sm02489

PART NUMBER TOOL NAME 1

HD-33416 UNIVERSAL DRIVER
HD-39301-A STEERING HEAD BEARING RACE
REMOVER
2
sm02275
1

1. Remover (2 pieces)
2. Collet
3. Driver
Figure 2-8. Race Remover Tools

Steering Head Bearing Race Removal

1. See Figure 2-9. With the tapered side down, seat the two-
piece STEERING HEAD BEARING RACE
REMOVER (Part No. HD-39301-A) (1) on the upper
bearing race leaving a gap in the middle.
3
2. Install the collet (2) on the UNIVERSAL DRIVER (Part
No. HD-33416).
3. Insert the driver at the bottom of the steering head tube
(3), and while holding the remover tool on the race, center
the collet in the gap. Tap the driver to remove the upper
race. 4
4. Reverse the tool and repeat the procedure (4) to remove
the lower bearing race.

NOTE
If bearing cups are removed, the bearings cannot be reused.
They must be replaced. The lower bearing cone is not pressed
on fork stem and may be slipped off fork stem along with lower
dust shield.

1. Install remover on upper race

2. Install collet on driver
3. Install driver in remover and remove upper race
4. Remove lower race
Figure 2-9. Remove Races

2-10 2008 FXDSE2 Service: Chassis

ASSEMBLY NOTE
Overtightening adjusting nut will cause the bearings to wear
PART NUMBER TOOL NAME excessively leading to the need for premature bearing
HD-39302 STEERING HEAD BEARING RACE replacement.
INSTALLER 1. See Figure 2-7. Insert stem and bracket assembly (12)
HD-99857-97 SPECIAL PURPOSE GREASE into frame steering head and install upper bearing and
dust shield. Secure with adjusting nut (5).Tighten adjusting
1. Pack the new bearings with SPECIAL PURPOSE nut until there is no noticeable shake or freeplay between
GREASE (Part No. HD-99857-97). bearings and races. Fork stem must turn freely from side
NOTE to side.
Press only on inner bearing race or damage to bearing will 2. Install upper bracket (4), a new lockwasher (6) and fork
occur. stem nut (7). Tighten nut securely.
2. See Figure 2-7. Install the lower dust shield (11) and new 3. Install headlamp assembly. See HEADLAMP in Dyna
bearing (10) on the fork stem (12). Service Manual.
4. Install fork assemblies. See 2.7 FRONT FORK.
5. Install front wheel. See 2.5 FRONT WHEEL.
Properly seat bearing cups in steering head bore. Improper
seating can loosen fork stem bearings adversely affecting 6. Install front fender. See 2.4 FRONT FENDER.
stability and handling, which could result in death or ser-
7. Adjust steering head bearings. See STEERING HEAD
ious injury. (00302a)
BEARINGS in the Dyna Service Manual.
3. Lubricate the races with engine oil. Install the new races
using STEERING HEAD BEARING RACE 8. Tighten fork stem nut to 35-40 ft-lbs (47.5-54.2 Nm). Bend
INSTALLER (Part No. HD-39302). lockwasher tab against flat of nut.
9. Install fork stem cover (8) and secure with set screw.
INSTALLATION Tighten set screw to 14-16 in-lbs (1.6-1.8 Nm)
10. Install Maxi-Fuse.
11. Align headlamp. See 1.2 HEADLAMP ALIGNMENT.
Properly adjust fork stem bearings. Improper adjustments
affect stability and handling, which could result in death
or serious injury. (00301a)

2008 FXDSE2 Service: Chassis 2-11

FRONT FORK 2.7
GENERAL DISASSEMBLY
The FXDSE2 model motorcycle uses an inverted-type left and PART NUMBER TOOL NAME
right side fork assemblies with unique rebuild and service pro-
HD-41177 FORK TUBE HOLDER
cedures that differ from conventional forks. Follow instructions
below for fork assembly rebuild procedure. HD-41494 FLSTS/C HUBCAP REMOVAL TOOL

REMOVAL HD-45966 FORK SPRING COMPRESSING TOOL

PART NUMBER TOOL NAME

HD-48287 TRIPLE TREE WEDGES
Wear safety glasses or goggles when servicing fork
assembly. Do not remove slider tube caps without relieving
spring preload or caps and springs can fly out, which could
result in death or serious injury. (00297a)
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
NOTES
ceeding. (00251b)
• When using FORK SPRING COMPRESSING TOOL (Part
1. Remove Maxi-Fuse. No. HD-45966) be sure not to bind outer fork tube on tool.
2. Support motorcycle so front wheel is raised and front forks • FORK SPRING COMPRESSING TOOL (Part No. HD-
are fully extended. 45966) comes with a cup and screw that are for FLT
3. Remove caliper and front wheel. See 2.5 FRONT WHEEL. models only and not to be used with this fork assembly.

4. Remove front fender. See 2.4 FRONT FENDER. 1. See Figure 2-11. Obtain FORK TUBE HOLDER (Part
No. HD-41177) and clamp end of tool in vise as shown.
5. Remove headlamp bracket. Attach headlamp to frame Secure fork assembly in holder.
using rubber bungee strap. See HEADLAMP in the Dyna
Service Manual. 2. See Figure 2-12. Remove fork cap (6). Fork plug is
threaded to outer fork tube (5) and cartridge assembly (1).
6. Remove upper and lower fork clamp pinch bolts.
3. Loosen nut (17).
7. Remove chrome fork bracket caps.
4. Pull down on fork spring and remove spring end plate (11).
8. See Figure 2-10. Using TRIPLE TREE WEDGES (Part
No. HD-48287), insert tool in triple clamps. 5. Place drain pan under fork and turn fork over to allow oil
to drain from fork. When all oil has drained, turn fork back
9. Remove forks from upper and lower clamps. to upright position.
6. Remove screw and washer (14).
sm04451
7. Remove cartridge assembly (1) and preload spacer (16).
8. Use FLSTS/C HUBCAP REMOVAL TOOL (Part No. HD-
41494) to disengage dust cover (13) and dust seal (4).
Slide them down towards bottom of fork tube assembly.
9. Compress retaining ring (3) and remove clip from internal
groove of outer fork tube (5).
10. Remove inner fork tube (12) from outer fork tube (5) until
upper bushing (7) on fork tube contacts lower bushing (9)
in outer fork tube. Use upper bushing in a slide hammer
motion to gently remove oil seal (10), spacer (15), and
lower bushing (9) from outer fork tube bore.

Figure 2-10. Insert Triple Tree Wedge (typical)

2-12 2008 FXDSE2 Service: Chassis

sm03229 sm05072
6
17 2
7

12

11

15

1 16 10

Figure 2-11. Fork Holding Tool (mounted vertically to 3

slider)
14
4

13
1. Cartridge assembly
2. O-ring, fork plug
3. Internal retaining ring
4. Dust seal
5. Outer fork tube
6. Fork plug
7. Upper bushing
8. Spring
9. Lower bushing
10. Oil seal
11. End plate, spring
12. Fork tube assembly
13. Dust cover
14. Screw and washer
15. Spacer, oil seal
16. Preload spacer
17. Locknut
Figure 2-12. Inverted Fork (left side shown)

NOTE
To overcome any resistance, use inner fork tube assembly as
a slide hammer, that is, first push inner fork tube into outer fork
tube, and then pull it outward with a moderate amount of force.
Repeat this sequence until inner fork tube separates from outer
fork tube.

CLEANING AND INSPECTION

1. Inspect fork for worn or damaged parts. If fork tubes,
spring, preload spacer or cartridge assembly are worn or
damaged, replace entire fork. When reassembling fork,
replace oil seal, bushings and dust seal using the fork
rebuild kit for this application.
NOTE
Any time fork pinch bolts are loosened or removed for any
reason, following procedure must be used. Fork tube installation

2008 FXDSE2 Service: Chassis 2-13

process is extremely critical and must follow this procedure
is00159
with no exceptions.
2. Thoroughly clean all locking material from the fastener
and bracket bolt hole threads. Fork pinch bolts must be
thoroughly cleaned of all lock patch material. Fork bracket
bolt holes must be tapped with a bottoming tap and blown
clear with compressed air to remove excess lock patch
material. If bolts can not be completely cleaned, it is
required that new fork pinch bolts be installed.

ASSEMBLY
PART NUMBER TOOL NAME
B-42571 FORK SEAL BUSHING TOOL
HD-59000B FRONT FORK OIL LEVEL GAUGE
Figure 2-13. Remove Excess Fork Oil
NOTE
Lubricate new oil seal with new Harley-Davidson Type E Fork
Oil before installing. 13. Pour approximately 15.7 oz (465 cc) of Harley-Davidson
Type E Fork Oil into fork tube assembly.
1. Protect seals from damage in the following steps by pla-
cing a plastic bag over top of area of lower fork tube 14. Pump cartridge rod 10 times to remove air from cartridge.
assembly.
15. See Figure 2-13. Measure and adjust fork oil level to 3.54
2. See Figure 2-12. Slide dust cover (13), dust seal (4), in. (90 mm) from top of inner fork tube using FRONT FORK
retaining ring (3), oil seal (10) (with letter side downward), OIL LEVEL GAUGE (Part No. HD-59000B).
oil seal spacer (15) (concave side upward) and lower
bushing (9) over inner fork tube assembly for later install- 16. Thread locknut (17) down cartridge until it bottoms.
ation. 17. Install spring (8) into fork tube assembly.
3. Remove plastic bag. 18. Press downward on spring (8) and install spring end plate
4. Install upper bushing (7) in groove of inner fork tube (12). (11) between spring and locknut (17) with concave side
Expand bushing only enough to fit over inner fork tube. up.

5. Install inner fork tube (12) into outer fork tube assembly 19. Install new o-ring from rebuild kit onto fork plug (6).
(5). 20. Install fork plug (6) onto cartridge assembly. Thread plug
6. Install bushing, spacer and seal into outer fork tube bore all the way down until it bottoms out, then thread locknut
by tapping components upward with FORK SEAL (17) up to plug and tighten.
BUSHING TOOL (Part No. B-42571). 21. Press downward on fork cap and pull up on outer fork tube
7. Install internal retaining ring (3) into groove in bottom of until it can be threaded into outer fork tube. Thread fork
outer fork tube. cap into outer fork tube until it bottoms out.

8. Install dust seal (4) and cover (13). 22. Repeat for other fork assembly.

9. Install cartridge assembly (1) into fork tube bore. INSTALLATION

10. Apply LOCTITE 638 (green) to threads of screw (14). PART NUMBER TOOL NAME
11. Install screw and washer (14) into bottom of fork tube HD-48287 TRIPLE TREE WEDGES
assembly (12). Move slider several times to verify proper
1. Loosely install fork bracket pinch bolts into upper and lower
component alignment.Then, apply downforce on cartridge
fork brackets.
assembly and tighten screw to 111 ft-lbs (150 Nm).
2. Insert TRIPLE TREE WEDGES (Part No. HD-48287) into
12. Insert preload spacer (16) over cartridge in fork tube bore.
fork bracket clamps and install right side fork up through
upper and lower fork brackets. Bottom out fork in bore.
Install fork cover and tighten pinch bolts of upper fork
bracket enough to hold fork in place. Repeat for left side.
3. Install front fender. See 2.4 FRONT FENDER.
NOTE
Ensure threaded axle insert is installed in left fork.
4. Install front wheel. See 2.5 FRONT WHEEL.
5. Compress front forks several times to prevent binding and
center right fork on axle.

2-14 2008 FXDSE2 Service: Chassis

6. Install axle cover (21) on end of axle. clean these threads will cause improper torque readings upon
assembly.
NOTE
Secure ground wire that was previously removed to upper fork 11. Remove pinch bolts from fork brackets.
bracket when installing right side riser bolt.
12. Apply small amount of LOCTITE 243 (blue) to threads of
7. Install front brake caliper per procedure in the Dyna Ser- pinch bolts and install.
vice Manual.
13. Tighten pinch bolts, in the following sequence, to 18-22
8. Secure ground wire attached to bottom of upper fork ft-lbs (24.4-29.8 Nm):
bracket between screw head and brake line clip. a. Tighten upper pinch bolt of each side of upper fork
9. Install headlamp assembly. bracket.

10. Adjust steering fall-away according to procedure in the b. Tighten lower pinch bolt of each side of upper fork
Dyna Service Manual. bracket.

NOTE c. Tighten upper pinch bolt of each side of lower fork

Completely clean excess lock patch from pinch bolt threads. bracket.
Clean bolt holes using a bottoming thread tap and blow bolt d. Tighten lower pinch bolt of each side of lower fork
hole threads clean with compressed air. Failure to properly bracket.
e. Repeat tightening sequence.

2008 FXDSE2 Service: Chassis 2-15

REAR AXLE COVERS 2.8
REMOVAL INSTALLATION
See Figure 2-14. Loosen set screw in rear axle cover and Place axle cover over axle on swingarm. Position so set-screw
remove axle cover from axle. is facing downward and tighten set-screw 60-84 in-lbs (6.8-
9.5 Nm).
sm04453

Figure 2-14. Loosen Set Screw

2-16 2008 FXDSE2 Service: Chassis

REAR FORK PIVOT COVERS 2.9
REMOVAL INSTALLATION
See Figure 2-15. Use a small flat blade screwdriver and gently 1. Orient cover and press into place.
pry in area shown by arrow and remove cap from rear fork.
2. Repeat for opposite side.

sm04454

Figure 2-15. Rear Fork Pivot Cover

2008 FXDSE2 Service: Chassis 2-17

LICENSE PLATE BRACKET 2.10
GENERAL 2. See Figure 2-17. Remove three screws (9) and nuts (7).

Domestic and HDI FXDSE2 models use two different styles of 3. Remove complete license plate bracket assembly from
license plate brackets. Both styles are covered. fender and disassemble as needed to repair or replace.

REMOVAL: DOMESTIC
sm04456
3
4
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
5
ceeding. (00251b)
1. Remove Maxi-Fuse. 6
1
2. See Figure 2-16. Remove three screws (1) and nuts (4).
9
3. Remove license plate bracket (2) and gasket (3) from 2
fender. 8

sm04455

3 7
1

4
1. Reflector
1. Screw (3) 2. License place bracket
2. License plate bracket 3. Screw
3. Gasket 4. Clamp plate
4. Nut (3) 5. Washer
6. Nut
Figure 2-16. License Plate Bracket (DOM) 7. Nuts (3)
8. Support bracket
9. Screws (9)
INSTALLATION: DOMESTIC
Figure 2-17. License Plate Bracket (HDI)
1. Insert screws (1) through license plate bracket (2) and
install gasket (3) on screws.
2. Install license plate bracket onto fender. INSTALLATION: HDI
3. Install nuts (4) and tighten to 60-90 in-lbs (6.8-10.1 Nm). NOTE
If removed, tighten screw (3) to 60-90 in-lbs (6.8-10.1 Nm)
4. Install Maxi-Fuse.
upon assembly.
REMOVAL: HDI 1. See Figure 2-17. Position complete, assembled license
plate bracket (consisting of all items except mounting
hardware) on rear fender.

To prevent accidental vehicle start-up, which could cause 2. Install three screws (9) and nuts (7). Tighten to 60-90 in-
death or serious injury, remove main fuse before pro- lbs (6.8-10.1 Nm).
ceeding. (00251b) 3. Install Maxi-Fuse.
1. Remove Maxi-Fuse.

2-18 2008 FXDSE2 Service: Chassis

REAR FENDER 2.11
GENERAL
sm04457
The FXDSE2 model motorcycle uses a wider rear tire than the
regular production Dyna model motorcycles. Therefore it is
equipped with a unique set of rear fender mount brackets and 3
wire clip.
Refer to the Dyna Service Manual for rear fender removal and 2
installation procedures, accommodating instructions below. 1
NOTE
Wire harness routing is critical on the inner rear fender
assembly. Note factory wiring paths and assemble exactly as
factory routing when installing rear fender assembly. Failure
to route wiring correctly will cause damage to the rear wiring
harness.
See Figure 2-18. To keep wiring harness from being damaged 1. Wiring channel in bracket
by rear tire, wiring must be retained in wire clip (2) before being 2. Wire clip
routed to wiring channel (1) at rear of each inner fender bracket 3. Wire path
and then to the turn signals. Figure 2-18. Rear Fender Wiring Bracket Wiring Channels

2008 FXDSE2 Service: Chassis 2-19

REAR SHOCKS 2.12
GENERAL the action of the shock with a new one to judge if it is worn.
Replace the shock if necessary.
When removing shocks for repair or replacement, remove and
install one shock at a time. This will eliminate the need for 2. Clean and examine the shock mounting hardware. Replace
raising the rear end of the motorcycle. If it is necessary to parts that are worn or damaged.
remove both shocks at once, place the motorcycle on a center
stand with the rear wheel off the ground.
INSTALLATION
1. See Figure 2-19. If removed, install stud (6), hardened
REMOVAL washer (7) and nut (8). Tighten to 70-85 ft-lbs (101.7-115.2
1. Block motorcycle underneath frame so rear wheel is raised Nm).
off the ground. 2. Fasten each shock to the frame and rear fork using the
2. See Figure 2-19. Remove lower shock mount screw (1). original hardware.
Nut (9) is only used on left side. 3. Attach lower shock mount to rear fork.
3. Remove upper shock mount nut (2), outer washer (4), a. Apply two to three drops of LOCTITE THREAD-
chrome cover (3), inner washer (4), and shock absorber LOCKER 243 (blue) to threads of bottom bolt (1).
(5).
b. Install bolt and hand tighten.
4. Repeat for other shock absorber.
4. Apply two to three drops of LOCTITE THREADLOCKER
5. If stud (6) is to be removed, remove nut (8) and washer 243 (blue) to threads of shock mount nut (2).
(7).
a. Install inside washer (4), shock (5), cover (3), (if
applicable,) outside washer (4) and upper shock
sm04458 mount nut (2).
8 b. Hand tighten nut (2).

7 NOTE
Before tightening, rotate shock cover (3) counterclockwise to
6 provide for proper alignment when tightened.
5
5. Tighten upper and lower shock mount screws as follows:
4 a. Lower mount: 30-40 ft-lbs (40.7-54.2 Nm)
2 b. Upper mount: 30-40 ft-lbs (40.7-54.2 Nm)
9
PRELOAD ADJUSTMENT
3

1 Be sure both shock absorbers are adjusted to same pre-

1. Lower mounting screw (2) load position. Improper adjustment can adversely affect
2. Upper mounting nut (2) stability and handling, which could result in death or ser-
3. Cover (2) ious injury. (00036a)
4. Washer (4)
5. Shock absorber (2) NOTE
6. Stud (2) The upper shock eye body has five adjustment index markers.
7. Hardened washer (2) Do not adjust shock preload past the 5th (lower) adjustment
8. Nut (2) mark.
9. Jam nut (lower-left side only)
1. See Figure 2-20. Use adjustment markings (2) on upper
Figure 2-19. Rear Shock Absorber Mounting (Typical) shock eye body (1) as adjustment guide.
2. Adjust shock preload by turning top spring cup (3) clock-
wise (as viewed from top of shock) to increase preload
INSPECTION (yielding a stiffer ride) or counter-clockwise to decrease
NOTE preload (yielding a softer ride).
Shocks are non-repairable items, except for the rubber NOTE
mounting bushings. If the shock is leaking or damaged, it must
be replaced as an assembly. If a stiff suspension is desired, it may be necessary to use a
rubber strap wrench to turn adjuster and increase preload on
1. Examine the rubber mounting bushings for cracks or wear. both rear shocks.
Examine the shock for leaks. The unit should not leak and
should compress slightly easier than it extends. Compare

2-20 2008 FXDSE2 Service: Chassis

sm03602

1. Upper shock eye body

2. Preload adjustment markings
3. Top spring cup
Figure 2-20. Rear Shock Preload Adjustment

2008 FXDSE2 Service: Chassis 2-21

REAR WHEEL 2.13
GENERAL 3. If scored, warped, or excessively worn, replace disc.

Maximum tire mileage and good handling qualities are directly Preliminary Inspection - Wheel/Tire
related to care given wheels and tires. Wheels and tires should
1. Block motorcycle underneath frame so front wheel is raised
be inspected regularly for wear. If handling problems occur,
off of ground.
check TROUBLESHOOTING in the Dyna Service Manual for
possible causes. 2. Inspect tire for wear and wear pattern. Remove wheel
assembly and replace tire as necessary. See TIRES in
Preliminary Inspection - Brake Disc the Dyna Service Manual.
1. Measure brake disc thickness for excessive wear. Min- 3. Inspect air valve. Replace as necessary.
imum acceptable thickness is stamped on side of disc.
4. Inspect wheel bearing end play and service bearings if
2. Replace disc if warped. Maximum allowable runout of a necessary. If end play is 0.002 in. (0.051 mm) or more,
rear brake disc is 0.012 in. (0.3 mm). replace wheel bearings. See SEALED WHEEL BEARINGS
in the Dyna Service Manual.

sm04459
15 1
10 16
14

8 9
6 13
12
11

7
4 6
5

2
1

1. Axle cover with set screw (2) 9. Left side spacer

2. Rear axle 10. Sprocket
3. Screw (5) 11. Washer
4. Brake disc 12. Axle nut
5. Right side spacer 13. Spring clip
6. Bearing (2) 14. Washer (5)
7. Sleeve 15. Fasteners (5)
8. Wheel 16. Caps (5)
Figure 2-21. Rear Wheel Components

2-22 2008 FXDSE2 Service: Chassis

REMOVAL 2. If necessary, remove brake disc and/or rear sprocket.
Label components so they may be installed in their original
1. Block motorcycle underneath frame so rear wheel is off location.
of ground.
a. On left side of wheel, remove five caps (16), screws
NOTE (15), and washers (14) to detach rear sprocket (10).
A scissors style jack will allow you to raise or lower motorcycle
b. On right side of wheel, remove five screws (3) and
at different points throughout procedure to provide both clear-
remove brake disc (4).
ance and alignment during removal and installation.
CLEANING AND INSPECTION
1. Inspect all parts for excessive wear or damage.
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
2. Remove Maxi-Fuse. Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
3. Remove chrome axle covers. See 2.8 REAR AXLE result in death or serious injury. (00111a)
COVERS.
2. Inspect brake rotor and pads. See PADS AND DISCS in
4. Remove belt guard and debris deflector. See 2.16 BELT the Dyna Service Manual.
GUARD AND DEBRIS DEFLECTOR.
3. Inspect belt and rear sprocket. See REAR BELT AND
5. If necessary, remove fasteners holding belt guard to rear SPROCKETS in the Dyna Service Manual.
fork. Back lower shock bolt out until belt guard is free and
remove belt guard. 4. Inspect wheel bearings and replace as necessary. See
REAR WHEEL in the Dyna Service Manual.
NOTE
Support rear tire from underneath and protect wheel finish ASSEMBLY
during removal. 1. Install brake disc (4) if removed.
6. Inspect wheel bearing end play and service bearings as a. Apply drop of LOCTITE 243 to five new screws (3).
necessary. See SEALED WHEEL BEARINGS in the Dyna
Service Manual. b. Tighten to 30-45 ft-lbs (40.7-61.0 Nm).

7. See Figure 2-21. Remove spring clip (13), axle nut (12), 2. Install belt sprocket (10) if removed.
and washer (11) from left side of axle (2). a. Apply two drops LOCTITE 262 to five new screws
8. Loosen but do not remove left and right upper shock (15). Install sprocket using screws (15) and washers
absorber fasteners. (14).

9. Remove left and right lower shock absorber fasteners. b. Tighten screws to 55-65 ft-lbs (74.6-88.1 Nm).

10. Allow rear fork and wheel to lower. 3. Install spacers (5 and 9) into hub with largest chamfered
end facing away from wheel.
11. Remove axle from wheel.
4. Verify that wheel and tire are true. See CAST WHEEL
NOTE
RUNOUT in the Dyna Service Manual.
Chrome plated wheels can be scratched or damaged when
slid out of and into the rear fork. Exercise caution to avoid INSTALLATION
dragging wheel and sprocket surfaces against rear fork com-
ponents. 1. Roll wheel into rear fork and position brake disc side
spacer between wheel and fork.
12. Move wheel forward and slip belt off of sprocket.
2. Slide drive belt over drive sprocket. Make sure brake disc
NOTE is centered between brake pads.
Tension may have to be relieved before belt will slip off. Spacer
may fall out when tension is relieved. 3. Coat the bores of both bearings and the axle with
LOCTITE ANTI-SEIZE LUBRICANT and install axle.
13. Remove wheel and belt sprocket from rear fork.
a. From right side, carefully insert axle through right rear
NOTE fork, rear caliper bracket, right side spacer and wheel
Do not operate rear brake pedal with rear wheel removed or bearing.
caliper piston may be forced from piston bores requiring disas-
b. Continue sliding axle through wheel hub sleeve, wheel
sembly of caliper.
bearing, left side spacer and left side fork.
DISASSEMBLY
1. See Figure 2-21. Remove spacers (5 and 9) from wheel.

2008 FXDSE2 Service: Chassis 2-23

4. Attach rear shocks. 6. Install spring clip (13).
a. Apply two or three drops of LOCTITE 243 to threads 7. Install debris deflector and belt guard. See 2.16 BELT
of lower shock mounting bolts. GUARD AND DEBRIS DEFLECTOR.
b. Lift rear fork and attach both shock absorbers to rear 8. Install axle covers. See 2.8 REAR AXLE COVERS
fork.
c. Tighten upper shock acorn nuts to 30-40 ft-lbs (40.7-
54.2 Nm) and lower shock fasteners to 30-40 ft-
lbs (40.7-54.2 Nm). Whenever a wheel is installed and before moving the
motorcycle, pump brakes to build brake system pressure.
Insufficient pressure can adversely affect brake perform-
ance, which could result in death or serious injury.
(00284a)
Check wheel bearing end play after tightening axle nut to
specified torque. Excessive end play can adversely affect 9. Pump brake pedal to move pistons out until they contact
stability and handling. Insufficient end play can cause both brake pads. Verify piston location against both pads.
bearing seizure. Either condition can cause loss of control,
10. Verify correct axle alignment. See VEHICLE ALIGNMENT
which could result in death or serious injury. (00285a)
in the Dyna Service Manual.
5. See Figure 2-21. Install washer and axle nut on left side
11. Check rear belt deflection. See. REAR BELT DEFLEC-
of axle. Tighten axle nut to 95-105 ft-lbs (128.8-142.4 Nm).
TION in the Dyna Service Manual.

2-24 2008 FXDSE2 Service: Chassis

SEAT 2.14
REMOVAL
sm04461
1. See Figure 2-22. Remove screw (1) from mounting bracket
on top of rear fender.
2. Raise seat slightly and slide rearward until seat detaches
from front seat mount (2).
3. Pull seat forward and up to remove from seat strap.
NOTE Figure 2-23. Seat Strap and Fasteners
See Figure 2-23. Seat straps are secured to fender under seat
by a nut, screw and washers.
INSTALLATION
sm04460 1. Slide rear part of seat through seat strap.
NOTE
1 There is a tab under seat that slides under rear fuel tank mount.
2. Slide seat forward until tab makes contact under rear fuel
tank mount and locks into place.
3. Push seat forward until rear fender seat retention bracket
is centered with mounting hole in fender.
4. Install mounting screw and tighten to 20-40 in-lbs (2.3-
4.5 Nm).

After installing seat, pull upward on seat to be sure it is

2 locked in position. While riding, a loose seat can shift
1. Screw causing loss of control, which could result in death or
2. Front seat mount serious injury. (00070b)

Figure 2-22. Seat 5. Pull up on seat to verify it is properly secured.

NOTE
If seat strap is removed, tighten fasteners to 60-90 in-lbs (6.8-
10.2 Nm) during installation.

2008 FXDSE2 Service: Chassis 2-25

FRONT SPOILER 2.15
REMOVAL
sm04464

Prevent accidental vehicle start-up, which could cause

death or serious injury. First disconnect negative (-) battery
cable at engine and then positive (+) cable from battery.
(00280b)
1. Remove negative battery cable.
2. Support motorcycle.
3. See Figure 2-24. Remove fasteners from voltage regulator.
4. See Figure 2-25. Move regulator to side.

Figure 2-26. Spoiler Lower Fasteners

sm04462

sm04466

Figure 2-24. Voltage Regulator Fasteners

Figure 2-27. Spoiler to Bracket Fasteners

sm04463 NOTE
On California emission vehicles, charcoal canister is located
under spoiler, mounted to spoiler frame mounting bracket.

sm04467

Figure 2-25. Voltage Regulator

5. See Figure 2-26. Remove fasteners from bottom of spoiler.

6. Remove spoiler from motorcycle by dropping spoiler
downward and guiding bracket through regulator harness
connections. Figure 2-28. Charcoal Canister Mounting Tabs

7. Repair or replace spoiler and/or charcoal canister as

necessary

2-26 2008 FXDSE2 Service: Chassis

INSTALLATION sm04468

1. See Figure 2-29. Guide chin spoiler bracket upward

between voltage regulator harness connections.
2. See Figure 2-26. Install spoiler lower fasteners. Do not
tighten at this time.
3. See Figure 2-24. Align spoiler bracket and voltage regu- 1
lator and insert two fasteners. Do not tighten at this time.
2
4. Align spoiler and tighten voltage regulator fasteners to
60-80 in-lbs (6.8-9.0 Nm).
5. Tighten lower spoiler fasteners to 72 in-lbs (8 Nm).

1. Spoiler bracket
2. Voltage regulator harness
Figure 2-29. Spoiler Bracket

2008 FXDSE2 Service: Chassis 2-27

BELT GUARD AND DEBRIS DEFLECTOR 2.16
REMOVAL 5. Remove self-tapping screws (11) from debris deflector (9)
and debris deflector chrome cover (10) and remove from
NOTE motorcycle.
During removal, inspect grommets and fasteners and replace
as necessary. INSTALLATION
1. See Figure 2-30. Remove screw (5), washer (4) and nut 1. See Figure 2-30. Position belt guard (8) in place on
(1) from rear of belt guard (8). motorcycle.

2. Remove screw (6) and washer (7) from front of belt guard. 2. Install screw (5), washer (4) and nut (1) in rear of belt
guard.
3. Remove belt guard.
3. Install screw (6) and washer (7) in front of belt guard.
4. Inspect grommets (3) and replace as necessary.
4. Tighten rear screw (5) and nut to 10-15 ft-lbs (13.6-20.3
a. If necessary, replace grommets by removing spacers
Nm).
(2) and pulling grommets free from belt guard.
5. Tighten front screw (6) to 10-15 ft-lbs (13.6-20.3 Nm).
b. Install new grommets (3) by pushing in place and
sliding spacers (2) through grommets to retain grom- 6. Position debris deflector (9) and debris deflector chrome
mets in place. cover (10) on motorcycle and install self tapping screws
(11).
7. Tighten self tapping screws to 40-60 in-lbs (4.5-6.8 Nm).

sm04469
3 4
5
3 2
6
2

1
7
8

10

11

1. Nut 5. Screw 9. Debris deflector

2. Spacer 6. Screw 10. Debris deflector chrome cover
3. Grommet 7. Washer 11. Screw, self-tapping (3)
4. Washer 8. Belt guard
Figure 2-30. Debris Deflector/Belt Guard (shown removed for clarity)

2-28 2008 FXDSE2 Service: Chassis

FORK TUBE AND STEERING NUT COVERS 2.17
REMOVAL INSTALLATION
Steering Nut Cover Steering Nut Cover
Loosen the set screw and remove cover from motorcycle. Place cover over steering nut and tighten set screw to 14-16
in-lbs (1.6-1.8 Nm).
Fork Covers
Loosen upper fork bracket screws just enough to relieve tension
Fork Covers
from fork caps and gently pry fork tube covers from fork. NOTE
Any time fork pinch bolts are loosened or removed for any
sm04470 reason, a specific procedure must be followed. Fork tube
installation process is extremely critical and must follow this
procedure with no exceptions.
Install chrome cover on fork and secure upper fork bracket
2 screws. See 2.7 FRONT FORK, Cleaning and Inspection and
2 2.7 FRONT FORK, Installation.

1
1. Steering nut cover with set screw
2. For tube covers
Figure 2-31. Steering Nut Cover and Fork Tube Covers

2008 FXDSE2 Service: Chassis 2-29

FOOTPEGS AND FORWARD CONTROLS 2.18
REMOVAL
sm04472
Footpeg Assembly 4 11
1. See Figure 2-32. Remove footpeg mounting screw (7) and
2
remove footpeg housing (8) and pad (6) from footpeg
support (5).
8
2. Rider Peg: Remove retaining ring (1), washers (2), spring
washer (3) and clevis pin (4). 1 2
3 7
3. Passenger Peg: Remove retaining acorn nut (10), spring 5
washers (3) and bolt (9).
6
4. Remove footpeg support (5) from motorcycle.
12

3
10

8
6

7
1. Retaining ring
2. Washer
3. Spring washer
4. Clevis pin
5. Footpeg support
6. Pad
7. Footpeg mounting screw
8. Housing
9. Bolt, button head
10. Acorn nut
11. Rider peg components
12. Passenger peg components
Figure 2-32. Footpeg Assembly

Left Footpeg/Pedal Bracket

1. See Figure 2-33. Remove left footpeg components. See
procedure above.
2. Remove fastener (2) and pull foot shift lever (4) off shaft.
3. If necessary, remove fastener (1) to remove shifter peg
components.

2-30 2008 FXDSE2 Service: Chassis

4. Remove nut (7) to disconnect shift linkage.
sm05057
5. Remove fasteners (3) to remove bracket (5) and front shift
lever.
7

6. Remove front shift lever (8). 5 6

sm04771
4
8
7 3
2 8
1 9
10
6 12
13
5
4 11

14
1. Fastener, brake pedal/footpeg
2 3 2. Footpeg clevis
1 3. Rubber pad (HDI models)
4. Insert
1. Fastener, shifter peg 5. Cover
2. Fastener, foot lever clamp 6. Pivot shaft
3. Fastener, footpeg/pedal bracket (2) 7. Footpeg/pedal bracket
4. Foot shift lever 8. Fastener, footpeg/pedal bracket (2)
5. Footpeg/pedal bracket 9. Retaining ring
6. Wave washer 10. Washer
7. Linkage nut 11. Screw
8. Forward shift lever 12. Washer
13. Brake pedal
Figure 2-33. Left Footpeg/Pedal Bracket
14. Clevis pin
Figure 2-34. Right Footpeg/Pedal Bracket
Right Footpeg/Pedal Bracket
1. See Figure 2-34. Remove right footpeg components. See
procedure above. Passenger Footpeg Bracket
2. Remove fastener (1) to remove footpeg clevis (2), pedal NOTE
(13), and pivot shaft (6). The procedure for removing either footpeg bracket is similar.
3. Remove fasteners (8) to remove bracket (7). 1. Remove the footpeg components. See procedure above.

4. If needed, remove screw (11) and washer (12) to remove 2. Remove fasteners securing bracket to the frame. Remove
pedal pad components (3, 4, 5). bracket.

INSTALLATION
Footpeg Assembly
1. See Figure 2-32. Rider Peg: Install footpeg support (5)
to motorcycle by sliding clevis pin (4) through hole,
installing spring washer (3) and washer (2). Secure with
washer (2) and retaining ring (1).
NOTE
Be sure that retaining ring snaps securely in place.
2. Passenger Peg: Install footpeg support (5) to motorcycle
by sliding bolt (9) through hole, installing spring washers
(3) and acorn nut (10). Tighten acorn nut securely.
3. Install footpeg housing (8) and pad (6).
4. Apply a drop of LOCTITE 243 on footpeg retaining screw
threads. Install screw and tighten to 15-20 ft-lbs (20.3-27.1
Nm).

2008 FXDSE2 Service: Chassis 2-31

Left Footpeg/Pedal Bracket 2. Install brake pedal (3), pivot shaft (6), and right footpeg
clevis (2). Apply a drop of LOCTITE 243 on fastener
1. See Figure 2-33. Install front shift lever (8) in bracket (5). threads. Tighten fastener (1) to 32-37 ft-lbs (43.4-50.2
Apply a drop of LOCTITE 243 on footpeg bracket fastener Nm).
threads. Install bracket with lever using fasteners (3).
Tighten fasteners to 25-35 ft-lbs (33.9-47.5 Nm). 3. If removed, install brake pedal components (3, 4, 5) and
secure with screw (11) and washer (12). Tighten screw to
2. Connect linkage and tighten nut (7) to 13-16 ft-lbs (17.6- 69-84 in-lbs (7.8-9.5 Nm)
21.7 Nm).
4. Install right footpeg components. See procedure above.
3. Install foot shift lever (4) and tighten fastener (2) to 18-22
ft-lbs (24.4-29.8 Nm). Passenger Footpeg Bracket
4. If removed, install shifter peg components. Apply a drop 1. Install bracket on frame. Apply a drop of LOCTITE 243 on
of LOCTITE 243 on fastener threads. Tighten fastener (1) fastener threads and tighten to 25-35 ft-lbs (33.9-47.5
to 14-16 ft-lbs (19.0-21.7 Nm). Nm).
5. Install left footpeg. See procedure above. 2. Install footpeg components. See procedure above.

Right Footpeg/Pedal Bracket

1. See Figure 2-34. Apply a drop of LOCTITE 243 on fastener
threads. Install bracket (5) and tighten fasteners (4) to 25-
35 ft-lbs (33.9-47.5 Nm).

2-32 2008 FXDSE2 Service: Chassis

HANDGRIPS AND HAND CONTROLS 2.19
GENERAL
sm03168
When replacing only the throttle and brake controls or only the
clutch control, follow all safety procedures. The brake control
lever bracket should be installed and final positioned before
the clutch control lever bracket.

THROTTLE AND BRAKE CONTROLS

Removal
1
1. Remove seat. See 2.14 SEAT.

To prevent accidental vehicle start-up, which could cause

death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
2
2. Remove negative battery cable from battery.
3. Remove acorn nut, lock washer, small washer and rear
view mirror.
4. See Figure 2-35. Insert a piece of cardboard between front
brake lever and lever bracket.
1. Groove
2. 5/32 in. (4 mm) thick cardboard insert
Figure 2-35. Cardboard Insert
Do not remove or install the master cylinder assembly
without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
installing the master cylinder assembly without the insert
in place may result in damage to the rubber boot and sm04473

plunger on the front stoplight switch. (00324a) 2

1
5. Loosen but do not remove fasteners securing handlebar
clamp to master cylinder/reservoir and front brake lever.
6. Shorten throttle and idle cable adjusters and pull idle and
throttle cable inserts and elbows from housing.
7. Remove upper and lower fasteners holding throttle side
switch housings to handlebars.
8. See Figure 2-36. Use a screwdriver to rotate cable barrels
in throttle grip notches and remove cables.
9. Remove throttle grip from handlebar and remove cables
from housing.
10. Protect chrome and painted surfaces and tie idle and
throttle cables away from chrome and paint finishes.
Maintain the routing of the cables.
11. Remove fasteners securing handlebar clamp to master
1. Throttle
cylinder/reservoir and front brake lever.
2. Idle
NOTE
Figure 2-36. Throttle and Idle Cable Barrels
The turn signal bullets must be supported throughout this pro-
cedure to prevent pulling the grommet or the turn sign wires
out of the housing.
Installation
12. Protect chrome and painted surfaces and tie the master
1. Slide throttle control grip onto handlebar until it bottoms.
cylinder, reservoir and brake line out of the way.
Pull grip back about 1/8 in. (3.2 mm).
2. Push throttle and idle control cable inserts into the lower
switch housing and install new c-clips.

2008 FXDSE2 Service: Chassis 2-33

 NOTE
sm04474
The smaller idle cable insert is gold while the larger throttle
cable insert is silver. The inserts only fit their corresponding
hole in the switch housing.
3. Fit cable barrels through the notches in the throttle control
grip and rout the cables in the grooves.
4. Lengthen throttle and idle cable adjustors.
5. Loosely assemble handlebar clamp to brake control lever
bracket master cylinder and reservoir.
NOTE 1
Front brake master cylinder reservoir fits into a machined relief
in handlebar. Master cylinder can be damaged if not properly
located.
6. See Figure 2-37. Identify forward and aft alignment marks
(1, 2) under handlebar. Position mating surface of master 2 3
cylinder/reservoir to flat on handlebars with line (3) of
underside clamping surface between alignment marks (1,
2). Do not tighten.

1. Maximum aft rotation

Control wiring is routed inside handlebar and may be 2. Maximum forward rotation
pinched or cut if controls are rotated too far. Electrical 3. Clamping surface line
damage to control wiring can result. See Service Manual
Supplement or see a Harley-Davidson dealer. (00363a) Figure 2-37. Brake Clamp Horizontal Alignment

7. Assemble upper and lower switch housing to handlebars

and brake lever bracket and loosely install fasteners. 10. See Figure 2-39. Slide small washer on mirror stem and
a. Position the upper switch housing so the wire conduit install right rear view mirror stem through the brake control
wraps around the outside of the handlebar and sets lever bracket and into turn signal bracket (2). Install lock
in the depression at the bottom of handlebar. washer (5) and acorn nut (6).

b. See Figure 2-38. Engage the tab on the switch NOTE

housing with notch at the top of the brake lever Gently turn handlebars full right and full left while checking that
bracket. turn signals do not contact and damage fuel tank. Raise
handlebars to obtain clearance.
c. Verify that throttle and idle control cables work freely.
11. If necessary, adjust bullet housings to turn signal brackets.
d. Alternately tighten housing and bracket fasteners. See 8.4 FRONT TURN SIGNALS.
The fasteners should be only snug.
12. Face turn signal forwards and adjust rear view mirrors for
8. Rotate brake control lever bracket within forward and aft rider posture. Tighten acorn nut to 60-96 in-lbs (6.8-10.8
alignment marks for rider posture and tighten fasteners: Nm).
a. Control lever clamps beginning with top fastener to 13. If replacing throttle and brake controls only, follow the
60-80 in-lbs (6.8-9.0 Nm). The gap, if any, on top safety procedures found at the end of CLUTCH HAND-
should be tighter. GRIP AND CONTROLS.
b. Switch housing beginning with bottom fastener to
35-45 in-lbs (4.0-5.1 Nm). The rear gap, if any, should
be tighter.

9. Remove cardboard insert between brake lever and

bracket.

2-34 2008 FXDSE2 Service: Chassis

 6. Tie the clutch master cylinder and reservoir clutch fluid
sm04475
line away from chrome and paint finishes.

Installation
1. Assemble clutch lever bracket master cylinder and reser-
voir and clamp to handlebar and install fasteners.
2. See Figure 2-40. Orient grip to rider with 1/2 round on
bottom and slide left handgrip onto handlebar.
3. Fit clutch side switch housings.
a. Position the upper switch housing so the wire conduit
wraps around the front of the handlebar.
b. Fit groove in lower housing to handgrip 1/2 round.
c. Verify that the wires will not be pinched when
fasteners are tighten.
d. Engage lower switch housing tab with notch in the
Figure 2-38. Brake Lever Bracket Notch clutch lever bracket master cylinder and reservoir.
e. Install but do not tighten switch housing fasteners.
f. Alternately tighten the fasteners until the housing and
sm04476 the clamp is snug to the bracket.
3
2 NOTE
The brake lever control bracket should be installed and posi-
tioned for rider posture with the clamp aligned to the marks on
the handlebars before positioning the clutch lever control
4
1 bracket.
4. Rotate control lever brackets to match brake lever and
5
tighten fasteners:
7
a. Tighten brake control lever clamps beginning with the
6 top fastener to 60-80 in-lbs (6.8-9 Nm). The gap, if
any, on the top should be tighter.
b. Tighten switch housing beginning with the bottom
fastener to 35-45 in-lbs (4.0-5.1 Nm). The rear gap,
1. Bullet housing if any, should be tighter.
2. Turn signal bracket
3. Ball stud
4. Set screw
5. Lock washer
6. Acorn nut
7. Jam nut
Figure 2-39. Throttle and Brake Side Turn Signal

CLUTCH HANDGRIP AND CONTROLS

Removal
1. If replacing clutch control lever and handgrip only, follow
the safety procedures at the beginning of the procedure
to remove the THROTTLE AND BRAKE CONTROLS.
2. Remove acorn nut, lock washer, small washer and rear
view mirror.
3. Remove upper and lower fasteners holding left switch
housings to handlebars.
4. Separate housings and slide left handgrip from handlebars.
5. Remove fasteners and washers securing the handlebar
clamp to the clutch master cylinder and reservoir.

2008 FXDSE2 Service: Chassis 2-35

 sm04477

After installing seat, pull upward on seat to be sure it is

locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
9. Install seat. See 2.14 SEAT.

After repairing the brake system, test brakes at low speed.

If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)
10. Test front brake lever for pressure and operation.
11. Turn throttle and idle adjustors out. Test for correct opera-
tion. Adjust as required. See THROTTLE CABLES in Dyna
Models Service Manual.
12. Turn the Ignition/Light Key Switch to IGNITION and test
switches for proper operation.
13. Apply brake lever to test stop light lamp. Adjust as
required.
Figure 2-40. Clutch Handgrip Rubber 1/2 Round (Typical)

sm04478

5. See Figure 2-41. Slide small washer on mirror stem and

4
install left rear view mirror stem through clutch lever
bracket and turn signal bracket (3). Install lock washer (6) 3
and acorn nut (7).
2
NOTE 1
Gently turn handlebars full right and full left while checking that 5
turn signals do not contact and damage fuel tank. Raise
handlebars to obtain clearance. 6
6. Align turn signal mount brackets and adjust rear view
mirrors for rider posture. Tighten acorn nut to 60-96 in- 7
lbs (6.8-10.8 Nm).
7. If necessary, adjust bullet housings to turn signal brackets.
1. Set screw
See 8.4 FRONT TURN SIGNALS.
2. Ball stud
8. Connect negative battery cable to battery. 3. Turn signal bracket
4. Lamp housing
5. Jam nut
6. Lock washer
7. Acorn nut
Figure 2-41. Clutch Side Turn Signal

2-36 2008 FXDSE2 Service: Chassis

HANDLEBARS 2.20
REMOVAL
sm04479

To prevent accidental vehicle start-up, which could cause

death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a) 2
1. Disconnect negative battery cable from battery. See
BATTERY MAINTENANCE in the Dyna Service Manual.
2. Remove instrument console from fuel tank. See 1
INSTRUMENTS: FXDWG/FXDC/FXDF in the Dyna Ser-
vice Manual.
3. Disconnect fuel gauge connector located under the fuel
tank.
4. Remove fuel tank fasteners, vent, fuel supply fitting and
slide fuel tank back. See FUEL TANK in the Dyna Service
Manual.
1. Harness shield
5. Place blanket or protective cover over front of fuel tank to 2. Steering head plug (2)
protect against scratches and other damage.
Figure 2-42. Plugs and Shield
6. See Figure 2-42. Remove harness shield (1) and steering
head plugs (2) from left and right side of frame.
NOTE
sm04731
Make note of wire colors and locations in connector before 2
removal. This will ensure proper wire location in connector
during installation.
7. Disconnect turn signal connectors [31BR] and [31BL], and 1
hand control connectors [22A] and [24A] located in steering 1
head of frame.
8. Identify wire leads and remove terminals from connector
housings (left hand control connector [24], right hand
connector [22]). See MOLEX section in the Dyna Service
Manual.
9. Remove turn signal lamp terminals from the multilock
connector. See AMP MULTILOCK in the Dyna Service
Manual for connector information. 1. Upper handlebar clamp fastener
10. Remove front master cylinder assembly. See FRONT 2. Tachometer and handlebar clamp assembly
BRAKE MASTER CYLINDER in the Dyna Service Manual. Figure 2-43. Upper Handlebar Clamp/Tachometer Bracket
11. Remove clutch master cylinder assembly on left side of
handlebar. See 2.19 HANDGRIPS AND HAND CON-
TROLS.
12. Separate right handlebar switch assembly and remove
throttle. See 2.19 HANDGRIPS AND HAND CONTROLS.
13. Remove left handlebar grip. See 2.19 HANDGRIPS AND
HAND CONTROLS.
14. See Figure 2-43. Remove fasteners (1). Remove upper
clamp and tachometer (2) from handlebar and gently lay
on covered front fender.
15. Remove handlebar from motorcycle.
16. See Figure 2-44. If lower clamps require removal, remove
bolts (10), lockwashers (9, 12), cup washers (6) ground
cable (11), bushings (7), spacers (8), and lower handlebar
clamps (5).

2008 FXDSE2 Service: Chassis 2-37

 NOTE
sm04481
1 In next step, make sure cup washers (6), bushings (7) and
spacers (8) are in position in upper fork bracket.
3. Slide lower handlebar clamp fasteners through upper fork
bracket.
2
4. Loosely install lower handlebar clamps to upper fork
bracket using fasteners (10).
3 5. Using mechanics wire, neatly wrap socket terminals, wires
and conduits with a few twists to form leaders for turn
4 signal wires.
6. String mechanics wire along wires. String sufficient wire
to pull conduits through handlebars.
5
7. Wrap wires with electrical tape and wrap open ends of
6 conduit.

7 12
8 Grommets in each of the wiring holes in the handlebar
must remain in position after routing the wiring through
7 the handlebar. Operation without the grommets in place
11 can damage wires, causing a short circuit which could
6 result in death or serious injury. (00416d)
8. Lubricate wire conduits with glass cleaner.
9
9. Thread wire leaders through handlebar grommets to center
10 hole in handlebar.

1. Screw, upper clamp 10. Pull wire bundles through hand grip grommets to center
2. Upper clamp/tachometer housing hole in handlebar.
3. Grommet (2) 11. Loosely install left and right switch housings.
4. Grommet
5. Lower handlebar clamp 12. Final pull wires and unwrap tape and mechanics wire.
6. Cup washer (4)
13. Insert wire terminals in their respective connector housing.
7. Bushing (4)
See A.1 WIRING DIAGRAM INFORMATION for wire loc-
8. Spacer (2)
ation. See APPENDIX A in the Dyna Service manual for
9. Lockwasher (2)
connector service information.
10. Bolt (2)
11. Ground cable 14. See Figure 2-44. Place handlebars on lower handlebar
12. Lockwasher, ground clamps. Install upper handlebar clamp/tachometer bracket
(2). Install but do not tighten clamp fasteners.
Figure 2-44. Handlebar Assembly
15. Using knurled areas of handlebar as a guide, center
handlebars between lower handlebar clamps.
INSTALLATION
16. Raise handlebars to normal riding position and hold in
NOTE position.
The turn signal wires enter the switch housings through a relief 17. Secure handlebars:
grommet in the housing. The turn signals must be supported
a. See Figure 2-44. Tighten two rear fasteners (1) until
throughout this procedure to prevent pulling the grommet or
cast-in spacers contact lower handlebar clamps.
the turn signal wires out of the housing.
b. Tighten front fasteners to 12-16 ft-lbs (16.3-21.7 Nm).
1. Repair or replace switch, turn signal and socket wires, or
grommets (3, 4) on handlebar wire openings as necessary. c. Final tighten rear fasteners to 12-16 ft-lbs (16.3-21.7
Nm). Slight gap between upper and lower clamps
NOTE
should exist at front.
For handlebar switch repair procedures, see HANDLEBAR
SWITCH ASSEMBLIES in the Dyna Model Service Manual. 18. Tighten lower handlebar clamp fasteners (10) to 30-40 ft-
2. See Figure 2-44. If lower handlebar clamps (5) were lbs (40.7-54.2 Nm).
removed, install lockwashers (9) on lower handlebar clamp 19. Mate turn signal connectors [31BR] and [31BL], and hand
fasteners (10). Install ground cable (11) and ground cable control connectors [22A] and [24A]. Neatly locate con-
washer (12) on right-side fastener. nectors in steering head of frame.

2-38 2008 FXDSE2 Service: Chassis

20. See Figure 2-42. Install harness shield (1) and steering 26. Test throttle for correct operation. Adjust as required. See
head plugs (2). THROTTLE CABLES in the Dyna Service Manual.
21. Install handgrips and controls. See 2.19 HANDGRIPS 27. Turn ignition/light key switch to IGNITION and test
AND HAND CONTROLS. switches for proper operation.
22. Install fuel tank and connect fuel gauge harness connector.
See FUEL TANK in the Dyna Service Manual.
23. Install instrument console. See INSTRUMENTS: Be sure that all lights and switches operate properly before
FXDWG/FXDC/FXDF in the Dyna Service Manual. operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
24. Connect negative battery cable to battery. See BATTERY
MAINTENANCE in the Dyna Service Manual. 28. Apply brake lever to test stop lamp.

25. Test front brake lever for pressure and operation. 29. Turn handlebars full left and full right verify correct function.

2008 FXDSE2 Service: Chassis 2-39

CLUTCH MASTER CYLINDER AND RESERVOIR 2.21
GENERAL
The clutch is hydraulically actuated. Squeezing the clutch hand
lever causes the clutch master cylinder to apply pressure via Be sure no clutch fluid gets on tires, wheels or brakes
the clutch fluid in the clutch line to the secondary clutch actuator when draining fluid. Traction can be adversely affected,
mounted in the clutch release cover. The secondary clutch which could result in loss of control and death or serious
actuator piston extends and contacts the clutch release bearing injury. (00295a)
which disengages the clutch.
A bleeder valve at the secondary clutch actuator is used to
bleed air from the clutch line. D.O.T. 4 HYDRAULIC BRAKE D.O.T. 4 brake fluid will damage painted and body panel
FLUID (Part No. 99953-99A) is used in the clutch system and surfaces it comes in contact with. Always use caution and
is referred to as clutch fluid in this manual. protect surfaces from spills whenever brake work is per-
Check the clutch fluid level in the clutch fluid reservoir on left formed. Failure to comply can result in cosmetic damage.
handlebar. If the sight glass is dark, the fluid level in the (00239b)
reservoir is above the sight glass prism and the reservoir is • Do not wipe any spilled brake fluid off of finished surfaces.
full. If the sight glass appears clear, the fluid level is below the Always flush the affected components with water (not
sight glass prism and the fluid level should be checked. Clutch soapy).
fluid should be level with the internal shelf marked FILL LEVEL
with the motorcycle upright and the gasket surface level. NOTE
Place a large cup under the banjo fitting. Hydraulic fluid will
begin draining from the reservoir as the banjo bolt is removed.
D.O.T. 4 hydraulic brake fluid is used in the hydraulic 5. Slowly loosen banjo bolt (6) and allow clutch fluid from
clutch. Do not use other types of fluids as they are not reservoir to drain into cup.
compatible and could cause equipment damage. (00353a)
NOTE
NOTE Dispose of clutch fluid in accordance with local regulations.
Clutch fluid volume in reservoir actually increases with clutch 6. Remove banjo bolt (6) and two steel/rubber washers (7).
wear. Do NOT overfill clutch reservoir. Discard steel/rubber washers.

REMOVAL NOTE
To prevent the rest of the clutch fluid from draining from the
1. Remove acorn nut, lockwasher and rear view mirror with clutch line and secondary clutch actuator, support the banjo
washer. Support turn signal bullet housing and bracket. fitting and clutch fluid line upright. Plug the banjo bolt hole with
a finger to transfer the assembly to a workbench without spilling
2. Loosen left handlebar switch housing fasteners.
clutch fluid.
7. Remove master cylinder clamp screws and remove clutch
master cylinder/reservoir assembly.
Do not allow dirt or debris to enter the master cylinder
reservoir. Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)
3. See Figure 2-45. Loosen, but do not remove, fasteners
(10) that secure handlebar clamp to clutch master cyl-
inder/reservoir.
4. Loosen both cover screws (3) to relieve pressure in master
cylinder/reservoir.

Direct contact of D.O.T. 4 brake fluid with eyes can cause

irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

2-40 2008 FXDSE2 Service: Chassis

 sm03991
8
2
3 Avoid leakage. Prevent damage to piston or piston bore.
Use non-metallic tools when servicing components.
(00529d)
11 6. Remove cups (5, 7) from piston using a toothpick.

10 1
9
3 Use denatured alcohol to clean clutch system components.
4 Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even
7 after assembly. Deterioration of these components can
7
cause clutch failure, which could result in death or serious
injury. (00296a)
6
5 7. Wipe the housing with a lint free cloth. With a clean air
supply, blow out drilled passages and bore in the master
cylinder housing.

1. Cover NOTE
2. Clutch hand lever Do not use a wire or sharp instrument to clean drilled passages.
3. Cover screws 8. Inspect cylinder housing bore for scoring, pitting or corro-
4. Retaining ring sion. Also check outlet port for damage. Replace housing
5. Fluid line if necessary.
6. Banjo bolt
7. Steel/rubber washers 9. Inspect the cover, sight glass, and gasket for cuts, tears
8. Clamp or general deterioration.
9. Washer
10. Screw (2) sm03992
11. Pivot pin
1
Figure 2-45. Clutch Master Cylinder/Reservoir
2

DISASSEMBLY
7

8
Do not allow dirt or debris to enter the master cylinder
reservoir. Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)
1. Remove master cylinder cover and gasket. Turn housing
upside down to remove remaining clutch fluid from reser- 5 3
voir.
6

Wear safety glasses or goggles when removing or

installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause 4
serious eye injury. (00312a)
2. See Figure 2-45. Remove retaining ring (4) from pivot pin
(11).
1. Boot
NOTE 2. Piston
To remove piston spring load from the pivot pin, gently force 3. Shoulder
the clutch lever toward the piston (as if operating the clutch). 4. Spring
3. Remove pivot pin (11) and clutch lever. 5. Primary cup
6. Groove - primary cup
4. See Figure 2-46. Using a toothpick or small screwdriver, 7. Secondary cup
gently pry outer edge of piston boot (1) out of piston bore. 8. Groove - secondary cup
5. Remove piston (2) and spring (4). Figure 2-46. Clutch Master Cylinder Components

2008 FXDSE2 Service: Chassis 2-41

ASSEMBLY sm03993

To rebuild clutch master cylinder, use the components found 1 2

in the Service Parts Kit.
3
NOTE
See Figure 2-47. The flared ends of the primary cup and the
secondary cup must face the spring end of the piston.
1. Using lubricant in SERVICE PARTS KIT, lightly lubricate
inside of primary cup (3) and fit over lip on spring end of
piston.
2. Using lubricant in SERVICE PARTS KIT, lightly lubricate 1. Boot installed in piston groove
inside of secondary cup (2) and fit over the lip on outboard 2. Secondary cup
end of piston. 3. Primary cup
3. Install boot (1), large sealing ID first, on piston until seal Figure 2-47. Assembled Cups and Piston
on smaller ID fits snugly into thin groove in piston.
4. Using lubricant in SERVICE PARTS KIT, thoroughly coat
outside diameters of primary and secondary cups and INSTALLATION
master cylinder piston bore.
5. Install spring into piston assembly.
6. Align and install piston assembly into bore. Firmly press Avoid leakage. Be sure gaskets, banjo bolt(s) and clutch
on flat end of piston, compressing spring, until the entire line are clean and undamaged before assembly. (00329a)
assembly slides into cylinder bore. 1. See Figure 2-48. Attach master cylinder/reservoir to
handlebar with handlebar clamp. Orient lever to rider
NOTE
position, with mating surface joint (1) within range marks
When installing the piston sealing boot, be careful not to tear,
(2) in handlebar. Tighten clamp fasteners to 72-84 in-
perforate or damage the piston sealing boot.
lbs (8.1-9.5 Nm).
7. Compress piston until it is even with the end of bore. Using
2. Tighten handlebar switch housing screws to 35-45 in-
a small dull bladed screwdriver or similar tool, gently work
lbs (4.0-5.1 Nm)
around sealing edges of boot until entire circumference
of boot is seated in cylinder bore groove. 3. Attach banjo fitting to master cylinder using new
steel/rubber washers. Tighten banjo bolt finger tight.
8. If cover gasket and/or sight glass replacement is neces-
sary, proceed as follows: 4. Fill reservoir with D.O.T. 4 HYDRAULIC BRAKE FLUID
a. From inboard side, push sight glass toward top of (Part No. 99953-99A). Allow fluid to fill clutch line until a
cover until free. steady flow of clutch fluid flows from bleeder valve. Finger
tighten bleeder valve.
b. Pull rubber gasket from cover.
5. Bleed clutch line. See 1.6 BLEEDING CLUTCH FLUID
c. Fit nipple of new gasket into hole of cover aligning LINE.
gasket and cover thru holes.
6. Verify that fluid level in clutch fluid reservoir is at FILL
d. From bottom of gasket, push flat end of sight glass LEVEL with motorcycle upright and gasket surface level.
through nipple until top of glass is flush with top of
gasket. Verify that glass is square in bore. If lubri- NOTE
cation is necessary, use clean D.O.T. 4 HYDRAULIC Clutch fluid volume in reservoir actually increases with clutch
BRAKE FLUID (Part No. 99953-99A). wear. Do NOT overfill clutch reservoir.
7. Verify operation by squeezing clutch hand lever.
9. Install cover with gasket on master cylinder/reservoir.
Install two screws to fasten the cover to reservoir, but do 8. Tighten fasteners as follows:
not tighten. a. Banjo bolt to 21-25 ft-lbs (28.5-33.9 Nm).
b. Bleeder screw to 12-15 in-lbs (1.4-1.7 Nm).
c. Reservoir cover screws to 6-8 in-lbs (0.7-0.9 Nm).
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the 9. Install rear view mirror and turn signals with bracket. See
pliers and could be propelled with enough force to cause 8.4 FRONT TURN SIGNALS.
serious eye injury. (00312a)
10. Install clutch hand lever, pivot pin, and a new retaining
ring.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

2-42 2008 FXDSE2 Service: Chassis

10. Test ride motorcycle.
sm04496

1. Clamping surface
2. Range marks
Figure 2-48. RH Assembly to Handlebar

2008 FXDSE2 Service: Chassis 2-43

CLUTCH HAND LEVER 2.22
REMOVAL INSTALLATION
1. See Figure 2-49. Slide bushing cups onto pins of roller
(3).
To prevent accidental vehicle start-up, which could cause NOTE
death or serious injury, remove main fuse before pro- Be careful when handling the bushing cups. The bushing cups
ceeding. (00251b) are hard plastic and easily broken.
1. Remove the maxi-fuse. 2. With connector bow portion of the bushing cups parallel
with groove in clutch handle, snap roller pin and bushing
2. See Figure 2-49. Remove the retaining ring (1) from the
cups into clutch lever roller groove. Roller/bushing
pivot pin (2).
assembly will install with a snap and will be held securely.
3. Remove pivot pin and lever.
3. Lightly grease pivot bushing (5) and install into clutch hand
4. Disassemble roller pin (3) and bushing cups (4). lever pivot hole. Position bushing until it is flush with both
sides of lever.
5. Remove pivot bushing (5).
NOTE
If the clutch master cylinder/reservoir is full of clutch fluid under
sm03994
pressure, it may be necessary to apply force to the hydraulic
piston in order to align the clutch hand lever and to allow the
2
pivot pin to be inserted.
5 4. Orient clutch lever in lever mounting bracket. Insert pivot
pin from top.
5. Install new retaining ring on pivot pin.
3
6. Install maxi-fuse.
4 7. Verify clutch lever operation.

1. Retaining ring
2. Pivot pin
3. Roller pin
4. Bushing cups
5. Pivot bushing
Figure 2-49. Clutch Hand Lever

2-44 2008 FXDSE2 Service: Chassis

CLUTCH FLUID LINE 2.23
REPLACEMENT
sm04483

Direct contact of D.O.T. 4 brake fluid with eyes can cause

irritation. Avoid eye contact. In case of eye contact flush
1
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF 2
CHILDREN. (00240a)

Be sure no clutch fluid gets on tires, wheels or brakes

when draining fluid. Traction can be adversely affected,
which could result in loss of control and death or serious
injury. (00295a)

Removal
1. Place a suitable container under clutch release cover and
drain fluid line. See 1.6 BLEEDING CLUTCH FLUID LINE. 1. O-ring
2. Flare nut
NOTE
Dispose of clutch fluid in accordance with local regulations. Figure 2-51. Clutch Fluid Line (typical)

2. Remove flare nut from clutch release cover.

3. See Figure 2-51. Remove and discard o-ring. Installation
NOTE
Clutch fluid line o-ring may remain in clutch release cover. Use
a pick to remove old o-ring and other debris. Do not allow dirt or debris to enter the master cylinder
4. Remove anchor strap securing clutch fluid line to front reservoir. Dirt or debris in the reservoir can cause improper
engine mount cross member. operation and equipment damage. (00205c)

5. Remove clutch fluid line bracket and remove clutch fluid 1. See Figure 2-50. Route clutch fluid line down through top
line from frame. fork clamp, along left downtube, and above front engine
mount cross member towards the clutch release cover.
6. Remove banjo bolt and two steel/rubber washers to dis- Secure to cross member using a new anchor strap.
connect fitting of hydraulic clutch fluid line from clutch
reservoir and master cylinder. Discard washers. 2. Loosely attach banjo fitting of clutch fluid line to master
cylinder with new steel/rubber washers.
7. Remove clutch fluid line from motorcycle.
3. See Figure 2-51. Install new o-ring on end of clutch fluid
line.
sm04482
4. Attach clutch fluid line to clutch release cover and secure
finger-tight.
5. Install clutch fluid line bracket.
6. Remove clutch master cylinder/reservoir cover and fill
reservoir with D.O.T. 4 Brake Fluid. Loosen bleeder screw
and allow fluid to fill clutch line until a steady flow of clutch
fluid flows from bleeder screw. Finger tighten bleeder
screw.
NOTE
A vacuum-type brake bleeder with a fitting that mates to bleeder
valve can be used to draw fluid down clutch line.
7. Bleed clutch fluid line. See 1.6 BLEEDING CLUTCH FLUID
LINE.

Figure 2-50. Clutch Fluid Line Routing

2008 FXDSE2 Service: Chassis 2-45

 NOTE 11. Test ride motorcycle. Air in line or incorrect fluid level can
Clutch fluid volume increases with clutch wear. Do not overfill cause:
clutch reservoir. a. Dragging clutch.
8. Verify that fluid level in clutch fluid reservoir is at FILL b. Hard shifting.
LEVEL with motorcycle upright and gasket surface level.
9. Test pressure by squeezing clutch hand lever. NOTE
Refer to 6.1 CLUTCH RELEASE BEARING AND PUSHROD
10. Tighten fasteners as follows: to check for proper hydraulic clutch system operation.
a. Clutch fluid reservoir banjo bolt to 21-25 ft-lbs (28.5-
33.9 Nm).
b. Clutch line flare nut to 72-120 in-lbs (8.1-13.6 Nm).
c. Clutch actuator bleeder screw to 12-15 in-lbs (1.4-
1.7 Nm).
d. Reservoir cover screws to 6-8 in-lbs (0.7-0.9 Nm).

2-46 2008 FXDSE2 Service: Chassis

SUBJECT............................................................................................................................PAGE NO.
3.1 SPECIFICATIONS: ENGINE.....................................................................................................3-1
3.2 SERVICE WEAR LIMITS...........................................................................................................3-3
3.3 CYLINDER HEAD.....................................................................................................................3-5
3.4 PISTONS.................................................................................................................................3-16
3.5 BORING AND HONING CYLINDERS.....................................................................................3-17
3.6 CRANKCASE ASSEMBLY......................................................................................................3-20

ENGINE
NOTES
SPECIFICATIONS: ENGINE 3.1
GENERAL MANUFACTURING TOLERANCES
NOTE
Table 3-3. Rocker Arms Specifications
This chapter provides unique information for models equipped
with Twin-Cam 110 engines. For models manufactured for sale ROCKER ARMS IN. MM
in the country of Japan that are equipped with Twin-Cam 96
Shaft fit in bushing (loose) 0.0005-0.0020 0.013-0.051
engines, see the Service Manual for specifications and service
procedures. End clearance 0.003-0.013 0.08-0.33
Bushing fit in rocker arm (tight) 0.002-0.004 0.051-0.102
Table 3-1. Engine: TWIN-CAM 110

ITEM SPECIFICATION Table 3-4. Rocker Arm Shaft Specifications

Number of cylinders 2 ROCKER ARM SHAFTS IN. MM
Type 4-cycle, 45° Shaft fit in rocker arm support 0.0007-0.0022 0.018-0.056
V-Type, air cooled plate (loose)
Torque 105 ft-lbs (142 Nm) @ 3000
RPM Table 3-5. Hydraulic Lifter Specifications
Bore 4.000 in. (101.60 mm)
HYDRAULIC IN. MM
Stroke 4.38 in. (111.13 mm) LIFTERS
Piston displacement (approx.) 110 cu. in. (1800 cc) Fit in crankcase 0.0008-0.0020 0.02-0.05
Compression ratio 9.3:1 (loose)
Cam system Twin cams, chain driven with
hydraulic tensioners Table 3-6. Cylinder Heads
Max. sustained engine speed 5500 RPM ITEM IN. MM
Idle speed 1000 RPM ± 50 Valve guide in head 0.0020-0.0033 0.051-0.084
(tight)
Table 3-2. Oiling System Intake valve seat in 0.004-0.0055 0.102-0.140
head (tight)
ITEM SPECIFICATION
Exhaust valve set in 0.003-0.0045 0.076-0.114
Oil tank capacity 4 qt (3.78 L) head (tight)
with filter
Head gasket sur- 0.0-0.006 0.0-0.0152
Preferred oil SYN3 20W50 (Part No. 99824-03/00QT face (flatness)
quart)
Pump Twin gerotor, dual scavenge, crank
mounted and driven, internal oil pump, Table 3-7. Valves
dry sump ITEM IN. MM
Pressure 30-38 psi (207-262 kN/m2) at 2000 RPM Fit in guide (intake 0.0011-0.0029 0.028-0.074
and normal operating temperature of and exhaust)
230° F (110° C)
Seat width 0.034-0.062 0.86-1.57
Filtration 5 micron media, filtered between pump
and engine Stem protrusion 1.990-2.024 50.55-51.41
from cylinder head
Cooling Thermostat controlled oil cooler boss

Table 3-8. Valve Springs Specifications

ITEM PRESSURE DIMENSION

Closed 175 lbs (79 kg) 1.800 in (45.7 mm)
Open 432 lbs (196 kg) 1.250 in. (31.8 mm)
Free length n/a 2.210 in (56.1 mm)

2008 FXDSE2 Service: Engine 3-1

 Table 3-9. Pistons Table 3-11. Flywheels

ITEM IN. MM ITEM IN. MM

Fit in cylinder 0.0018-0.0027 0.046-0.069 Runout (shaft measured 0.000-0.010 0.0-0.254
Piston pin fit (loose) 0.0005-0.0009 0.013-0.023 in case)

Ring end gap: Runout (measured in 0.000-0.004 0.0-0.102

truing stand)
Top compression ring 0.016-0.024 0.406-0.610
End play 0.003-0.010 0.076-0.254
2nd compression ring 0.014-0.022 0.356-0.559
Oil control ring 0.010-0.030 0.254-0.762 Table 3-12. Crankshaft/Sprocket Shaft Bearing
Ring side clearance: Specifications
Top compression ring 0.00098-0.0024 0.025-0.061 CRANK- IN. MM
2nd compression ring 0.00098-0.0024 0.025-0.061 SHAFT/SPROCKET
SHAFT BEARINGS
Oil control ring 0.002-0.004 0.051-0.102
Roller bearing fit (loose) 0.0002-0.0015 0.005-0.038

Table 3-10. Connecting Rods Bearing fit in crankcase 0.0038-0.0054 0.097-0.137

(tight)
ITEM IN. MM
Bearing inner race on 0.0004-0.0014 0.010-0.036
Piston pin fit (loose) 0.0006-0.0012 0.015-0.030 crankshaft (tight)
Side play between fly- 0.005-0.015 0.13-0.38
wheels
Connecting rod to 0.0004-0.0017 0.0102-0.0432
crankpin (loose)

3-2 2008 FXDSE2 Service: Engine

SERVICE WEAR LIMITS 3.2
GENERAL
Table 3-17. Cylinders
Wear limits can be used as a guide when deciding whether to
reuse engine parts. Replace used parts whenever the following ITEM REPLACE IF WEAR EXCEEDS
wear limits are exceeded. IN. MM
Taper 0.002 0.051
Table 3-13. Rocker Arm/Rocker Arm Shaft
Out of round 0.002 0.051
ROCKER ARM/ROCKER REPLACE IF WEAR EXCEEDS Warpage of gasket or 0.006 0.152
ARM SHAFT IN. MM O-ring surfaces: top
Shaft fit in bushing (loose) 0.0035 0.089 Warpage of gasket or 0.004 0.102
O-ring surfaces: base
End clearance 0.025 0.635
Shaft fit in rocker arm 0.0035 0.089
support (loose) Table 3-18. Cylinder Bore

ITEM REPLACE IF WEAR EXCEEDS

Table 3-14. Hydraulic Lifters IN. MM
ITEM REPLACE IF WEAR EXCEEDS Standard 4.002 101.65
IN. MM 0.005 in. oversize 4.007 101.78
Fit in crankcase 0.003 0.08 0.010 in. oversize 4.012 101.90
Roller fit 0.0015 0.038
Roller end clearance 0.015 0.38 Table 3-19. Pistons

ITEM REPLACE IF
Table 3-15. Cam Support Plate WEAR EXCEEDS
IN. MM
CAM SUPPORT PLATE REPLACE IF
Fit in cylinder (loose) 0.003 0.076
IN. MM
Piston pin fit (loose) 0.0009 0.023
Cam chain tensioner shoe More than 0.090 More than 2.29
Ring end gap Top compression 0.034 0.864
1/2 thickness of shoe
2nd compression 0.032 0.813
Crankshaft bushing max- More than More than
imum ID 0.8545 21.704 Oil control ring rails 0.030 0.762
Camshaft bore 1.1023 27.998 Ring side clearance Top compression 0.0032 0.081
2nd compression 0.0032 0.081
Table 3-16. Cylinder Heads Oil control ring rails 0.004 0.102
ITEM REPLACE IF
Table 3-20. Connecting Rods
IN. MM
Valve guide (tight) Less than 0.002 Less than 0.051 ITEM REPLACE IF WEAR
(intake and EXCEEDS
exhaust) IN. MM
Intake seat (tight) Less than 0.004 Less than 0.102 Piston pin fit (loose) 0.002 0.051
Exhaust seat (tight) Less than 0.003 Less than 0.076 Side play between flywheels 0.020 0.51
Head warpage Greater than 0.006 Greater than 0.152 Fit on crankpin (loose) 0.002 0.05

Table 3-21. Flywheels

ITEM REPLACE IF WEAR EXCEEDS

IN. MM
Runout (shaft measured 0.012 0.305
in case)
Runout (measured in 0.005 0.127
truing stand)
End play 0.010 0.254

2008 FXDSE2 Service: Engine 3-3

 Table 3-22. Crankshaft Roller Bearing Table 3-23. Breather Assembly

ITEM REPLACE IF BREATHER ASSEMBLY REPLACE IF WEAR

IN. MM EXCEEDS

Roller bearing fit (loose) More than More than IN. MM

0.0015 0.038 Breather cover warpage 0.005 0.13
Crankshaft runout More than More than Breather baffle warpage 0.005 0.13
0.003 0.076
Bearing fit in crankcase (tight) Less than Less than Table 3-24. Valve Stem to Guide
0.0038 0.097
VALVE STEM TO GUIDE REPLACE IF WEAR EXCEEDS
Inner race on crankshaft (tight) Less than Less than
0.0004 0.010 IN. MM
Intake 0.0038 0.0965
Exhaust 0.0038 0.0965

3-4 2008 FXDSE2 Service: Engine

CYLINDER HEAD 3.3
GENERAL
sm04037
For service wear limits, refer to Table 3-16.

REMOVAL
See the Service Manual for removal of cylinder heads.
NOTE
Separate ACR connectors from the rear [203R] and front [203F]
cylinder heads when removing the heads from the cylinders.

DETERMINING SERVICE
To determine if cylinder head disassembly and reconditioning
is necessary.
1. Raise valve ports of cylinder head to strong light source.
If light is visible around edges of seats, then move to
DISASSEMBLY to recondition cylinder head.
2. Fill ports at top of cylinder head with solvent. Wait ten full
seconds and then check for leakage into combustion
chamber. If solvent leakage into combustion chamber is
evident, then move to DISASSEMBLY to recondition cyl-
inder head.

sm04036
Figure 3-2. Spring/Valve Stack and ACR

DISASSEMBLY
PART NUMBER TOOL NAME
HD-34736-B VALVE SPRING COMPRESSOR
HD-39786 CYLINDER HEAD HOLDING FIXTURE
HD-48498 ACR SOLENOID SOCKET

1. Use the ACR SOLENOID SOCKET (Part No. HD-48498)

to remove the ACR. See 8.6 AUTOMATIC COMPRES-
SION RELEASE.
2. See Figure 3-3. Obtain the CYLINDER HEAD HOLDING
FIXTURE (Part No. HD-39786) and proceed as follows:
a. Thread the 12 mm end of the tool into the spark plug
hole of the cylinder head.
b. See Figure 3-4. Clamp tool in vise at a 45 degree
angle (or one that offers a comfortable working posi-
tion).
Figure 3-1. Combustion Chamber
3. See Figure 3-5. Obtain the VALVE SPRING COM-
PRESSOR (Part No. HD-34736-B) and proceed as follows:
a. Place tool over cylinder head so that the blunt end is
centered on the valve head and adapter at end of
forcing screw is seated on the valve spring retainer.
b. Rotate forcing screw to compress valve springs.
c. If spring retainer has not broken free of tapered
keepers, give head of tool a sharp tap with a soft
mallet. Using magnetic rod or small screwdriver,
remove the keepers from the valve stem groove.
d. Rotate forcing screw to release the valve spring
compression.

2008 FXDSE2 Service: Engine 3-5

4. Remove the spring retainer and inner and outer valve
sm02495
springs.
5. Slide the valve from the valve guide.
6. Using pliers, twist and remove the valve guide seal from
the top of the valve guide. Discard the valve guide seal. 2
7. Remove the spring seat from the cylinder head.
8. Mark the bottom of the valve "F(ront)" or "R(ear)" to
indicate the cylinder head from which it was removed.
Also, separate and tag tapered keepers, valve springs,
spring retainers and spring seats so that they are installed
on the same valve at time of assembly. 1
9. Repeat to remove the other valve.
2
10. Release the cylinder head holding fixture from the vise
and then remove the tool from the spark plug hole.

sm04038

2
1
1. Holding fixture
2. Compressor

1. 14 mm end Figure 3-5.Valve Spring Compressor (Part No. HD-34736-B)

2. 12 mm end
Figure 3-3. Cylinder Head Holding Fixture (Part No. CLEANING
HD-39786-A)
1. Remove old gasket material from cylinder head. Gasket
material left on sealing surfaces will cause leaks.
2. Remove all carbon deposits from combustion chamber
sm04039 and machined surfaces of cylinder head. Exercise caution
to avoid removing any metal material. For best results,
use an air tool with a worn wire brush. Scraping may result
in scratches or nicks.
3. To soften stubborn deposits, soak the cylinder head in a
chemical solution, such as GUNK HYDRO-SEAL or other
carbon and gum dissolving agent. Repeat last step as
necessary.

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
4. Thoroughly clean the cylinder head, spring retainers,
tapered keepers, valves, inner and outer valve springs
and spring seats in a non-volatile cleaning solution or
solvent. Follow up with a thorough wash in hot soapy
Figure 3-4. Install Cylinder Head Holding Fixture in Vise
water. Blow dry with compressed air.

3-6 2008 FXDSE2 Service: Engine

 NOTES
• If bead blasting is used, use walnut shells or other soft
cleaning materials.
Do not use glass or sand to bead blast surfaces exposed
to engine oil. Blasting materials can lodge in pores of the • Be aware that bead blasting materials may also enter
casting. Heat expansion releases this material which can threaded holes adversely affecting fastener engagement
contaminate oil resulting in engine damage. (00534b) and torque indication. Carefully cover all threaded holes
if bead blasting is employed.

sm04040
22
2 23
3
1 24
5
4 14
9 25
6 16
24

7
10
8
11 21

19
20
21 15
12

26 17

13
18

1. Automatic compression release (ACR) 14. Cylinder head gasket

2. Tapered keepers 15. Cylinder
3. Spring retainer 16. Ring dowel
4. Outer spring 17. O-ring seal
5. Inner spring 18. Cylinder stud
6. Valve guide seal 19. Piston
7. Spring seat 20. Piston pin
8. Valve guide 21. Circlip (2)
9. Cylinder head bolt, short (2) 22. Top compression ring
10. Cylinder head bolt, long (2) 23. Second compression ring
11. Cylinder head 24. Oil rail
12. Valve seat 25. Oil rail spacer
13. Valve 26. Screamin' Eagle nameplate
Figure 3-6. Cylinder Head/Cylinder/Piston Assemblies (Exploded View)

2008 FXDSE2 Service: Engine 3-7

INSPECTION Valves
PART NUMBER TOOL NAME 1. Replace the valve if there is evidence of burning or
cracking.
HD-34723 VALVE GUIDE HONE
2. Inspect the end of the valve stem for pitting or uneven
HD-34751 VALVE GUIDE CLEANING BRUSH
wear. Replace the valve if either of these conditions are
HD-48627 CYLINDER TORQUE PLATES found.
HD-96796-47 VALVE SPRING TESTER 3. Inspect for burrs around the valve stem keeper groove.
Remove burrs with a fine tooth file if found.
Cylinder Head
4. To determine if the valve stem is excessively worn, see
1. Check for scratches and nicks on all gasket sealing sur-
VALVE GUIDES above.
faces.
2. With the combustion chamber side facing upward, set a Valve Springs
straightedge diagonally across the length of the cylinder 1. Inspect springs for broken or discolored coils. Replace
head intersecting the upper and lower corners of the springs if either of these conditions are found.
gasket surface. Slide a feeler gauge beneath the
straightedge to check the head for warpage. Checking the 2. Set the intake and exhaust valve springs on a level surface
opposite diagonal, repeat the procedure to verify that the and use a straightedge to check for proper squareness
gasket surface is flat (especially if a head gasket was and height.
blown). Discard the head if any low spot is 0.006 3. Check free length of inner and outer springs using a dial
inch (0.15 mm) or greater. vernier caliper or load test with the VALVE SPRING
NOTE TESTER (Part No. HD-96796-47). Replace springs if free
For good results, use one of the CYLINDER TORQUE length or compression force do not meet specifications.
PLATES (Part No. HD-48627) in lieu of the straightedge. Lay See 3.1 SPECIFICATIONS: ENGINE.
the upper plate flat on the machined surface of the head. As
Tapered Keepers
a preliminary check, see if the plate rocks from side to side. A
head on which the plate rocks is immediately suspect. Insert 1. Inspect parts for damage or rust pits. Replace as neces-
a feeler gauge between the plate and head at various locations sary.
to see if warpage exceeds above specification.
2. Inspect inboard side of tapered keepers for excessive
3. Verify that oil passageways are open and clean. wear. Upraised center must be pronounced and fit snugly
in valve stem groove. Place keepers into groove and verify
Valve Guides that they grip tightly without sliding.
1. Inspect external surfaces for cracks (particularly the com-
bustion chamber side). Replace the guide if any cracks
Valve Seats
are found. 1. Inspect seats for cracking, chipping or burning. Replace
seats if any evidence of these conditions are found.
2. To verify cleanliness of valve guides, lightly hone using
the VALVE GUIDE HONE (Part No. HD-34723) and then 2. Check seats for recession by measuring valve stem pro-
scrub with the VALVE GUIDE CLEANING BRUSH (Part trusion.
No. HD-34751) to remove any dust or debris. Polish the
valve stem with fine emery cloth or steel wool to remove
carbon buildup, and then check valve stem to guide
clearance as follows:
a. Carefully measure the inside diameter of the valve
guide using an inside ball micrometer.
b. Measure the outside diameter of the valve stem with
an outside micrometer.
c. The clearance is the difference between the two
measurements. The valve stem and/or guide are
excessively worn if the clearance exceeds the limits
shown in Table 3-25. To determine if the guide is
excessively worn and must be replaced, repeat
measurements using a new valve.

Table 3-25. Service Wear Limits

VALVE VALVE STEM TO GUIDE CLEARANCE

Intake 0.0038 in. (0.0965 mm)
Exhaust 0.0038 in. (0.0965 mm)

3-8 2008 FXDSE2 Service: Engine

REPLACING VALVE GUIDES sm04193

PART NUMBER TOOL NAME

HD-34740 VALVE GUIDE AND VALVE GUIDE
SEAL HANDLE
HD-34740 VALVE GUIDE AND VALVE GUIDE
1
SEAL HANDLE
HD-34751 VALVE GUIDE CLEANING BRUSH
HD-39782-A CYLINDER HEAD SUPPORT STAND
HD-39782-A CYLINDER HEAD SUPPORT STAND
HD-39786 CYLINDER HEAD HOLDING FIXTURE
HD-39847 RATCHETING TAP HANDLE
HD-39847 RATCHETING TAP HANDLE
HD-39932 VALVE GUIDE REAMER 3
HD-39964 REAMER LUBRICANT 2
HD-39964 REAMER LUBRICANT 1. Intake seat adapter
HD-48628 VALVE GUIDE INSTALLER 2. Exhaust seat adapter
3. Cylinder head support stand
Removal Figure 3-7. Cylinder Head Support Stand (HD-39782-A)
1. See Figure 3-7. Obtain the CYLINDER HEAD SUPPORT
STAND (Part No. HD-39782-A) and proceed as follows:
a. Insert sleeve of intake or exhaust seat adapter into
tube at top of support stand. sm04041

b. Position cylinder head so that valve seat is centered

on seat adapter. Support stand ensures that valve
guide and seat are perpendicular. If perpendicularity
is not achieved, the cylinder head valve guide bore Figure 3-8. Valve Guide & Valve Guide Seal Handle
will be damaged during the press procedure. (HD-34740)

NOTE
Do not press out the valve guide from the bottom of the cylinder
head. Carbon buildup on the combustion chamber side of the sm02498
guide can deeply gouge the cylinder head bore diminishing
the likelihood of achieving the proper interference fit and pos-
sibly requiring replacement of the cylinder head casting. 1
2. See Figure 3-8. At the top of the cylinder head, insert
VALVE GUIDE AND VALVE GUIDE SEAL HANDLE (Part
No. HD-34740) into valve guide bore until stopped by
shoulder.
3. See Figure 3-9. Center valve guide driver under ram of
arbor press. Apply pressure until valve guide drops free
of cylinder head. Discard the valve guide.

1. Valve guide driver

2. Cylinder head stand
Figure 3-9. Remove Valve Guide

2008 FXDSE2 Service: Engine 3-9

Installation
Table 3-26. Oversized Valve Guides
1. Check valve guide to valve bore clearance.
VALVE GUIDE IN. MM
a. Measure the outside diameter of a new standard
valve guide. Intake 0.001 0.025

b. Measure the cylinder head valve guide bore. The 0.002 0.05
valve guide should be 0.0020-0.0033 in. (0.051-0.084 0.003 0.08
mm) larger than the bore.
Exhaust 0.001 0.025
c. If clearance is not within specification, then select an 0.002 0.05
oversized valve guide. Refer to Table 3-26.
0.003 0.08
NOTE
Since some material is typically removed when the guide is
pressed out, it is normal to go to the next larger valve guide sm02299
for the proper interference fit.
2. See Figure 3-7 and Figure 3-10. Obtain the CYLINDER
HEAD SUPPORT STAND (Part No. HD-39782-A), VALVE 1
GUIDE AND VALVE GUIDE SEAL HANDLE (Part No. HD-
34740) and VALVE GUIDE INSTALLER (Part No. HD- 2
48628). Proceed as follows:
a. See Figure 3-10. Insert sleeve of intake or exhaust
seat adapter into tube at top of support stand. Position
cylinder head so that valve seat is centered on seat
adapter.
1
NOTE
Support stand ensures that valve guide and seat are per-
pendicular. If perpendicularity is not achieved, cylinder
head valve guide bore will be damaged during the press 2
procedure.
b. Apply petroleum jelly to lightly lubricate external sur-
faces of valve guide. Spread lubricant so that thin film
covers entire surface area.
c. At top of cylinder head, start valve guide into bore.
d. Place installer sleeve over valve guide, and then insert
tapered end of valve guide driver into installer sleeve.
e. Center valve guide driver under ram of arbor press
and apply pressure only until valve guide is started
in bore and then back off ram slightly to allow guide
to center itself.
3
f. Verify that support stand and driver are square.
Center driver under ram and press valve guide further
into bore, but then back off ram again to allow valve 1. Valve guide driver
guide to find center. 2. Valve guide installer sleeve
g. Repeat previous step and then apply pressure to 3. Cylinder head stand
driver until installer sleeve contacts machined area Figure 3-10. Install Valve Guide
of cylinder head.

NOTE 3. See Figure 3-3. Obtain the CYLINDER HEAD HOLDING

Always back off ram to allow the valve guide to find center. FIXTURE (Part No. HD-39786) and proceed as follows:
Pressing guide into cylinder head in one stroke can bend driver,
a. Thread the 12 mm end of the tool into the spark plug
break guide, distort cylinder head casting and/or damage cyl-
hole of the cylinder head.
inder head valve guide bore.
b. Clamp tool in vise at a 45 degree angle (or one that
offers a comfortable working position).

3-10 2008 FXDSE2 Service: Engine

 NOTES
sm04043
• Valve guides must be reamed to within 0.0005-0.0001
in. (0.013-0.0025 mm) of finished size.
• For best results, do not push on reamer or apply pressure
to the reamer handle. While excessive pressure results in
a rough cut, bore will be tapered if pressure is not centrally
applied.
• Never back reamer out of valve guide or bore will be
damaged.
4. See Figure 3-11. Obtain the VALVE GUIDE
REAMER (Part No. HD-39932), RATCHETING TAP
HANDLE (Part No. HD-39847) and REAMER LUB-
RICANT (Part No. HD-39964). Proceed as follows:
a. Install tap handle (2) on reamer (1).
b. Apply a liberal amount of reamer lubricant to valve
guide bore and bit of reamer. Start bit of reamer into
bore at top of cylinder head.
c. See Figure 3-12. Placing thumb on drive socket of
RATCHETING TAP HANDLE (Part No. HD-39847), Figure 3-12. Ream Valve Guide Bore
apply slight pressure on reamer while rotating in a
clockwise direction. Squirt additional lubricant onto
6. See Figure 3-13. Clean valve guide bore with the VALVE
reamer and into guide as necessary.
GUIDE CLEANING BRUSH (HD-34751).
d. Continue rotating RATCHETING TAP HANDLE (Part
7. See Figure 3-14. Obtain the 8 mm VALVE GUIDE FLEX
No. HD-39847) until entire bit has passed through
HONE (HD-34723) and REAMER LUBRICANT (Part
valve guide bore and shank of reamer rotates freely.
No. HD-39964). Proceed as follows:
e. Remove tap handle from reamer, and carefully pulling a. Install hone in a high speed electric drill.
on bit, draw shaft of reamer out combustion chamber
side of valve guide. b. Apply reamer lubricant to finishing stones of hone and
valve guide bore.
NOTE
c. Start finishing stones of hone into bore.
Abrasive particles can damage machined surfaces and plug
oil passageways possibly resulting in engine failure. d. See Figure 3-15. Activating the drill, move the entire
length of the finishing stone arrangement forward and
5. Direct compressed air into the valve guide bore to remove
backward through the bore for 10 to 12 complete
any metal shavings or debris.
strokes. Work for a crosshatch pattern of approxim-
ately 60°.
sm04042
NOTE
Abrasive particles can damage machined surfaces and plug
oil passageways possibly resulting in engine failure.
8. Direct compressed air into the valve guide bore to remove
1 any debris and then clean with the VALVE GUIDE
CLEANING BRUSH (Part No. HD-34751). See
Figure 3-13.
NOTE
Always verify valve stem to valve guide clearance after honing,
since a worn reamer may cut the bore undersize.
9. Measure the inside diameter of the valve guide with an
2 inside ball micrometer. Measure the outside diameter of
the valve stem with an outside micrometer. The valve stem
1. Valve guide reamer may be excessively worn or the valve guide bore undercut
2. Ratcheting tap handle if the clearance is not within the limits (low end preferable)
shown in Table 3-27.
Figure 3-11. Valve Guide Reamer and Ratcheting Tap
Handle 10. Using cleaning solvent, thoroughly clean valve guide bore.
Scrub valve guide bore with the VALVE GUIDE
CLEANING BRUSH (Part No. HD-34751).

2008 FXDSE2 Service: Engine 3-11

 sm04046
Table 3-27. New Parts Limits

VALVE VALVE STEM TO GUIDE CLEARANCE

Intake 0.0011-0.0029 in. (0.028-0.074 mm)
Exhaust 0.0011-0.0029 in. (0.028-0.074 mm)

NOTE
For best results, use a thin engine oil and clean valve guide
bore with the type of swabs or patches found in gun cleaning
kits. Continue to wipe bore until clean cloth shows no evidence
of dirt or debris.

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
Figure 3-15. Hone Valve Guide Bore
flow rates. (00061a)
11. Clean valves, cylinder head and valve seats in solvent.
Follow up with a thorough wash in hot soapy water. Blow
dry with low pressure compressed air. sm04047

sm04044

Figure 3-13. Valve Guide Cleaning Brush

sm04045

Figure 3-14. 8mm Valve Guide Flex Hone

Figure 3-16. Scrub Valve Guide Bore

3-12 2008 FXDSE2 Service: Engine

ASSEMBLY
PART NUMBER TOOL NAME
Failure to install plastic capsule can cause the valve stem
HD-34736-B VALVE SPRING COMPRESSOR seal to catch the edge of the valve stem keeper groove.
HD-34740 VALVE GUIDE AND VALVE GUIDE The resulting damage can cause leakage around the valve
SEAL HANDLE stem, excessive oil consumption and valve sticking.
(00535b)
HD-34751 VALVE GUIDE CLEANING BRUSH
11. See Figure 3-17. Push on head of valve until it contacts
HD-39786 CYLINDER HEAD HOLDING FIXTURE
the valve seat. Placing finger at head of valve to keep
HD-48644 VALVE GUIDE SEAL INSTALLER valve seated, slide plastic capsule over valve stem tip and
keeper groove.
1. Obtain the CYLINDER HEAD HOLDING FIXTURE (Part
No. HD-39786) and proceed as follows: 12. See Figure 3-18. Apply a very thin film of clean H-D 20W50
a. Thread the 12 mm end of the tool into the spark plug engine oil to capsule. Slide new valve guide seal over
hole of the cylinder head. capsule and down valve stem until contact is made with
top of valve guide. Remove capsule from valve stem tip.
b. Clamp tool in vise at a 45 degree angle (or one that
offers a comfortable working position).
sm04048
2. Slide spring seat over valve guide until it contacts the
machined area on the cylinder head casting. Use a little
grease to hold the spring seat in position, if necessary.
NOTE 1
At the time of disassembly, all parts should have been marked
or tagged so that they are installed on the same valve (and in
the same head).
3. Run the VALVE GUIDE CLEANING BRUSH (Part No. HD-
34751) through the valve guide bore to verify cleanliness.
4. Using TORCO MPZ or another suitable product, apply a 2
liberal amount of engine assembly lube to valve stem.
5. From the bottom of the cylinder head, insert the valve stem
into the valve guide.
6. To distribute the assembly lube evenly around the valve
stem and guide, hand spin the valve as it is installed. Work
the valve back and forth in the bore to verify that it slides
1. Plastic capsule
smoothly and seats properly.
2. Spring seat
7. Remove the valve and apply a second coat of assembly
Figure 3-17. Install Plastic Capsule on Valve Stem
lube to the valve stem. Install the valve in the valve guide.
8. Retract the valve so that the stem is not visible above the
top of the valve guide.
9. Using isopropyl alcohol or other suitable degreaser, thor-
oughly clean external surface of valve guide until com-
pletely free of grease and oil.
NOTE
Do not apply LOCTITE to inside of valve guide seal or top of
valve guide or valve may stick to seal resulting in loss of com-
pression and valve sticking.
10. Obtain tube of LOCTITE RC/620 HIGH TEMPERATURE
RETAINING COMPOUND (green). Carefully apply Loctite
to valve guide seal seating surface on outside diameter
of valve guide. Exercise caution to keep compound out of
valve guide bore.

2008 FXDSE2 Service: Engine 3-13

 sm04049 sm04052

Figure 3-20. Seat Valve Guide Seal

1. Plastic capsule
sm04052
2. Valve guide seal 1
Figure 3-18. Install Valve Guide Seal

13. See Figure 3-19. Obtain the VALVE GUIDE SEAL

INSTALLER (Part No. HD-48644) and proceed as follows:
a. Slide the installer tool over the valve guide seal using
2
valve stem as pilot. The tool bore allows insertion of
the valve stem, while the counterbore fits over the
valve guide seal.
b. See Figure 3-20. Using a small hammer, gently tap
the end of the tool until it lightly bottoms on the
installed spring seat. For best results, brace the cyl- 3
inder head to prevent movement during seal installa- 4
tion.
5
NOTES
• Repeated blows on installer after seal is in place will cause
seal distortion resulting in leakage around the valve stem,
excessive oil consumption and valve sticking.
• See Figure 3-21. If an arbor press is the preferred method
of valve guide seal installation, use the VALVE GUIDE
SEAL INSTALLER (Part No. HD-48644) with the VALVE
GUIDE AND VALVE GUIDE SEAL HANDLE (Part No. HD-
34740).
• Do NOT remove valve after seal is installed. Removing
the valve after seal installation will cause the valve guide 6
seal to catch the edge of the valve stem keeper groove.
The resulting damage will lead to leakage around the valve 1. Valve guide & valve guide seal handle
stem, excessive oil consumption and valve sticking. 2. Valve guide seal installer
3. Valve guide seal
4. Valve
sm04051
5. Valve guide
6. Valve seat
Figure 3-21. Using Arbor Press to Install Valve Guide Seal

Figure 3-19. Valve Guide Seal Installer

14. Apply a liberal amount of assembly lube to valve stem tip
and keeper groove.
15. Install the inner and outer valve springs over the valve
guide. Fit the spring retainer on top of the inner and outer

3-14 2008 FXDSE2 Service: Engine

 valves springs. Like the spring seat, the smaller diameter 17. Tap the end of the valve stem once or twice with a soft
flange fits inside the inner valve spring.The larger diameter mallet to ensure that tapered keepers are tightly seated
flange separates the inner and outer springs. in the valve stem groove.
16. Obtain the VALVE SPRING COMPRESSOR (Part No. HD- 18. Repeat all previous steps to install the other valve compon-
34736-B) and proceed as follows: ents.
a. Place tool over cylinder head so that the blunt end is 19. Verify that the copper seal washer is in place on the ACR.
centered on the valve head and adapter at end of
forcing screw is seated on the valve spring retainer. 20. Apply three equally spaced dots of LOCTITE 246
THREADLOCKER MEDIUM STRENGTH/HIGH TEMPER-
b. Rotate forcing screw to compress valve springs. ATURE around the lower third of the threads. Tighten to
c. With the tapered side down, fit the keepers into the 11-15 ft-lbs (14.9-20.3 Nm). See 8.6 AUTOMATIC COM-
valve stem groove. For best results, apply a dab of PRESSION RELEASE.
grease to the inboard side of the keepers before 21. Release the cylinder head holding fixture from the vise
installation and use a magnetic rod for easy place- and then remove the tool from the spark plug hole.
ment.
22. Cover the cylinder head to protect it from dust and dirt
d. Arranging tapered keepers so that the gaps are evenly until time of installation.
spaced, turn forcing screw to release valve spring
compression. INSTALLATION
NOTE See Service Manual for cylinder head installation procedure.
Over-compressing the valve spring can damage the valve guide
seal resulting in leakage around the valve stem, excessive oil
consumption and valve sticking.

2008 FXDSE2 Service: Engine 3-15

PISTONS 3.4
GENERAL
sm04055
See Figure 3-22. Though Twin Cam 110 pistons differ from
Twin Cam 96 in specification and appearance, piston service
procedures are the same except for measuring the nominal
diameter. See PISTON in SUBASSEMBLY SERVICE AND
REPAIR in the Service Manual. For service wear limits, refer
to Table 3-19.

MEASURING PISTON
1. Allow the piston to cool to room temperature.
2. See Figure 3-23. With a pencil or marker, mark the piston
on each side of the skirt across the thrust faces (perpen-
dicular to the piston pin bore) 0.394 in. (10 mm) from the
bottom edge.
NOTE
Set the piston skirt down on a level table and use a rule to
measure 0.394 in. (10 mm) high on the skirt.
3. Using a micrometer at the marks, measure the nominal
diameter of the piston.
4. Use a dial bore gauge to measure the piston ring travel Figure 3-22. Twin-Cam 110 Piston
zone in the cylinder bore.
NOTE
For Cylinder Bore Measurement: See CYLINDER in SUB-
ASSEMBLY SERVICE AND REPAIR in the Service Manual. sm04056

5. Replace piston and/or cylinder if running clearance

exceeds 0.003 in. (0.076 mm).

Figure 3-23. 0.394 in. (10 mm)

3-16 2008 FXDSE2 Service: Engine

BORING AND HONING CYLINDERS 3.5
INSPECTION
sm02506
3
PART NUMBER TOOL NAME
HD-33446-B CYLINDER TORQUE PLATES
TA360 SNAP-ON TORQUE ANGLE GAUGE

NOTE
Failure to use cylinder torque plates can produce measure-
ments that vary by as much as 0.001 in. (0.025 mm), possibly
resulting in the use of parts that are not suitable for service.
1. See Figure 3-25. To simulate an assembled cylinder for 2
accurately measuring cylinder taper and out-of-round 4 1
conditions, as well as for boring, honing or deglazing,
1. Bolts
obtain the CYLINDER TORQUE PLATES (Part No. HD-
2. Lower plate
33446-B). Install the torque plates as follows:
3. Upper plate
a. Remove o-ring seal from cylinder sleeve, if installed. 4. Vise grip step
b. Place used head gasket over two dowel pins at top Figure 3-24. Cylinder Torque Plates
of cylinder.
c. Install brass jaws or shop towels around teeth of vise
to prevent damage to tool. Clamp stepped side of NOTE
lower plate in vise with the simulated split line Maximum cylinder wear occurs at the very top of top ring travel.
(machined strip) facing away. Minimum wear occurs below ring travel. Failure to measure
d. See Figure 3-25. Lightly oil threads and shoulders of the cylinder at these points may result in a faulty decision
four bolts (1) with clean H-D 20W50 engine oil. Slide regarding the suitability of the cylinder for continued use.
four bolts all the way through holes of lower plate (2) 2. See Figure 3-26. Using an inside micrometer or dial bore
until washers contact outboard side. gauge, check cylinder bore for out-of round and taper.
e. Slide cylinder down bolts with the indent in the cooling Proceed as follows:
fins facing upward. a. At the top of the piston ring travel zone, starting about
0.50 in. (12.70 mm) or from the top of the cylinder,
f. With the two dowel pins and head gasket in place, measure the cylinder diameter at two locations; par-
align holes in upper plate with ends of bolts. Blind allel and perpendicular to the crankshaft. Record the
holes in upper plate accommodate dowel pins in cyl- readings.
inder. Alternately tighten four bolts into upper plate in
a crosswise pattern until finger tight. b. Repeat the two measurements at the center of the
piston ring travel zone.
g. See Figure 3-27. Tighten the bolts to 120-144 in-
lbs (13.6-16.3 Nm) in the sequence shown. c. Repeat the measurements again at the bottom of the
bore at a point below the piston ring travel zone.
h. Following the same sequence, tighten each bolt to
15-17 ft-lbs (20.3-23.1 Nm). d. Rebore the cylinder if the parallel and perpendicular
measurements at either the top, middle or bottom of
i. Using a grease pencil, mark a straight line on one of the bore vary by more than 0.002 in. (0.051 mm).
the bolts continuing the line over onto the lower plate. This indicates an out-of-round condition.
Repeat step for remaining three bolts.
e. Rebore the cylinder if the top, middle and bottom bore
j. Using the marks as a guide, turn each bolt 1/4 turn diameters either parallel or perpendicular to the
or 90°. Be sure to tighten the bolts in the sequence crankshaft vary by more than 0.002 in. (0.051 mm).
shown in Figure 3-27. This indicates excessive taper.
NOTE
For best results, obtain SNAP-ON TORQUE ANGLE 3. Continue with cylinder service.
GAUGE (Part No. TA360). a. If cylinders are not scuffed or scored and are not worn
beyond the service limits, see Deglazing Cylinder in
k. For purposes of inspection, remove the assembly
the Service Manual.
from the vise and place on bench top.
b. If cylinders are worn beyond the service limits, then
they must be rebored and/or honed to accept the next
standard oversize piston. See 3.5 BORING AND
HONING CYLINDERS, Cylinder Bore Finished Size.

2008 FXDSE2 Service: Engine 3-17

 sm02530 sm02532
2
1

1. Bolt (4)
2. Lower plate
3. Vise
Figure 3-25. Attaching Cylinder Torque Plates

Figure 3-27. Measure for Out-of-Round and Taper

sm02531
3 CYLINDER BORE FINISHED SIZE
4 1. For cylinder removal, cleaning, inspection, boring and
honing and installation, see CYLINDER in the Service
Manual.
2. Refer to Table 3-28. Bore the cylinder to 0.003 in. (0.08
mm) under the desired finished size. See BORING and
HONING CYLINDER in the Service Manual.
2
1
An incorrect cross hatch pattern or too fine a hone will
result in insufficient oil retention and possible piston
seizure and/or high oil consumption. (00538b)
3. Hone the cylinder to its finished size using a 280 grit rigid
hone followed by a 240 grit flexible ball hone. Honing must
be done with the torque plates attached. All honing must
Figure 3-26. Cylinder Torque Plate Bolt Sequence be done from the bottom (crankcase end) of the cylinder.
Work for a 60° crosshatch pattern.
4. Stop frequently to examine the cylinder bore and/or take
measurements. Remember, a precise 60° cross hatch
pattern in the piston travel area is important.

Failure to remove all abrasive particles may result in pre-

mature cylinder, piston and ring wear and engine failure.
(00537b) .
5. Thoroughly wash the cylinder bore with liquid dish soap
and warm water to remove all abrasive particles and
residual girt. Continue cleaning until a clean cloth shows
no evidence or dirt or debris.
6. Immediately apply a thin film of clean engine oil to a clean
white paper towel and thoroughly wipe the inside of the
cylinder to prevent the cylinder bore from rusting.

3-18 2008 FXDSE2 Service: Engine

 NOTE
sm04057
After wiping the cylinder with a clean, oiled paper towel, the
towel will be dark with contamination. Repeat this process
using a new lightly oiled paper towel each time until the towel
remains white. The cylinder is now clean.
7. With the cylinder at room temperature, check the piston
clearance in the cylinder in which the piston will run. See
INSPECTION under PISTON in Service Manual.
8. For cylinder installation, see CYLINDER in Service Manual.

PISTON ORIENTATION
See Figure 3-28. When replacing a piston, orient the piston so
that the etched arrow on the top of the piston faces forward.

Figure 3-28. Piston Orientation Arrow (arrow points to front

of engine)

Table 3-28. Oversize Pistons and Cylinder Bores

PISTON CYLINDER BORE FINISHED SIZE

TYPE SIZE MINIMUM MAXIMUM
Standard STD 4.0000 in. (101.6 mm) 4.0005 in. (101.613 mm)
Oversize 0.005 in. (0.13 mm) 4.0050 in. (101.727 mm) 4.0055 in. (101.740 mm)
0.010 in. (0.25 mm) 4.0100 in. (101.854 mm) 4.0105 in. (101.867 mm)

2008 FXDSE2 Service: Engine 3-19

CRANKCASE ASSEMBLY 3.6
GENERAL
sm04059
With the exception of the top center crankcase bolt, crankcase
service is identical to original equipment. See the Service
1
Manual for complete procedure.

ASSEMBLY 1
PART NUMBER TOOL NAME
HD-39361-B SPROCKET SHAFT OIL SEAL
INSTALLER 2
HD-42326-A CRANKSHAFT GUIDE
HD-97225-55C SPROCKET SHAFT BEARING
INSTALLER

1. Install left crankcase half in engine stand so that the split

line face is vertical.
2. See Figure 3-29. To prevent damage to the sprocket shaft
(roller) bearing, slide CRANKSHAFT GUIDE (Part No. HD-
42326-A) over end of sprocket shaft.
3
3. Slide flywheel assembly into left case half and remove
tool.
4. Tip crankcase in engine stand so that flywheel pinion shaft
is pointing straight up.
NOTE
O-rings that are missing, distorted, pinched or otherwise dam-
aged will result in either oil leakage or low oil pressure. Use of
4
the wrong o-ring will have the same results. Since many o-rings
are similar in size and appearance, always use new o-rings
keeping them packaged until use to avoid confusion.
5. Install new o-rings over two ring dowels in split line face
of right case half.
2
5
6. Apply a small bead of sealant approximately 0.056 in. (1.4
mm) wide to the split line face. For best results, use High-
Performance Sealant (gray), (Part No. HD-99650-02).
7. To prevent damage to the crankshaft (roller) bearing, slide
CRANKSHAFT GUIDE (Part No. HD-42326-A) over end 1. Water pipe insulation
of crankshaft until it contacts shoulder on shaft. 2. Crankshaft guide
8. See Figure 3-30. Slide bearing in right crankcase half over 3. Left crankcase
end of crankshaft to mate case halves. Remove tool. 4. Crankshaft bearing
5. Right crankcase
Figure 3-30. Crankshaft Guide
sm04058

NOTE
See Figure 3-31. The center upper bolt (1) is longer than the
remaining eight crankcase bolts. If any of the other bolts are
installed in that position, the threads will not engage the threads
in the crankcase and the bolt will spin. If the center upper bolt
is installed in a different location, the head of the bolt will be
standing above the crankcase.
Figure 3-29. Crankshaft Guide

3-20 2008 FXDSE2 Service: Engine

9. Start the nine crankcase bolts and tighten:
sm04060
a. Alternately turn each crankcase bolt until finger tight.
1
b. In sequence, tighten the crankcase bolts to 10 ft-
lbs (13.6 Nm).
4
c. In sequence, tighten each bolt to 15-19 ft-lbs (20.3- 5
25.8 Nm).

10. Rotate crankcase in the engine stand so that the stator 8

mount flange (sprocket shaft side) is facing upward. 7
11. Slide thrust washer over sprocket shaft with "THIS SIDE
OUT" facing out (and the chamfer inboard).
NOTE
If using OE part without markings, orient as required to preserve
existing wear pattern.
12. To install new oil seal into bearing bore, obtain pilot, Nice
2
bearing, large flat washer and handle from SPROCKET 3
SHAFT BEARING INSTALLER (Part No. HD-97225-55C)
and proceed as follows:
9 6
a. Verify that seal lip garter spring is in place on both
sides of seal. Figure 3-31. Crankcase Torque Sequence (left side)
b. Thread pilot onto sprocket shaft until contact is made
with shoulder.
c. With the lettering facing outside, slide oil seal over
sm04061
pilot until it contacts bearing bore.
d. See Figure 3-32. Slide SPROCKET SHAFT OIL SEAL
INSTALLER (Part No. HD-39361-B) over pilot until it
contacts oil seal.
e. Slide Nice bearing and large flat washer over pilot
until contact is made with seal installer.
f. Thread handle onto pilot shaft.
g. See Figure 3-33. Rotate handle in a clockwise direc- Figure 3-32. Sprocket Shaft Oil Seal Installer
tion until oil seal installer makes firm contact with
crankcase stator mount.
h. Remove handle, flat washer, Nice bearing, seal
installer and pilot from sprocket shaft.

13. Slide sprocket shaft spacer over end of sprocket shaft.

Push spacer into oil seal until seated against bearing race.

2008 FXDSE2 Service: Engine 3-21

 sm02348

1. Seal Installer
Figure 3-33. Sprocket Shaft Oil Seal Installer

3-22 2008 FXDSE2 Service: Engine

SUBJECT............................................................................................................................PAGE NO.
4.1 FUEL SYSTEM..........................................................................................................................4-1

FUEL SYSTEM
NOTES
FUEL SYSTEM 4.1
NO UNIQUE CONTENT
Any information not presented in this supplement can be found
in the Dyna Models Service Manual.

2008 FXDSE2 Service: Fuel System 4-1

NOTES

4-2 2008 FXDSE2 Service: Fuel System

SUBJECT............................................................................................................................PAGE NO.
5.1 SPECIFICATIONS: STARTER...................................................................................................5-1

ELECTRIC STARTER
NOTES
SPECIFICATIONS: STARTER 5.1
GENERAL

Table 5-1. Starter

ITEM SPECIFICATION
Output 1.4 Kw
Free (no load) speed 3000 RPM (min.) @ 11.5 V
Free (no load) current 90 Amp (max.) @ 11.5V
Stall torque 8.7 ft-lbs (11.8 Nm) min. @
2.4 V
(500 Amps max.)

2008 FXDSE2 Service: Electric Starter 5-1

NOTES

5-2 2008 FXDSE2 Service: Electric Starter

SUBJECT............................................................................................................................PAGE NO.
6.1 CLUTCH RELEASE BEARING AND PUSHROD......................................................................6-1

DRIVE
NOTES
CLUTCH RELEASE BEARING AND PUSHROD 6.1
GENERAL
sm04072
The following procedure is unique to this motorcycle. For all
other clutch service procedures refer to the Service Manual.

REMOVAL

To prevent accidental vehicle start-up, which could cause

death or serious injury, disconnect negative (-) battery 5
2
cable before proceeding. (00048a)
1. Remove seat. See SEAT in Service Manual. 4
2. Remove negative cable from battery.
3. See Figure 6-1. To access clutch release bearing, remove
clutch inspection cover.
3

4. See Figure 6-2. Remove bearing plate retaining ring (1).

5. Pull out release bearing plate (3) with release bearing (4) 1
and push rod (5).
6. Remove push rod retainer (2). 1. Bearing plate retaining ring
2. Push rod retainer
7. Press release bearing out of bearing plate. 3. Release bearing plate
INSTALLATION 4. Release bearing
5. Push rod
1. See Figure 6-2. Pressing on the outer race, press a new
Figure 6-2. Push Rod and Release Bearing
release bearing (4) into bearing plate (3).
2. Assemble push rod (5) to bearing.
3. Snap in push rod retainer (2).
Measure Release Plate Movement
1. Attach the standoff of a dial indicator to one of the 1/4-20
4. Slide push rod and clutch release bearing assembly
clutch-inspection (derby) cover mounting holes, or use a
through clutch pack to secondary clutch actuator.
magnetic base and dial indicator mounted suitably. Posi-
5. Snap in bearing plate retaining ring (1). tion the indicator anvil (rod) to the end of the push rod.

NOTE
Before installing clutch inspection cover check push rod and
release plate movement as follows. Insufficient clutch-release plate movement can lead to
difficulty or inability to shift, causing loss of control, which
could result in death or serious injury. (00345a)
sm04071
2. Actuate the clutch lever to measure the axial movement
of the push rod and the clutch-release plate assembly.
The axial movement must be at least 0.065 in. (1.65 mm).

NOTE
Proper bleeding of the system will typically yield plate move-
ment of greater than 0.065 in. (1.65 mm). If clutch release
plate movement is less than 0.065 in. (1.65 mm), the system
must be bled and plate movement measured again.

Install Clutch Inspection Cover

1. Thoroughly clean all gasket material from clutch inspection
cover and mating surface on primary cover.
2. See Figure 6-3. Install clutch inspection cover with new
gasket. Make sure the correct side of the gasket faces the
Figure 6-1. Clutch Release Bearing clutch inspection cover. In sequence shown, tighten
fasteners to 84-108 in-lbs (9.5-12.2 Nm).
3. Connect negative (-) battery cable to battery.

2008 FXDSE2 Service: Drive 6-1

 sm02844

After installing seat, pull upward on seat to be sure it is 2

locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or 5
serious injury. (00070b)
4. Install seat. See SEAT in Service Manual.

4
3

Figure 6-3. Clutch Cover Torque Sequence

6-2 2008 FXDSE2 Service: Drive

SUBJECT............................................................................................................................PAGE NO.
7.1 SPECIFICATIONS: TRANSMISSION........................................................................................7-1
7.2 CLUTCH RELEASE COVER.....................................................................................................7-2
7.3 SECONDARY CLUTCH ACTUATOR.........................................................................................7-4

TRANSMISSION
NOTES
SPECIFICATIONS: TRANSMISSION 7.1
GENERAL
Table 7-2. Transmission Gear Ratios

Table 7-1. Transmission Data GEAR RATIO

1 3.34
ITEM DATA
2 2.31
Type 6-speed Cruise Drive™
forward - constant mesh 3 1.72
SYN3 20W50 Quart Part No. 99824-03/00QT 4 1.39
Capacity (dry) 32 oz. (946 ml) 5 1.18
6 1.00

NOTE
Transmission gear ratios indicate the number of mainshaft
revolutions required to drive the output sprocket one revolution.

2008 FXDSE2 Service: Transmission 7-1

CLUTCH RELEASE COVER 7.2
REMOVAL
sm04074
1. Remove filler plug and dipstick.
2. Place a suitable container under transmission. Remove
magnetic drain plug at bottom right of oil pan and drain 1 1
transmission lubricant.
3. Remove seat.
2

To prevent accidental vehicle start-up, which could cause

death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
4. Remove negative battery cable.
5. To access the clutch release cover assembly, remove
right side exhaust system. See EXHAUST SYSTEM,
REMOVAL in the Service Manual.
1. Hole for locating dowel
6. Place a pan under clutch release cover. Remove cap and 2. Secondary clutch actuator
open bleeder valve. Loosen flare nut and allow clutch fluid
to drain. Figure 7-1. Inside Clutch Release Cover

7. Remove flare nut on outside of the clutch release cover.

Remove clutch fluid line and drain line. See 1.6 BLEEDING INSTALLATION
CLUTCH FLUID LINE.
1. See Figure 7-2. Place a new clutch release gasket (2) on
NOTE locating dowels (1) and position clutch release cover on
Dispose of clutch fluid in accordance with local regulations. transmission side door.
8. See Figure 7-3. Discard o-ring on end of clutch fluid line. 2. Install fasteners with the two short fasteners at the top of
NOTE the release cover. Tighten fasteners to 120-144 in-
Clutch fluid line o-ring may stick to inside of clutch release lbs (13.5-16.3 Nm).
cover. Use a non-metallic pick to remove old o-ring and other 3. See Figure 7-3. Install a new clutch fluid line o-ring on the
debris. end of the clutch fluid line.
9. Remove clutch release cover fasteners, cover and gasket. 4. Install clutch fluid line flare nut to clutch release cover.
10. Clean and inspect clutch release cover. Clean with dena- Tighten to 72-120 in-lbs (8.1-13.6 Nm).
tured alcohol or D.O.T. 4 HYDRAULIC BRAKE FLUID
(Part No. 99953-99A) only.
sm04075

NOTE
If required, replace locating dowels in transmission side door. 1
1
11. See Figure 7-1. Disassemble and inspect secondary clutch 2
actuator (2). Rebuild if required. See 7.3 SECONDARY
CLUTCH ACTUATOR.

1. Locating dowels
2. Gasket
Figure 7-2. Transmission Side Door

7-2 2008 FXDSE2 Service: Transmission

 2. Inspect o-ring on transmission lubricant drain plug and
sm04076
replace as necessary. Install drain plug and tighten to 14-
21 ft-lbs (19.0-28.5 Nm).
3. Fill the transmission with 32 oz. (946 ml) of transmission
lubricant or until the lubricant level on the dipstick of the
filler plug is at the F (FULL) mark with the motorcycle level
and upright and the filler plug resting on the threads. Use
only Harley-Davidson FORMULA+ TRANSMISSION AND
PRIMARY CHAINCASE LUBRICANT, Part No. 998851-
05 (quart).
4. Inspect the filler plug and dipstick o-ring and install filler
plug/dipstick. Tighten the plug to 25-75 in-lbs (2.8-8.5
Nm).
5. Install exhaust system. See EXHAUST, INSTALLATION
in the Service Manual.
6. Install negative battery cable.

After installing seat, pull upward on seat to be sure it is

locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
Figure 7-3. Clutch Fluid Line O-ring serious injury. (00070b)
7. Install seat.

FILL AND BLEED

1. Fill clutch reservoir and bleed clutch fluid system. See
1.6 BLEEDING CLUTCH FLUID LINE.

2008 FXDSE2 Service: Transmission 7-3

SECONDARY CLUTCH ACTUATOR 7.3
REPLACEMENT 7. While pushing piston into actuator bore, use a wooden
tooth pick or the end of a cable wrap to prevent primary
1. Remove the clutch release cover. See 7.2 CLUTCH cup from rolling over.
RELEASE COVER.
8. Install the clutch release cover. See 7.2 CLUTCH
RELEASE COVER.

Compressed air can pierce the skin and flying debris from sm04077
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never 1
use your hand to check for air leaks or to determine air 2
flow rates. (00061a)
2. Remove piston.
a. If the bleeder valve was removed, reinstall. 3
b. Support on a wooden block and apply low pressure
compressed air to clutch fluid line hole to remove
piston from cover bore.

3. See Figure 7-4. If necessary, wiggle piston from actuator

bore to completely remove.
4. Remove the spring. Discard spring and piston assembly.

Avoid leakage. Prevent damage to piston or piston bore.

Use non-metallic tools when servicing clutch actuator.
1. Piston
(00328a)
2. Primary cup
5. Lubricate new piston assembly and piston bore with the 3. Spring
service kit lubricant.
Figure 7-4. Secondary Clutch Actuator Components
6. Install new spring.

7-4 2008 FXDSE2 Service: Transmission

SUBJECT............................................................................................................................PAGE NO.
8.1 SPECIFICATIONS: ELECTRICAL.............................................................................................8-1
8.2 FUEL GAUGE............................................................................................................................8-2
8.3 TACHOMETER..........................................................................................................................8-4
8.4 FRONT TURN SIGNALS...........................................................................................................8-5
8.5 REAR TURN SIGNALS.............................................................................................................8-8
8.6 AUTOMATIC COMPRESSION RELEASE.................................................................................8-9

ELECTRICAL
NOTES
SPECIFICATIONS: ELECTRICAL 8.1
GENERAL
Table 8-2. Fuses

Table 8-1. Ignition FUSES AMPERES

MAXIFUSE 40
IGNITION DATA
Accessory fuse 15
Idle speed 1000 ± 50 RPM
Battery fuse
Spark plug size 12 mm
Customer accessory fuse 15
Spark plug gap 0.038-0.043 in.
ECM fuse 15
0.97-1.09 mm
Engine control fuse 15
Spark plug type Harley-Davidson
No. 6R12 Fuel pump fuse 15
(no substitute) Ignition fuse 15
Ignition coil primary resistance 0.5-0.7 ohms Instruments fuse 15
Ignition coil secondary resistance 5500-7500 ohms Lighting fuse 15

Table 8-3. Charging System

CHARGING SYSTEM DATA

Battery 19 amp hour/270 CCA
Alternator AC voltage output 16-23 VAC per 1000 RPM
Alternator stator coil resistance 0.1-0.2 ohms
Regulator voltage output @ 3600 14.3-14.7
RPM @
75° F (24° C)
Regulator amperes @ 3000 RPM 35-50 amps

2008 FXDSE2 Service: Electrical 8-1

FUEL GAUGE 8.2
CLEANING 3. Disconnect fuel gauge connector [117] under the fuel tank.

NOTES 4. Remove the wire lead pin terminals from the connector
housing. See MULTILOCK ELECTRICAL CONNECTORS
• The fuel gauge is mirror glass. Recommended cleaning
in the Service Manual.
is with glass cleaner. Any abrasive chrome cleaner could
damage the face of the gauge as well as the surrounding 5. Open clips and thread wires through protective conduit.
painted surface.
6. Press down on center of fuel gauge until it clicks and pops
• A light-sensitive sensor in the gauge causes the gauge to up.
illuminate brighter in lighted conditions.
7. Pull gauge and wire leads through tunnel and out through
• The low fuel lamp in the speedometer face illuminates fuel tank cup.
when the fuel tank has less than 1.0 gal (3.8 L) fuel.
8. See Figure 8-2. Loosen Torx locking screws.
• See Figure 8-1. The gas pump icon (1) is not a fuel
warning gauge. It is continuously lit when the ignition key 9. See Figure 8-3. To remove the housing, rotate the housing
is in IGNITION. to the unlocked position.

• From the left, the LEDs indicate the fuel available in the
fuel tank. When all seven LEDs (2) are illuminated the ed01660

tank is full. As the next five LEDs are extinguished, it

indicates 1/6 less fuel available for each sequential LED.
The final LED (3) indicates that less than 1/6th remains.

ed01659

Figure 8-2. Gauge Housing (Locked)

3
2 ed01661

1. Gas pump icon (continuously lit)

2. Full
3. Less than 1/6 full
Figure 8-1. Gauge Face

REMOVAL
1. Remove seat.

To prevent accidental vehicle start-up, which could cause

death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a) Figure 8-3. Gauge Housing (Unlocked)

REPAIR
When servicing the fuel system, do not smoke or allow
open flame or sparks in the vicinity. Gasoline is extremely 1. Place new fuel gauge assembly next to discarded unit
flammable and highly explosive, which could result in and cut wires to proper length.
death or serious injury. (00330a) 2. Crimp new pin terminals onto fuel gauge wires.
2. Disconnect battery cables, negative (-) cable first.

8-2 2008 FXDSE2 Service: Electrical

 NOTE
ed01662
For instructions on crimping wire terminals, see MULTILOCK
ELECTRICAL CONNECTORS in the Service Manual.

INSTALLATION
1. Assemble gauge to housing.
2. Thread wire leads down fuel tank cup. Slip conduit over
wires.
3. Feed connector conduit into tunnel over the top of the
crossover and tuck up into the tunnel.
4. See Figure 8-4. Align narrow tab on the gauge housing
with the tabs at the front of the fuel tank cup.
NOTE
The wide tab on the gauge housing must align with the tabs
Figure 8-4. Mating Tabs at Front of Gauge Housing and
at the rear of the fuel tank cup.
Fuel Tank Cup
5. Press down on the center of the fuel gauge until it clicks.
6. Pull gauge from housing without pulling wire leads from
fuel tank cup.
ed01663
7. See Figure 8-2. Secure housings in the locked position
with four Torx screws. 2 3
NOTE
Loosen but do not remove the screws. Press fingers against 1 4
screw heads and rotate clockwise along the slot to the counter-
sunk hole.
8. Install gauge in housing and press down until it clicks.
9. Feed wire leads through protective conduit and close
harness and frame clip.
10. See Figure 8-5. Install the pin terminals of the three wire
leads into the connector housing. See the MULTILOCK
ELECTRICAL CONNECTORS in the Service Manual.
Refer to Table 8-4.
Figure 8-5. Connector [117] Terminal Numbers
11. Mate fuel gauge connector [117] housings.
12. Connect battery cables, negative (-) cable first.
Table 8-4. Connector [117] Terminals and Wire Leads

FUEL GAUGE TERMINAL WIRE COLOR

After installing seat, pull upward on seat to be sure it is TERMINAL
locked in position. While riding, a loose seat can shift I 1 O
causing loss of control, which could result in death or
S 2 Y/W
serious injury. (00070b)
- 3 -
13. Install seat.
G 4 BK

2008 FXDSE2 Service: Electrical 8-3

TACHOMETER 8.3
REMOVAL
ed01664
1. See Figure 8-6. Remove two screws (1) and pull tacho-
meter out of housing.
2
2. Remove connector from back of tachometer (3). Remove
tachometer with gasket (2).
3. If jumper harness requires removal, remove instrument
console from fuel tank. See INSTRUMENTS:
FXDWG/FXDC/FXDF in the Dyna Service Manual. 1
4. See Figure 8-7. If the tachometer jumper harness must
be removed, proceed as follows:
a. Remove fuel tank to access the harness shield. See
FUEL TANK in the Dyna Service Manual. 3
b. Remove harness shield.
1. Tachometer
c. Disconnect connector [146] and remove jumper har-
2. Gasket
ness.
3. Screw (2)
INSTALLATION Figure 8-6. Tachometer and Bracket
NOTE
To ease installation, glass cleaner or alcohol may be applied
to the surface of the gasket.
ed01665

1. See Figure 8-7. If removed, route the jumper harness fol-

lowing the original path and connect main harness con-
nector [146].
2. Install the harness shield and fuel tank. See FUEL TANK
in the Dyna Service Manual.
3. Install gasket (2) on tachometer.
4. See Figure 8-6. Install connector to back of tachometer
(3) and slide tachometer into housing. Press firmly until
fully seated.
5. Install two screws (1) and tighten to 18-26 in-lbs (2.0-2.9
Nm).

Figure 8-7. Harness Shield

8-4 2008 FXDSE2 Service: Electrical

FRONT TURN SIGNALS 8.4
BULB REPLACEMENT REMOVAL
NOTE
The same procedure applies to the rear turn signals for bulb
replacement. To prevent accidental vehicle start-up, which could cause
1. See Figure 8-8. Locate latch slot on circumference of turn death or serious injury, remove main fuse before pro-
signal lens. Press in with small screw driver or coin to ceeding. (00251b)
remove lens. 1. Remove MAXIFUSE.
2. Push bulb in and rotate 1/4 turn counterclockwise to 2. See Figure 8-9. Remove set screws (1) from turn signal
remove. brackets (3, 11).
3. Inspect contacts in socket. If necessary, clean contacts 3. Loosen jam nuts (8).
with a small wire brush and electrical contact cleaner.
4. Use a ball Allen wrench to remove ball studs (2).
4. Evenly apply dielectric grease to the contacts and bottom
of the new bulb. 5. Remove acorn nut (10), lock washer, and rear view mirror
with washer. Discard lockwasher.
5. Push and rotate new bulb clockwise into socket.
6. Separate the control housings from the clutch or brake
6. Snap-in and rotate turn signal lens to position latch slot at lever brackets.
bottom.
7. Cut the turn signal lamp wires at the exit from the housing.
Remove the turn signal bullet housings.
ed01666

Figure 8-8. Latch Slot

2008 FXDSE2 Service: Electrical 8-5

 ed01667
4

3 5

2 8 6
7
1 9

10

1
2
11
9

8 10

1. Set screw 7. Lens

2. Ball stud 8. Jam nut
3. Left turn signal bracket 9. Lockwasher
4. Bullet housing 10. Acorn nut
5. Socket 11. Right turn signal bracket
6. Bulb
Figure 8-9. Front Turn Signal Lamp Assembly

INSTALLATION 8. Thread ball stud (2) into bullet housing (4).

1. See Figure 8-9. Trim back the conduit and strip 1/2 9. Finger tighten jam nut (8) against bullet housing (4).
in. (12.7 mm) off the turn signal lamp wires from the 10. Install but do not tighten set screw (1) into bracket (11).
handlebars grommet inside the control housings.
11. With motorcycle upright with front fork pointed straight
2. Strip 1/2 in. (12.7 mm) of insulation off wires of the new ahead, adjust mirrors to clearly reflect area behind
turn signal bullet housing assemblies (4) and thread them motorcycle.
through into grommets in control housings.
NOTE
3. Slide shrink tubing over wires. Twist matching wire colors, Adjust mirrors so a small portion of the rider's shoulder is visible
solder and heat shrink tubing over each separate splice. in each mirror. This visually establishes the distance of vehicles
See GENERAL REPAIR PROCEDURES under to the rear of the motorcycle.
HANDLEBAR SWITCHES in DYNA Models Service
Manual. 12. Tighten acorn nuts (10) to 60-96 in-lbs (6.8-10.8 Nm).

4. Loosely install housings over lever brackets and clamp. 13. Position turn signal housings (4) to point lenses straight
ahead. Tighten each setscrew (1) to 50-60 in-lbs (5.7-6.8
5. Assemble right turn signal bracket (11) to mirror and small Nm).
washer with new lockwasher (9) and acorn nut (10).
NOTE
6. Install ball stud (2) through through signal bracket (11) After setscrew is tightened, it is not necessary, nor desirable,
from inboard side. to completely remove setscrew to adjust housing. Loosen
7. Thread on jam nut (8) all the way onto ball stud (2). setscrew 1/8 turn, adjust housing and tighten set screw to the
proper torque. Nylon lock pellet on setscrew maintains locking

8-6 2008 FXDSE2 Service: Electrical

ability after many adjustments. If set screw is completely 16. Install MAXIFUSE.
removed, replace.
17. Test handlebar switches to make sure turn signals are
14. Hold each bullet housing and tighten jam nut (8). functioning properly and wiring is not pinched.
15. Adjust the wire conduits inside and outside the control
switch housings to avoid pinching the wires. Tighten the
housing fasteners to 35-45 in-lbs (4.0-5.1 Nm).

2008 FXDSE2 Service: Electrical 8-7

REAR TURN SIGNALS 8.5
BULB REPLACEMENT 2. Remove rear tail lamp housing from rear fender. Locate
appropriate rear turn signal harness and connector inside
1. Locate latch slot on circumference of turn signal lens. tail lamp housing recess in rear fender.
Press in with small screw driver or coin to remove lens.
3. See Figure 8-10. Disconnect socket harness connector
2. Push bulb in and rotate 1/4 turn counterclockwise to from main wiring harness on motorcycle.
remove.
4. Support turn signal assembly and remove screw (8) and
3. Inspect contacts in socket. If necessary, clean contacts washer (7).
with a small wire brush and electrical contact cleaner.
5. Remove turn signal assembly from motorcycle.
4. Evenly apply dielectric grease to the contacts and bottom
of the new bulb. INSTALLATION
5. Push and rotate new bulb clockwise into socket. 1. Install new turn signal assembly, routing wiring harness
connector back through holes in fender.
6. Snap-in and rotate turn signal lens to position latch slot
on bottom. 2. Insert terminals into turn signal connector in main wiring
harness and mate harness connectors.
REMOVAL
3. Install rear turn signal assembly to rear fender. Insert
screw (8) and washer. Tighten to 12-16 ft-lbs (16.3-21.7
Nm) .
To prevent accidental vehicle start-up, which could cause 4. Install tail lamp assembly into rear fender.
death or serious injury, remove main fuse before pro-
ceeding. (00251b) 5. Install MAXIFUSE.

1. Remove MAXIFUSE. 6. Test handlebar switches to make sure turn signals are
functioning properly and wiring is not pinched.
NOTE
Before removing turn signal wires, carefully note routing and
location of each wire terminal in connector.

ed01668

1 8
7
2 6

3
4
5

1. Lens 6. Turn signal mount

2. Bulb 7. Washer
3. Socket 8. Screw
4. Insulator 9. Socket harness connector
5. Turn signal housing
Figure 8-10. Rear Turn Signal Assembly

8-8 2008 FXDSE2 Service: Electrical

AUTOMATIC COMPRESSION RELEASE 8.6
GENERAL
ed01625
See Figure 8-11. The Automatic Compression Release (ACR)
is opened and closed by the ECM to assist starting.
See Figure 8-12. When open, compressed gases are released
through the exhaust port.

REMOVAL
PART NUMBER TOOL NAME
HD-48498 ACR SOLENOID SOCKET

1. While preparing motorcycle for service, separate the ACR

rear [203R] and front [203F] connectors from the main
wiring harness.
2. Remove the rocker cover and the rocker box. See
STRIPPING MOTORCYCLE FOR SERVICE and TOP
END OVERHAUL in the Service Manual for procedures. Figure 8-13. ACR in Head

3. See Figure 8-16. Use ACR SOLENOID SOCKET (Part

No. HD-48498) to remove the ACR from the cylinder head. INSTALLATION
PART NUMBER TOOL NAME
ed01623
HD-48498 ACR SOLENOID SOCKET

1. Verify that the copper seal washer is in place on the ACR.

2. See Figure 8-14. Identify a location around the threads of
the ACR approximately 1/3 of the way up from the end.
3. See Figure 8-15. Apply three equally spaced dots of
LOCTITE 246 THREADLOCKER MEDIUM STRENGTH
/ HIGH TEMPERATURE (blue) on threads.
4. To prevent cross threading, install and finger tighten.
5. See Figure 8-16. Using ACR SOLENOID SOCKET (Part
No. HD-48498), tighten to 11-15 ft-lbs (14.9-20.3 Nm).
6. Before installing the rocker box on each cylinder head,
route the wire harness toward the inside of the cylinder V.
Figure 8-11. ACR Valve in Combustion Chamber
7. With rocker boxes installed and the engine in the chassis,
mate the ACR connectors [203R] and [203F] to the corres-
ponding socket housings on the main wiring harness.
ed01624

Figure 8-12. ACR Exhaust Port Release

2008 FXDSE2 Service: Electrical 8-9

 ed01626 ed01628

Figure 8-16. ACR Solenoid Socket (HD-48498) and ACR

COMPRESSION TEST
PART NUMBER TOOL NAME
HD-33223-1 CYLINDER COMPRESSION GAUGE

A compression test can determine the source of cylinder

leakage. Use CYLINDER COMPRESSION GAUGE (Part
No. HD-33223-1) with a screw-in type adapter.
NOTE
The Twin Cam 110 Engine uses a 12 mm adapter with the
compression gauge.

Figure 8-14. Bottom Third 1. Operate engine to normal operating temperature.

2. Disconnect spark plug wires.
3. Clean around plug base and remove front cylinder spark
ed01627
plug.
4. Install compression tester to front cylinder per gauge
instructions.
NOTE
The test results will vary depending on whether the ACR is
connected or not. Refer to Table 8-5 for specifications.
5. Shift transmission to neutral. Crank engine continuously
through 5 to 7 compression strokes.
6. Record gauge readings at the end of the first and last
compression strokes (highest readings).
7. Replace front spark plug and repeat test on rear cylinder.
8. Refer to Table 8-5. Readings should be within specified
range. If readings are higher than normal, suspect a
Figure 8-15. Three Dots of Loctite 246 Medium compression release that is not functioning correctly. If
Strength/High Temperature readings are low, inject approximately 1/2 oz. (15 ml)
engine oil into each cylinder and repeat the compression
tests on both cylinders.
NOTE
Readings that are considerably higher after injecting the oil
indicate worn piston rings.

8-10 2008 FXDSE2 Service: Electrical

 3. If V/GY wire is shorted to ground, the ACR's will remain
Table 8-5. Compression Specifications on for a time that exceeds the design parameters and the
ACR solenoids will fail.
ACR STATUS PSI kN/m2
Connected 130-170 896-1,173
em00251
Disconnected 200-220 1,379-1,517

DIAGNOSTICS [119B]
PART NUMBER TOOL NAME [78A] [78B]
Y/GN K 87 5
HD-41404-B TEST CONNECTOR KIT T 87A 4
ACR 15 15 V/GY E 30 3
S 85 2
HD-48637 BREAK-OUT BOX U 86 1

Diagnostic Tips System

Relay
Refer to flow charts that follow for troubleshooting.

Diagnostic Notes
NOTES
• The reference numbers in Table 8-6 correlate with the

Y/GN

Y/GN
V/GY

V/GY
circled numbers in Figure 8-17.
ECM
• The step numbers below correlate with the circled numbers [203FB] 1 2 1 2 [203RB]
in the flow chart.
1. Use TEST CONNECTOR KIT (Part No. HD-41404-B) with
gray terminal probes and patch cords.
2. Connect BREAK-OUT BOX (Part No. HD-48637) to ECM.
Figure 8-17. ACR Circuit

Table 8-6. Connectors/Fuse in ACR Circuit

NUMBER DESCRIPTION TYPE LOCATION

[78] ECM 36-place Delphi Under seat
[203F] ACR 2-place Amp (Tyco) Between cylinders
[203R] ACR 2-place Amp (Tyco) Between cylinders
[119] System relay Lugs Fuse block

2008 FXDSE2 Service: Electrical 8-11

ACR Diagnostics (Part 1 of 2)

Is battery voltage 12.6

VDC or higher?

YES NO

Perform starter current draw test while cranking Charge battery.

engine at room temperature. Remove system
relay and repeat starter current draw test.
Is current draw 20-40 Amps greater with
system relay removed?

YES NO

Review symptoms. During the first 2 seconds after turning the

1
Issue is not ACR related. key on (while relay is energized) or while
cranking, measure voltage at terminal “1” on
connector [203FB] (front) or [203RB] (rear).
Is battery voltage present?

YES NO

2 Measure continuity between Locate and repair open on Y/GN

terminal “2” on connector [203FB] wire between terminal “1” on
(front) or [203RB] (rear) and connector [203FB] (front) or
breakout box terminal “15”. [203RB] (rear) and system relay.
Is continuity present?
7077

YES NO

Disconnect breakout box from ECM Locate and repair open on V/GY wire
leaving harness connected to breakout between terminal “2” on connector
box. Measure continuity between terminal [203FB] (front) or [203RB] (rear) and
“15” on breakout box and ground. ECM connector [78B] terminal “15”.
Is continuity present?
7076

YES NO

Disconnect connector [203FB] (front)

and [203RB] (rear) one at a time. STOP
Is continuity to ground still resent?

Go to
ACR Diagnostics
YES NO (Part 2 of 2).

Locate and repair short to ground on Replace grounded

3
V/GY wire between terminal “2” on ACR.
connector [203FB] (front) or [203RB]
(rear) and ECM connector [78B] 7077 fc01792_en
terminal “15” and replace both ACRs.
7078

8-12 2008 FXDSE2 Service: Electrical

ACR Diagnostics (Part 2 of 2)

Continued from ACR Diagnostics

(Part 1 of 2).

Measure voltage at breakout box terminal “15”

with breakout box disconnected from ECM.
Is voltage present?

YES NO

Locate and repair short to voltage Measure resistance between

on V/GY wire between terminal terminal “1” and “2” on connector
“2” on connector [203FB] (front) [203FA] (front) or [203RA].
or [203RB] (rear) and ECM Is continuity present?
connector [78B] terminal “15”.
7079

YES NO

Reconnect breakout box and ECM; and

ACRs to the engine wiring harness. Measure Replace defective
voltage at terminal “15” during cranking. ACR solenoid.

Is voltage 0.1-8.0 VDC and fluctuating while 7077

engine cranks?

YES NO

Perform compression test (only one spark plug can Replace ECM
be removed at a time or ACR will be disabled).
Refer to COMPRESSION TEST.
7080
Is compression 130 - 170 PSI (896- 1,173 kN/m2 0
with ACR connected and 200-220 PSI (1379-1517
kN/m2) with ACR disconnected?

YES NO

Review symptoms. Issue Replace ACR on cylinder

is not ACR related. that is non-functional.

7077

fc01793_en

2008 FXDSE2 Service: Electrical 8-13

NOTES

8-14 2008 FXDSE2 Service: Electrical

SUBJECT............................................................................................................................PAGE NO.
A.1 WIRING DIAGRAM INFORMATION.........................................................................................A-1

APPENDIX A WIRING
NOTES
WIRING DIAGRAM INFORMATION A.1
WIRING DIAGRAM INFORMATION
ed01269
Wire Color Codes
Wire traces on wiring diagrams are labeled with alpha codes.
Refer to Table A-1. 3 4
For Solid Color Wires: See Figure A-1. The alpha code 5
identifies wire color (3).
1 2
For Striped Wires: The code is written with a slash (/) between

GN/Y

TN
W
the solid color code and the stripe code (4). For example, a 6
trace labeled GN / Y is a green wire with a yellow stripe.
[21A] 1 2 4

Wiring Diagram Symbols [21B] 1 2 4 7

See Figure A-1. On wiring diagrams and in service/repair

GN/Y

TN
instructions, connectors are identified by a number in brackets
(1). The letter (2) inside the brackets identifies whether the 8
housing is a socket or pin housing. 1 2
A=Pin: The letter A after a connector number and the pin
symbol (6) identifies a pin housing. 10 9
B=Socket: The letter B after a connector number and the
socket symbol (5) identifies a socket housing.
Other symbols found on the wiring diagrams include the symbol
for a diode (7), a symbol for a wire-to-wire connection (8), a 1. Connector number
symbol that verifies that no connection (9) between two wire 2. Terminal code (A=pin, B=socket)
traces exists and a symbol identifying two wires that are twisted 3. Solid wire color
together (10). 4. Striped wire color
5. Socket symbol
6. Pin symbol
7. Diode
8. Connection
9. No connection
10. Twisted pair
Figure A-1. Connector/Wiring Diagram Symbols (typical)

Table A-1. Wire Color Codes

ALPHA CODE WIRE COLOR

BE Blue
BK Black
BN Brown
GN Green
GY Grey
LGN Light Green
O Orange
PK Pink
R Red
TN Tan
V Violet
W White
Y Yellow

2008 FXDSE2 Service: Appendix A Wiring A-1

WIRING DIAGRAMS

Wiring Diagram List

DIAGRAM LOCATION
2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Main Wiring Harness (1 of 3) Figure A-2
2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Main Wiring Harness (2 of 3) Figure A-3
2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Main Wiring Harness (3 of 3) Figure A-4
2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Lighting and Controls Figure A-5
2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Charging System, Security System, and Fuse/Relay Figure A-6
Blocks

A-2 2008 FXDSE2 Service: Appendix A Wiring

et00062 Crank Position Sensor Fuel Fuel Pump & Ignition
Speedometer Gauge Sender ASSY
[142B] [39B] See Figure A-4 Switch
Manifold See See Front Rear
Figure A-4 Figure A-4 Injector Injector To front IGN − I A R/BK
Security 1 2 56 7 9 Absolute turn BATT − B B R
Siren BN/GY Pressure [117B] [141B] P&A
Power A A signal ACC − A C R/GY 1
(Optional) Signal B B LGN/BN Sensor 1 2 4 AB CD See Figure A-5 Battery

BK/GN
BN/GY
LGN/V

R
[160B]

O/W

Y/W
[142A] Ground C C BK [31LA] [31RA] [33A] [33B]

BK
R

BK/GN

BK/GN
O/GY
Y/W
1 2 3 3 2 1

Y/W

BK
O
[30A] [30B] [64B]

BN
BE
BE
BK

BK
Turn Signal &

V
[79A] 1 2 [80A]
Security Module Battery 1 1 BN/GY A B C [84A] [85A]
TSM/TSSM Ignition 2 2 GY 1 2 Spare - 15A F
Serial data 3 LGN/V
3 LGN/V [79B] [80B] A BC A B A B E
Neutral switch 4 4 TN BK BK [5]

BK
R

BK

BE

BN
Left turn feed 5 5 V A B A B 40 Amp
U

BK/W
S CUST ACCY - 15A

R/W
V/W
Right turn feed 6 6 BN
Right turn switch input 7 7 W/BN [84B] [85B] O R/GY MAXIFUSE

GN/GY
Y/GN
Y/GN
Left turn switch input 8 8 W/V

W/Y
Start relay control 9 9 TN/GN D P&A IGN - 15A C
Clutch switch 10 10 BK/R R/BK
Alarm signal 11 11 LGN/BN
Ground 12 12 BK/GN G IGN - 15A H
GY R/BK B A
See security circuit for hands free A INSTR - 15A B
security module (See Figure A-6) [78A] [78B] R/BK

R
O
ECM M Lights - 15A O
Active exhaust feedback (HDI) 1 1 V/BE See Figure A-3 BE R/BK

P ACCY - 15A R
System relay 4 4 GN/O O/W R/GY
Serial data 5 5 LGN/V
Engine temperature 6 6 PK/Y I Battery - 15A J
Intake air temperature 7 7 LGN/Y BR/GY
Oxygen sensor (A) (except HDI) 8 8 PK/O See See O ENG CTL - 15A M
Jiffy stand sensor (HDI) 9 9 GN/BN Figure A-3 Figure LGN/R R/BK R
Ground 10 10 BK/GN A-3
Coil rear 11 11 Y/BE G Fuel pump - 15A H
Crank pos sensor (−) 12 12 BK O/GY
Switched power 13 13 W/BK
5V sensor power 14 14 R/W A ECM - 15A B
ACR (CVO) 15 15 V/GY See BE R
Figure A-3 Y/GN
Idle air control (A) HI 17 17 BK/O
Idle air control (B) LOW 18 18 BK/PK Y/GN I 5 87 See charging
Injector rear 19 19 GN/GY Q 4 87A circuit for further
Active exhaust (HDI) 20 20 V/O See Figure A-3 C 3 30
System
W/Y
BE/GY
Relay connections
Injector front 21 21 GN/O P 2 85
Active intake solenoid (HDI) 22 22 GY/O See to charging
W/BK R 1 86
Oxygen sensor (B) (except HDI) 23 23 PK/GN Figure A-3 system
Throttle pos sensor input 24 24 GY/V (See Figure A-6)
MAP sensor input 25 25 V/W
BK/W GN K 5 87
5V sensor ground 26 26 Start
GY/BE T 4 87A
Ion sense 27 27
Ground 28 28 BK/GN R/BK E 3 30 Relay
Coil front 29 29 BE/O TN/GN S 2 85 (GY)
Crank pos sensor (+) 30 30 R BK/R U 1 86
Battery 31 31 BE/GY
[62B]
Vehicle speed sensor input 33 33 W/GN

Idle air control (A) LOW 35 35 BE/GN

Idle air control (B) HI 36 36 BN/R GN 1 Starter Solenoid
[128B]
O/R 1 Customer
Vehicle R/Y 2
A R/W O/R 3
Accessory
Speed B W/GN BK 4 Connector
Sensor C BK/GN
[4A]
A
[65B] Y/BK

BK/GN
Horn

BK
[122]

O/W

R/Y
LGN/Y
BK/W

BN

BK
BK

BE
BK
V
BK
BE/GN
BK/PK

B
BN/R

BK/O

BK/GN
BN
TN
W

O
V
[89B]
BK/W
BK/W

PK/Y

Ignition
R/W

GY/V

1 2 1 2 3 4 5 67 8
[87B]
Coil [83A] [83B] [89C] 1 2
[88B] [90B] A BC D To rear [GND1] [GND2] [62B]
Fuseblocks
BK/W

[64B]
LGN/Y

A BC D
lighting [7A] To Rear Ground
Power A A Y/GN 1 2 3 B A harness indicators Stud
BK/GN

W/BN
W/BK

BK/R
R/BK
Y/BK
W/V

O/W
See

R/Y
Ion sense B B GYBE See
O/W

GY
1 2 3 under ECM Spare P&A IGN Instruments
BE
W

[89D] Start Rly System Rly

Y

B A

O/W
R/Y
Coil rear C C Y/BE 1 2 Figure A-5 Figure A-4 electrical B A F E D C B A
Coil front D D BE/O [89A] 1 2 1 2 3 4 5 6 7 8 1 23 4 5 6 [21A] center E C
Spare Battery Ignition
Fuel Pump
O/W

A B
BK

Idle Speed [24B] To To K I H G L K J I H G

W
Y

left hand [22B] right hand [121B] A B

Data Control (GY) U T S R Q P Eng Ctl Cust Accy Accessories Lights
4 GY Throttle [87A] controls (BK) controls
Link 3 LGN/V Engine 1 2 3 4 [38A] Rear O M U S R P O M
Connector 2
Position See See Stop Lamp
BK/GN Temp
(GY) 1 Intake Air Sensor Sensor
Figure A-5 To Figure A-5 Switch
Temp [88A] headlamp [121]
Sensor [90A] See
[91A] Top View Top View
Figure A-5 Fuseblocks

Figure A-2. 2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Main Wiring Harness (1 of 3)
 Figure A-2. Figure A-2.
2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Main 2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Main
Wiring Harness (1 of 3) Wiring Harness (1 of 3)
et00063

Front Rear (CVO Only)

Domestic Only ACR ACR
Front Rear
O2 O2
Sensor Sensor
[203FA] 1 2 [203FA] 1 2

[203FB] 1 2 [203FB] 1 2

GY/BK

GY/BK
BE

BE

Y/GN

Y/GN
V/GY

V/GY
Ignition
[138A] 1 2 1 2 [137A] Switch
[138B] 1 2 1 2 [137B] IGN − I A R/BK
BATT − B B R
ACC − A C 40 Amp

BK/W

BK/W
PK/GN
PK/O
MAXIFUSE
[33A] [33B]

[5]
ECM [78A] [78B]
A B

Active Exhaust Feedback (HDI) 1 1 V/BE

R
System Relay 4 4 GN/O

Oxygen Sensor (A) (Except HDI) 8 8 PK/O

Jiffy Stand Sensor (HDI) 9 9 GN/BN O ENG CTL - 15A M
Ground 10 10 BK/GN LGN/R R/BK

Switch Power 13 13 W/BK

5V Sensor Power 14 14 R/W
ACR (CVO) 15 15 V/GY A ECM - 15A B
BE/GY R

Active Exhaust (HDI) 20 20 V/O

Active Intake Solenoid (HDI) 22 22 GY/O

Oxygen Sensor (B) (Except HDI) 23 23 PK/GN
Y/GN I 5 87
5V Sensor Ground 26 26 BK/W
Q 4 87A System
BE/GY C 3 30 Relay
Ground 28 28 BK/GN GN/O P 2 85
W/BK R 1 86

Battery 31 31 BE/GY [62B]

BK/GN
GN/BN
BK/GN
R/W

BK/GN
LGN/R
LGN/R
GY/O

[133B]

V/BE
1 2 3 GND1

V/O
1 2 3 Rear Ground
[133A] Stud Under
[178B] [179B] 4 3 2 1
2 1
HDI Only Electrical

BK
W
R
Center
2 1 [178A] [179A] 5 4 3 2 1
HDI Only
HDI Only
BK

BK

Active Intake Solenoid Exhaust Actuator

Jiffy Stand Sensor

Figure A-3. 2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Main Wiring Harness (2 of 3)
 Figure A-3. Figure A-3.
2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Main 2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Main
Wiring Harness (2 of 3) Wiring Harness (2 of 3)
et00064 Fuel Gauge Fuel Pump & Sender In Tank
Tachometer
[142A] [142B] Speedometer
Security [86]

Ground
Signal
Siren

Power
Power A A BN/GY
(Optional)

O/GY
Signal B B LGN/BN

Y/W
BK
BK
Ground C C BK
[141A] Ignition
AB C D
Switch

Y/W
Full: 39.5 / 27.5

BK
O
1/2 : 118.0 / 97.0 R/BK
Empty: 260.0 / 240.0 IGN − I A
[30A] [30B] [117A] 1 2 4 BATT − B B R
TSM/TSSM/HFSM [141B] P&A
(GY) A B C D ACC − A C R/GY 1
[117B] 1 2 4 Battery

R
Battery 1 1 BN/GY [160B]

Y/W
Trip Odometer Reset Switch

Trip Odometer Reset Switch

O/GY

BK/GN
BK
Ignition 2 2 [33A] [33B]

Y/W
GY

BK/GN
O
Serial Data 3 3 LGN/V
Neutral Switch 4 4 TN
Left Turn Feed 5 5 V [64B]
Right Turn Feed 6 6 BN

Serial Data

Accessory
Right Turn Switch Input 7 7 W/BN

Ground
Ignition

Battery
Left Turn Switch Input 8 8 W/V

Serial Data

Accessory

Fuel Level
Start Relay Control 9 9 TN/GN
F Spare - 15A E

Ground
Ignition

Battery
Clutch Switch 10 10 BK/R
Alarm Signal 11 11 LGN/BN BK BK [5]
Ground 12 12 BK/GN Trip Odometer [108A] 1 2 5 6 7 40 Amp
Reset Switch [39A] 1 2 5 6 7 8 9 11 [108B] 1 2 5 6 7 MAXIFUSE

O/W
O/W
BN/GY

BN/GY
BK/GN

Y/W

O
O

LGN/V
LGN/V

BK
BK

BK
ECM [154]
G IGN - 15A H
GY R/BK B A
Serial Data 5 5 LGN/V A INSTR - 15A B

R
O R/BK
[146A] 1 2 3 4 5
M Lights - 15A O
[146B] 1 2 3 4 5 BE R/BK
Ground 10 10 BK/GN
P ACCY - 15A R

O/W
BN/GY
O
LGN/V

BK
O/W R/GY
Switch Power 13 13 W/BK
I Battery - 15A J
BN/GY

G Fuel pump - 15A H

O/GN

R
Y/GN
Y/GN I 5 87 See Charging
BK/GN

28 28
Q 4 87A
System Circuit For Further
Ground BK/GN C 3 30 Connections
BK

P 2 85 Relay
Rear To Charging
W/BK R 1 86
Ground System
Stud Under Y/BK A A Horn
Electrical [122] K 5 87
BK B B T 4 87A Start
GND1 GND2 R/BK E 3 30 Relay
TN/GN S 2 85 (GY)
BK/R U 1 86
[78A] [78B]
[62B]
BK/GN
LGN/V
GY

BN 1 1 BN
GN/Y 2 2 GN/Y
[91A] 1 2 3 4 W 3 3 W
(GY) V 4 4 V To Customer
Data Link BK/GN 5 5 BK/GN Accessory
(See Figure A-2) O 6 6 O Connector
TN 7 7 TN
(See Figure A-2)

O/W
R/Y
[21A] [21B]
GN/Y

BK B A
TN

[121B]

BK/GN

W/BN
B A

W/BK
BK/R

BK/R
Y/BK

O/W
O/W

O/W

O/W
W/V

R/Y

R/Y
B A [121B]

BN

BK
BK

BK
GN/Y

BE

GY
BK
BE
W

V
Y
Y
BK

TN
BK

BN
BK
W

O
V

1 2 3 4 5 6 7 8 1 2 3 4 1 2 3 4 5 6 7 8 1 2 3 4 5 6
Oil To To To Rear To Rear
Pressure Neutral Ground Left Hand Headlamps Lighting Right Hand Stop Lamp
Sending Switch Left Hi Neutral Oil Right Controls [38A] [7A] Controls Switch
Unit [131] Indicator Beam [157] [158] Indicator [24B] (See Figure A-5) (See Figure A-5) [22B]
[120] [155] [156] [159] (See Figure A-5) (See Figure A-5)

Figure A-4. 2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Main Wiring Harness (3 of 3)
 Figure A-4. Figure A-4.
2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Main 2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Main
Wiring Harness (3 of 3) Wiring Harness (3 of 3)
et00065

Front Lighting
BK
Front
Right BN
BE
Turn Position Lamp
[31R] (HDI Only)
[29]
O/W
BK
Rear Lighting Harness
High [38B]
W
Headlamp Y O/W 1 To Main
W 2
Low Y 3 Harness
BK BK 4 [38A] 7 6 5 4 3 2 1
[38]
[7B]

O/W
R/Y

BN
[31RB]

BE

BK

V
Front DOM Only
Left BK 1
Turn

BE
BN 2
BE 3 To Main
Harness

BK
V
[31L] BE 3
V 2 [31L&R]
BK 1

[31LB]

[94B]
O/W 1
BN 2
BE 3
R/Y 4
V 5
Right Hand BK 6

Controls

Right Turn Switch

Engine Stop Switch
Start Switch Rear Lighting
Front Stop Lamp Switch
Right Rear
BN Directional
BK
Lamp
W/BN
W/BK
BK/R

To Rear Lighting Harness Brake

O/W
R/Y
GY

[94B] Light
6 5 4 3 2 1 [22A] 6 5 4 3 2 1 BK
(BK) R/Y
See Sheet 1 or 3 [18B] [94A] BE
BN 1 1 BE
[24A] 1 2 3 4 5 6 7 8 2 [18A]
BK 2 Tail
(GY)
O/W

W/V

BK/R
W

Y/BK
BE
Y

BK/GN HDI Only

Clutch Switch [19B]
V 1 1 Tail
2 [19A] Taillamp
BK 2 DOM Only
Horn Switch 4 4
1 3 3
Headlamp Hi/Lo Switch 2 2 2
3 1 1
Left Turn Switch
[45A] [93A] [93B] Left Rear
V Directional
BK Lamp

Left Hand
Controls

Figure A-5. 2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Lighting and Controls
 Figure A-5. Figure A-5.
2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Lighting 2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Lighting
and Controls and Controls
et00066

Charging Circuit Security System

Stator
40 Amp
MAXIFUSE

BK

BK

BK
Red [5]
BK [30A] [30B]
Band
Turn Signal &
Battery Security Battery 1 1 BN/GY
Ignition 2 2 GY
BK Module Serial Data 3 3 LGN/V
TSM/HFSM Neutral Switch 4 4 TN
Left Turn Feed 5 5 V
Right Turn Feed 6 6 BN See
Right Turn Switch Input 7 7 W/BN Figure A-2

BK
BK
BK
R

R
Left Turn Switch Input 8 8 W/V
Start Relay Control 9 9 TN/GN or
[46B] Clutch Switch 10 10 BK/R Figure A-4
1 2 3 Alarm Signal 11 11 LGN/BN
Ground 12 12 BK/GN

[BATT] 1 2 3
[46A] Receive Antenna 1 1 Y/BK

BK
Transmit Antenna A 2 2 O/Y

BK
BK
BK
Starter Solenoid Transmit Antenna B 3 3 BK
Connection
[208A] [208B]
[128A]

Starter [209B] [209A] Hands Free Antenna

O/Y 1 1 Antenna ’A’

BK 2 2 Antenna ’B’

BK
BK
BK
Regulator

BK
BK
[77B] [77A]

R 1 1 BK
BK 2 2 BK

See Figure A-2

For Further R
Connections

[GND3]
Front Ground
Stud Under
Electrical
Center

Figure A-6. 2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Charging System, Security System, and Fuse/Relay Blocks
 Figure A-6. Figure A-6.
2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Charging 2008 FXDSE2 DOMESTIC and INTERNATIONAL Models, Charging
System, Security System, and Fuse/Relay Blocks System, Security System, and Fuse/Relay Blocks
SUBJECT............................................................................................................................PAGE NO.
B.1 GLOSSARY..............................................................................................................................B-1

APPENDIX B GLOSSARY
NOTES
GLOSSARY B.1
ACRONYMS AND ABBREVIATIONS
Table B-1. Acronyms and Abbreviations

ACRONYM OR ABBREVIATION DESCRIPTION

A Amperes
AC Alternating Current
ACC Accessory
ACR Automatic Compression Release
AGM Absorbed Glass Mat (battery)
AMP Ampere
AWG American Wire Gauge
B+ Battery Voltage
BAS Bank Angle Sensor
BTDC Before Top Dead Center
C Celsius (Centigrade)
CA California
CAL Calibration
CC Cubic Centimeters
CCA Cold Cranking Amps
CKP Crankshaft Position
cm Centimeter
DC Direct Current
DLC Data Link Connector
DOM Domestic
DTC Diagnostic Trouble Code
DVOM Digital Volt Ohm Meter
ECM Electronic Control Module
ECT Engine Coolant Temperature
EEPROM Electrically Erasable Programmable Read Only Memory
EFI Electronic Fuel Injection
ET Engine Temperature
EVAP Evaporative Emissions Control System
F Fahrenheit
ft-lbs Foot-Pounds
fl oz. Fluid Ounce
g Gram
GAL Gallon
GAWR Gross Axle Weight Rating
GND Ground (electrical)
GVWR Gross Vehicle Weight Rating
HDI Harley-Davidson International
H-DSSS Harley-Davidson Smart Security System
HFSM Hands Free Security Module
Hg Mercury
IAC Idle Air Control

2008 FXDSE2 Service: Appendix B Glossary B-1

 Table B-1. Acronyms and Abbreviations

ACRONYM OR ABBREVIATION DESCRIPTION

IAT Intake Air Temperature
ID Inside Diameter
IGN Ignition Light/Key Switch
IM Instrument Module
In. Inch
INJ PW Injector Pulse Width
in-lbs Inch-Pounds
Kg Kilogram
Km Kilometer
kPa Kilopascal
km/hr Kilometers Per Hour
L Liter
LCD Liquid Crystal Display
LED Light Emitting Diode
mA Milliampere
MAP Manifold Absolute Pressure
ml milliliter
mm millimeter
MPH Miles Per Hour
ms millisecond
Nm Newton-Meter
N/A Not Applicable
no. Number
O2 Oxygen
OD Outside Diameter
OEM Original Equipment Manufacturer
oz Ounce
P&A Parts and Accessories
PN Part Number
PSI Pounds per Square Inch
RES Reserve
RPM Revolutions Per Minute
SCFH Cubic Feet per Hour at Standard Conditions
TCA Throttle Control Actuator
TDC Top Dead Center
TGS Twist Grip Sensor
TP Throttle Position
TMAP Intake Air Temperature/Manifold Absolute Pressure
TSM Turn Signal Module
TSSM Turn Signal/Security Module
V Volt
VAC Volts of Alternating Current
VDC Volts of Direct Current

B-2 2008 FXDSE2 Service: Appendix B Glossary

 Table B-1. Acronyms and Abbreviations

ACRONYM OR ABBREVIATION DESCRIPTION

VIN Vehicle Identification Number
VSS Vehicle Speed Sensor

2008 FXDSE2 Service: Appendix B Glossary B-3

NOTES

B-4 2008 FXDSE2 Service: Appendix B Glossary

 Tools Used in This Manual
PART NUMBER TOOL NAME NOTES
B-42571 FORK SEAL BUSHING TOOL 2.7 FRONT FORK, Assembly
HD-33223-1 CYLINDER COMPRESSION GAUGE 8.6 AUTOMATIC COMPRESSION RELEASE, Compres-
sion Test
HD-33416 UNIVERSAL DRIVER 2.6 STEERING HEAD, Disassembly
HD-33446-B CYLINDER TORQUE PLATES 3.5 BORING AND HONING CYLINDERS, Inspection
HD-34723 VALVE GUIDE HONE 3.3 CYLINDER HEAD, Inspection
HD-34736-B VALVE SPRING COMPRESSOR 3.3 CYLINDER HEAD, Disassembly
HD-34736-B VALVE SPRING COMPRESSOR 3.3 CYLINDER HEAD, Assembly
HD-34740 VALVE GUIDE AND VALVE GUIDE SEAL 3.3 CYLINDER HEAD, Replacing Valve Guides
HANDLE
HD-34740 VALVE GUIDE AND VALVE GUIDE SEAL 3.3 CYLINDER HEAD, Replacing Valve Guides
HANDLE
HD-34740 VALVE GUIDE AND VALVE GUIDE SEAL 3.3 CYLINDER HEAD, Assembly
HANDLE
HD-34751 VALVE GUIDE CLEANING BRUSH 3.3 CYLINDER HEAD, Inspection
HD-34751 VALVE GUIDE CLEANING BRUSH 3.3 CYLINDER HEAD, Replacing Valve Guides
HD-34751 VALVE GUIDE CLEANING BRUSH 3.3 CYLINDER HEAD, Assembly
HD-39301-A STEERING HEAD BEARING RACE 2.6 STEERING HEAD, Disassembly
REMOVER
HD-39302 STEERING HEAD BEARING RACE 2.6 STEERING HEAD, Assembly
INSTALLER
HD-39361-B SPROCKET SHAFT OIL SEAL INSTALLER 3.6 CRANKCASE ASSEMBLY, Assembly

TOOLS
HD-39782-A CYLINDER HEAD SUPPORT STAND 3.3 CYLINDER HEAD, Replacing Valve Guides
HD-39782-A CYLINDER HEAD SUPPORT STAND 3.3 CYLINDER HEAD, Replacing Valve Guides
HD-39786 CYLINDER HEAD HOLDING FIXTURE 3.3 CYLINDER HEAD, Disassembly
HD-39786 CYLINDER HEAD HOLDING FIXTURE 3.3 CYLINDER HEAD, Replacing Valve Guides
HD-39786 CYLINDER HEAD HOLDING FIXTURE 3.3 CYLINDER HEAD, Assembly
HD-39847 RATCHETING TAP HANDLE 3.3 CYLINDER HEAD, Replacing Valve Guides
HD-39847 RATCHETING TAP HANDLE 3.3 CYLINDER HEAD, Replacing Valve Guides
HD-39932 VALVE GUIDE REAMER 3.3 CYLINDER HEAD, Replacing Valve Guides
HD-39964 REAMER LUBRICANT 3.3 CYLINDER HEAD, Replacing Valve Guides
HD-39964 REAMER LUBRICANT 3.3 CYLINDER HEAD, Replacing Valve Guides
HD-41177 FORK TUBE HOLDER 2.7 FRONT FORK, Disassembly
HD-41404-B TEST CONNECTOR KIT 8.6 AUTOMATIC COMPRESSION RELEASE, Dia-
gnostics
HD-41494 FLSTS/C HUBCAP REMOVAL TOOL 2.7 FRONT FORK, Disassembly
HD-42326-A CRANKSHAFT GUIDE 3.6 CRANKCASE ASSEMBLY, Assembly
HD-45966 FORK SPRING COMPRESSING TOOL 2.7 FRONT FORK, Disassembly
HD-48287 TRIPLE TREE WEDGES 2.7 FRONT FORK, Removal
HD-48287 TRIPLE TREE WEDGES 2.7 FRONT FORK, Installation
HD-48498 ACR SOLENOID SOCKET 3.3 CYLINDER HEAD, Disassembly
HD-48498 ACR SOLENOID SOCKET 8.6 AUTOMATIC COMPRESSION RELEASE, Removal
HD-48627 CYLINDER TORQUE PLATES 3.3 CYLINDER HEAD, Inspection
HD-48628 VALVE GUIDE INSTALLER 3.3 CYLINDER HEAD, Replacing Valve Guides
HD-48637 BREAK-OUT BOX 8.6 AUTOMATIC COMPRESSION RELEASE, Dia-
gnostics
HD-48644 VALVE GUIDE SEAL INSTALLER 3.3 CYLINDER HEAD, Assembly
HD-59000B FRONT FORK OIL LEVEL GAUGE 2.7 FRONT FORK, Assembly

I
 Tools Used in This Manual
PART NUMBER TOOL NAME NOTES
HD-96796-47 VALVE SPRING TESTER 3.3 CYLINDER HEAD, Inspection
HD-97225-55C SPROCKET SHAFT BEARING INSTALLER 3.6 CRANKCASE ASSEMBLY, Assembly
HD-99857-97 SPECIAL PURPOSE GREASE 2.6 STEERING HEAD, Assembly
TA360 SNAP-ON TORQUE ANGLE GAUGE 3.5 BORING AND HONING CYLINDERS, Inspection

II TOOLS
 2008 FXDSE2 Model Service Manual Supplement
FASTENER TORQUE VALUE NOTES
Air cleaner cover screw 60-90 in-lbs 6.8-10.2 Nm 1.3 AIR FILTER (DOM), Installation
Air cleaner cover screw 36-60 in-lbs 4.1-6.8 Nm 1.4 AIR FILTER (HDI), Installation
Air cleaner medallion screw 20-30 in-lbs 2.3-3.9 Nm 1.3 AIR FILTER (DOM), Installation
Air filter bracket screws 40-60 in-lbs 4.5-6.8 Nm 1.4 AIR FILTER (HDI), Installation
Automatic compression release (ACR) 11-15 ft-lbs 14.9-20.3 Nm 3.3 CYLINDER HEAD, Assembly / Apply three
equally spaced dots of LOCTITE 246 THREAD-
LOCKER MEDIUM STRENGTH/HIGH TEMPER-
ATURE around lower third of threads
Automatic compression release (ACR) 11-15 ft-lbs 14.9-20.3 Nm 8.6 AUTOMATIC COMPRESSION
RELEASE, Installation / Apply three equally spaced
dots of LOCTITE 246 THREADLOCKER MEDIUM
STRENGTH/HIGH TEMPERATURE around lower
third of threads
Axle set screws 50-55 ft-lbs 68-75 Nm 2.5 FRONT WHEEL, Installation
Axle set screws 50-55 ft-lbs 68-75 Nm 2.5 FRONT WHEEL, Installation
Belt guard mounting screws 10-15 ft-lbs 13.6-20.3 Nm 2.16 BELT GUARD AND DEBRIS
DEFLECTOR, Installation
Belt guard mounting screws 10-15 ft-lbs 13.6-20.3 Nm 2.16 BELT GUARD AND DEBRIS
DEFLECTOR, Installation
Brake control lever clamp fasteners 60-80 in-lbs 6.8-9 Nm 2.19 HANDGRIPS AND HAND CONTROLS, Clutch
Handgrip and Controls

TORQUE VALUES
Brake disc screws 16-24 ft-lbs 21.7-32.5 Nm 2.5 FRONT WHEEL, Assembly
Brake pedal pad screw 69-84 in-lbs 7.8-9.5 Nm 2.18 FOOTPEGS AND FORWARD CON-
TROLS, Installation
Caliper mounting bolts, front 28-38 ft-lbs 38-52 Nm 2.5 FRONT WHEEL, Installation
Caliper mounting bolts, front 28-38 ft-lbs 38-52 Nm 2.5 FRONT WHEEL, Installation
Cartridge retaining screw 111 ft-lbs 150 Nm 2.7 FRONT FORK, Assembly
Clutch actuator bleeder screw 12-15 in-lbs 1.4-1.7 Nm 2.23 CLUTCH FLUID LINE, Replacement
Clutch actuator bleeder valve 12-15 in-lbs 1.4-1.7 Nm 1.6 BLEEDING CLUTCH FLUID LINE, Return
Motorcycle to Service
Clutch actuator bleeder valve 12-15 in-lbs 1.4-1.7 Nm 2.21 CLUTCH MASTER CYLINDER AND
RESERVOIR, Installation
Clutch fluid line flare nut 72-120 in-lbs 8.1-13.6 Nm 1.6 BLEEDING CLUTCH FLUID LINE, Draining
and Filling
Clutch fluid line flare nut 72-120 in-lbs 8.1-13.6 Nm 1.6 BLEEDING CLUTCH FLUID LINE, Return
Motorcycle to Service
Clutch fluid line flare nut 72-120 in-lbs 8.1-13.6 Nm 2.23 CLUTCH FLUID LINE, Replacement
Clutch fluid line flare nut 72-120 in-lbs 8.1-13.6 Nm 7.2 CLUTCH RELEASE COVER, Installation
Clutch inspection cover 84-108 in-lbs 9.5-12.2 Nm 6.1 CLUTCH RELEASE BEARING AND
PUSHROD, Installation
Clutch lever clamp 60-80 in-lbs 6.8-9.0 Nm 2.19 HANDGRIPS AND HAND CON-
TROLS, Throttle and Brake Controls
Clutch master cylinder banjo bolt 21-25 ft-lbs 28.5-33.9 Nm 1.6 BLEEDING CLUTCH FLUID LINE, Return
Motorcycle to Service
Clutch master cylinder banjo bolt 21-25 ft-lbs 28.5-33.9 Nm 2.21 CLUTCH MASTER CYLINDER AND
RESERVOIR, Installation
Clutch master cylinder banjo bolt 21-25 ft-lbs 28.5-33.9 Nm 2.23 CLUTCH FLUID LINE, Replacement
Clutch release cover screw 120-144 in-lbs 13.5-16.3 Nm 7.2 CLUTCH RELEASE COVER, Installation
Clutch reservoir cover screws 6-8 in-lbs 0.7-0.9 Nm 1.6 BLEEDING CLUTCH FLUID LINE, Return
Motorcycle to Service

III
 2008 FXDSE2 Model Service Manual Supplement
FASTENER TORQUE VALUE NOTES
Clutch reservoir cover screws 6-8 in-lbs 0.7-0.9 Nm 2.21 CLUTCH MASTER CYLINDER AND
RESERVOIR, Installation
Clutch reservoir cover screws 6-8 in-lbs 0.7-0.9 Nm 2.23 CLUTCH FLUID LINE, Replacement
Crankcase bolts, final 15-19 ft-lbs 20.3-25.8 Nm 3.6 CRANKCASE ASSEMBLY, Assembly
Crankcase bolts, initial 10 ft-lbs 13.6 Nm 3.6 CRANKCASE ASSEMBLY, Assembly
Cylinder bolts, final torque 15-17 ft-lbs 20.3-23.1 Nm 3.5 BORING AND HONING CYLINDERS, Inspec-
tion
Cylinder bolts, initial torque 120-144 in-lbs 13.6-16.3 Nm 3.5 BORING AND HONING CYLINDERS, Inspec-
tion
Debris deflector self tapping screws 40-60 in-lbs 4.5-6.8 Nm 2.16 BELT GUARD AND DEBRIS
DEFLECTOR, Installation
Drive sprocket mounting screws 55-65 ft-lbs 74.6-88.1 Nm 2.13 REAR WHEEL, Assembly
Filler plug and dipstick 25-75 in-lbs 2.8-8.5 Nm 7.2 CLUTCH RELEASE COVER, Fill and Bleed
Filter element screws 40-60 in-lbs 4.5-6.8 Nm 1.3 AIR FILTER (DOM), Installation
Footpeg/pedal bracket fastener 25-35 ft-lbs 33.9-47.5 Nm 2.18 FOOTPEGS AND FORWARD CON-
TROLS, Installation / LOCTITE 243
Footpeg/pedal bracket fastener 25-35 ft-lbs 33.9-47.5 Nm 2.18 FOOTPEGS AND FORWARD CON-
TROLS, Installation / LOCTITE 243
Footpeg pad mounting screw 15-20 ft-lbs 20.3-27.1 Nm 2.18 FOOTPEGS AND FORWARD CON-
TROLS, Installation / LOCTITE 243
Foot shift lever fastener 18-22 ft-lbs 24.4-29.8 Nm 2.18 FOOTPEGS AND FORWARD CON-
TROLS, Installation
Fork stem nut 35-40 ft-lbs 47.5-54.2 Nm 2.6 STEERING HEAD, Installation
Forward shift linkage fastener 13-16 ft-lbs 17.6-21.7 Nm 2.18 FOOTPEGS AND FORWARD CON-
TROLS, Installation
Front axle 65-70 ft-lbs 88-95 Nm 2.5 FRONT WHEEL, Installation
Front fender mounting screws 15-21 ft-lbs 20.3-28.5 Nm 2.4 FRONT FENDER, Installation
Front fork pinch bolts 18-22 ft-lbs 24.4-29.8 Nm 2.7 FRONT FORK, Installation
Front hub cover screws 16-24 ft-lbs 21.7-32.5 Nm 2.5 FRONT WHEEL, Assembly
Front master cylinder clamp fastener 72-84 in-lbs 8.1-9.5 Nm 2.21 CLUTCH MASTER CYLINDER AND
RESERVOIR, Installation
Gasket cover screws 6-8 in-lbs 0.7-0.9 Nm 1.5 HYDRAULIC CLUTCH FLUID, Clutch Fluid
Level
Handlebar switch housing fastener 35-45 in-lbs 4.0-5.1 Nm 2.19 HANDGRIPS AND HAND CON-
TROLS, Throttle and Brake Controls
Handlebar switch housing fastener 35-45 in-lbs 4.0-5.1 Nm 2.19 HANDGRIPS AND HAND CONTROLS, Clutch
Handgrip and Controls
Handlebar switch housing fastener 35-45 in-lbs 4.0-5.1 Nm 2.21 CLUTCH MASTER CYLINDER AND
RESERVOIR, Installation
Handlebar switch housing fastener 35-45 in-lbs 4.0-5.1 Nm 8.4 FRONT TURN SIGNALS, Installation
Insert screws 27-32 in-lbs 3.0-3.6 Nm 1.4 AIR FILTER (HDI), Installation
License plate bracket screws 60-90 in-lbs 6.8-10.1 Nm 2.10 LICENSE PLATE BRACKET, Installation:
Domestic
License plate bracket screws 60-90 in-lbs 6.8-10.1 Nm 2.10 LICENSE PLATE BRACKET, Installation: HDI
License plate bracket screws 60-90 in-lbs 6.8-10.1 Nm 2.10 LICENSE PLATE BRACKET, Installation: HDI
Lower handlebar clamp fastener 30-40 ft-lbs 40.7-54.2 Nm 2.20 HANDLEBARS, Installation

IV TORQUE VALUES
 2008 FXDSE2 Model Service Manual Supplement
FASTENER TORQUE VALUE NOTES
Lower shock mounting bolts 30-40 ft-lbs 40.7-54.2 Nm 2.13 REAR WHEEL, Installation
Lower spoiler screws 72 in-lbs 8 Nm 2.15 FRONT SPOILER, Installation
Passenger footpeg bracket fastener 25-35 ft-lbs 33.9-47.5 Nm 2.18 FOOTPEGS AND FORWARD CON-
TROLS, Installation / LOCTITE 243
Rear axle cap set screws 60-84 in-lbs 6.8-9.5 Nm 2.8 REAR AXLE COVERS, Installation
Rear axle nut 95-105 ft-lbs 128.8-142.4 Nm 2.13 REAR WHEEL, Installation
Rear brake disc mounting screws 30-45 ft-lbs 40.7-61.0 Nm 2.13 REAR WHEEL, Assembly
Rear turn signal fastener 12-16 ft-lbs 16.3-21.7 Nm 8.5 REAR TURN SIGNALS, Installation
Rear view mirror acorn nut 60-96 in-lbs 6.8-10.8 Nm 2.19 HANDGRIPS AND HAND CON-
TROLS, Throttle and Brake Controls
Rear view mirror acorn nut 60-96 in-lbs 6.8-10.8 Nm 2.19 HANDGRIPS AND HAND CONTROLS, Clutch
Handgrip and Controls
Rear view mirror acorn nut 60-96 in-lbs 6.8-10.8 Nm 8.4 FRONT TURN SIGNALS, Installation
Right footpeg clevis fastener 32-37 ft-lbs 43.4-50.2 Nm 2.18 FOOTPEGS AND FORWARD CON-
TROLS, Installation / LOCTITE 243
Seat mounting screw 20-40 in-lbs 2.3-4.5 Nm 2.14 SEAT, Installation
Seat strap screws 60-90 in-lbs 6.8-10.2 Nm 2.14 SEAT, Installation
Shifter peg fastener 14-16 ft-lbs 19.0-21.7 Nm 2.18 FOOTPEGS AND FORWARD CON-
TROLS, Installation / LOCTITE 243
Shock mounting fastener, lower 30-40 ft-lbs 40.7-54.2 Nm 2.12 REAR SHOCKS, Installation / Loctite
Threadlocker 343 (blue)
Shock mounting fastener, upper 30-40 ft-lbs 40.7-54.2 Nm 2.12 REAR SHOCKS, Installation / Loctite
Threadlocker 343 (blue)
Shock mounting stud nut, inner 70-85 ft-lbs 101.7-115.2 Nm 2.12 REAR SHOCKS, Installation
Steering nut cover set screw 14-16 in-lbs 1.6-1.8 Nm 2.6 STEERING HEAD, Installation
Steering nut cover set screw 14-16 in-lbs 1.6-1.8 Nm 2.17 FORK TUBE AND STEERING NUT
COVERS, Installation
Tachometer screws 18-26 in-lbs 2.0-2.9 Nm 8.3 TACHOMETER, Installation
Transmission drain plug 14-21 ft-lbs 19.0-28.5 Nm 7.2 CLUTCH RELEASE COVER, Fill and Bleed
Turn signal set screw 50-60 in-lbs 5.7-6.8 Nm 8.4 FRONT TURN SIGNALS, Installation
Upper handlebar clamp fastener 12-16 ft-lbs 16.3-21.7 Nm 2.20 HANDLEBARS, Installation
Upper handlebar clamp fastener 12-16 ft-lbs 16.3-21.7 Nm 2.20 HANDLEBARS, Installation
Upper shock mounting screws 30-40 ft-lbs 40.7-54.2 Nm 2.13 REAR WHEEL, Installation
Voltage regulator mounting screws 60-80 in-lbs 6.8-9.0 Nm 2.15 FRONT SPOILER, Installation

TORQUE VALUES V
NOTES

VI TORQUE VALUES
 A E
Air Filter: Domestic Engine Lubrication
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
F
Air Filter: HDI Footpegs
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Automatic Compression Release (ACR) Foreword
Compression Test. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Important General Information. . . . . . . . . . . . . . . . . . . i-I
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Fork Tube/Steering Nut Covers
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Front Axle Cover
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
B Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Belt Guard/Debris Deflector Front Fender
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Bleeding Clutch Fluid Line Front Fork
Bleed Fluid Line and Actuator. . . . . . . . . . . . . . . . . . 1-8 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Bleed Master Cylinder. . . . . . . . . . . . . . . . . . . . . . . . 1-8 Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 2-13
Draining and Filling. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Return Motorcycle to Service. . . . . . . . . . . . . . . . . . . 1-8 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Boring and Honing Cylinders Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Cylinder Bore Finished Size. . . . . . . . . . . . . . . . . . . 3-18 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Piston Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Front Spoiler
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
C Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Clutch Fluid Line Front Turn Signals
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45 Bulb Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Clutch Hand Lever Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

INDEX
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 Front Wheel
Clutch Master Cylinder/Reservoir Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . 2-6
Clutch Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 Fuel Gauge
Clutch Release Bearing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Clutch Release Bearing and Push Rod Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 G
Clutch Release Cover Glossary
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Acronyms and Abbreviations. . . . . . . . . . . . . . . . . . . B-1
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Crankcase Assembly
H
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Handgrips and Hand Controls
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Clutch Handgrip and Controls. . . . . . . . . . . . . . . . . 2-35
Cylinder General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Throttle and Brake Controls. . . . . . . . . . . . . . . . . . . 2-33
Cylinder Heads Handlebar
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Determining Service. . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Headlamp Alignment
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Hydraulic Clutch Fluid
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Clutch Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 L
Replacing Valve Guides. . . . . . . . . . . . . . . . . . . . . . . 3-9
License Plate Bracket
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Installation: Domestic. . . . . . . . . . . . . . . . . . . . . . . . 2-18

VII
 Installation: HDI. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Removal: Domestic. . . . . . . . . . . . . . . . . . . . . . . . . 2-18
T
Removal: HDI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Tachometer
Loctite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-II Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
P Trademarks
Pedal brackets Harley-Davidson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-II
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Referenced Products. . . . . . . . . . . . . . . . . . . . . . . . . . i-II
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Pistons
V
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Vehicle Identification Number (V.I.N.). . . . . . . . . . . . . . . . 2-2
Measuring Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 W
R Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Rear Axle Covers
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Rear Fender
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Rear Fork Pivot Covers
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Rear Shock Absorbers
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Rear Shocks
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Preload Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Rear Turn Signals
Bulb Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Rear Wheel
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 2-23
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
S
Seat
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Secondary Clutch Actuator
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Service Bulletins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-I
Service Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-I
Specifications
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Engine Tolerances. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
SPX Kent-Moore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-II
Steering Head
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . 2-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

VIII INDEX
INSIDE BACK COVER GOES HERE
OUTSIDE BACK COVER GOES HERE