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Harley Davidson 2008 FLHTCUSE3 Model. Service Manual Supplement - page 7

RADIO SOFTWARE UPDATE

8.12

1. See Figure 8-40. In the Diag Test display, press the

GENERAL

Update (1) or number 5 soft key to open the Update Radio

The Advanced Audio receiver software will need to be updated

display.

after replacing the GPS navigation module or the receiver

2. To update the radio, follow the text prompt "Insert CD" (2),

module. The software will also need to be updated after receipt

and insert the replacement CD. The CD will automatically

of software revisions.

initiate the download. Updating the radio will take up to 7

OPENING DIAG TEST DISPLAY

minutes.

a. The text message, "Verifying DSP Image" (3), is dis-

NOTE

played as the percentage of download is updated.

The receiver should be in a radio (FM) mode prior to the

update.

b. An automatic power down and up, will proceed the

text message "SUCCESSFUL" (4).

1. Turn the ignition/headlamp key switch to OFF.

c. Sequentially, "ICB COMM" (5), "Get Loader" (6), and

2. Simultaneously press and hold any two soft keys (1, 2, 3,

"Flashing Image" (7), text messages will be displayed

4, 5, or 6).

as the percentage of download is updated.

3. Turn the ignition/headlamp key switch to ACCESS.

d. The receiver will again automatically power down and

4. See Figure 8-39. Continue to hold the two soft keys while

up.

the Harley-Davidson Bar and Shield logo (1) is displayed.

NOTE

The display will cycle to Diag Test (2).

Should the CD not eject by pressing the eject button, turn the

IDENTIFYING VERSION NUMBER

radio OFF. Switch the ignition/headlamp key switch to OFF

and remove the maxi-fuse. Wait 5 minutes, install the maxi-

1. See Figure 8-39. In the Diag Test display, press the Soft-

fuse, turn the ignition knob to ACCESS and press the radio

ware or number 4 soft key (3) to display the software ver-

ON pushbutton. Wait for the Bar and Shield logo screen to

sion number.

close before attempting to eject the CD.

2. If the software version number (4) is lower than a disc

3. After the final automatic power down and up, press the

supplied with a replacement module or a disc received as

eject button to eject the CD. Remove the CD and close

a software update, update the software. See 8.12 RADIO

the CD door.

SOFTWARE UPDATE, Updating Receiver Software.

4. Proceed to 8.12 RADIO SOFTWARE UPDATE, Confirming

Version Number.

ed01611

1

advanced audio by

harman/kardon

2

3

4

7.4.0

7.4.0

1. Bar and Shield logo

2. Diag Test display

3. Software soft key 4

4. Software version number

Figure 8-39. Identify Software Version Number

UPDATING RECEIVER SOFTWARE

NOTE

Eject any CD. Leave the CD door open while the replacement

CD is in the reader.

2008 FLHTCUSE3 Service: Electrical 8-29

CONFIRMING VERSION NUMBER

ed01612

1. See Figure 8-41. In the Diag Test display, press the

1

"Software" (1) or number 4 soft key to display the software

version number (2).

2. Compare the displayed software version number to that

on the update CD. If the version number is different from

2

that supplied, start over at

8.12 RADIO SOFTWARE

UPDATE, Updating Receiver Software.

3. If both version numbers in the display match the update

CD, press the "TestExit" (3) or number 6 soft key. The

3

display will open to the current receiver mode.

ed01613

4

1

5

3

6

2

7

1. Software soft key 4

2. Software version number

1. Update soft key 5

3. TestExit soft key 6

2. Insert CD

3. Verifying DSP Image

Figure 8-41. Confirm Update Version Number

4. SUCCESSFUL

5. ICB COMM

6. Get Loader text

7. Flashing Image

Figure 8-40. Update Receiver Software

8-30 2008 FLHTCUSE3 Service: Electrical

ADVANCED AUDIO RADIO

8.13

REMOVING ADVANCED AUDIO

ed01614

NOTE

AM/FM/WB radio, CB transceiver, XM Satellite Radio module,

6

and the GPS Navigation module may all be removed as a unit.

2

1

1.

See Figure 8-42. Separate antenna connectors:

5

a. Depress latch and separate XM radio antenna cable

connector [185] (1). See 8.10 XM SATELLITE RADIO.

b. Depress latch and separate GPS Navigation antenna

connector [193] (3). See 8.11 GPS NAVIGATION.

c. Unscrew and remove CB radio antenna cable con-

nector [50] (2). See the ADVANCED AUDIO SYSTEM

in the Touring Models Service Manual.

4

3

7

8

d. Remove AM/FM/WB receiver antenna connector [51]

(4) by grasping ribbed plug and pulling straight out

1. XM antenna connector [185]

from radio. See the ADVANCED AUDIO SYSTEM in

2. CB antenna connector [50]

the Touring Models Service Manual.

3. GPS Navigation antenna connector [193]

4. AM/FM/WB antenna connector [51]

2.

Separate module connectors:

5. XM module 12-pin connector [185]

6. CB transceiver 12-pin connector [184]

a. Depress latches on either side of XM module 12-pin

7. AM/FM/WB radio 23-pin connector [27]

connector [185] (5) and separate connector.

8. AM/FM/WB radio 35-pin connector [28]

b. Depress latches on either side of CB transceiver 12-

Figure 8-42. Advanced Audio Connectors

pin connector [184] (6) and separate connector.

c. Depress latches on either side of AM/FM/WB radio

23-pin connector [27] (7) and 35-pin connector [28]

(8) and unplug connectors from receiver.

ed01615

3.

Locate cable strap with rosebud mount securing ignition

switch harness to bottom of radio chassis. Pull cable strap

mount from hole in chassis.

4.

See Figure 8-43. Unscrew and remove four screws with

captive washers (1), two on either side of radio chassis.

NOTE

1

Both screws on each side may be reached through tool access

slot (2).

5. Remove Advanced Audio Sound System assembly by

pulling straight forward and lifting up slightly after radio

bezel clears fairing.

6. If necessary, remove the CB, XM satellite, and GPS

modules.

2

1. Screw with captive washer (4)

2. Tool access slot

Figure 8-43. Sound System Mounting

INSTALLING ADVANCED AUDIO

1. If removed, install the CB, XM satellite, and GPS modules.

2008 FLHTCUSE3 Service: Electrical 8-31

ADVANCED AUDIO AMPLIFIER

8.14

GENERAL

ed01617

The Advanced Audio High-Output Amplifier is located under

the Tour-Pak and can be replaced without removing the Tour-

Pak from the vehicle.

REMOVAL

1. Turn ignition switch OFF.

NOTE

See Figure 8-45. Under the connector, use a flat blade screw-

driver to pull the latch down to release the connector [149].

2. See Figure 8-44. Unplug wiring harness connector [149]

from amplifier.

3. Open Tour-Pak and remove liner.

NOTES

•

Do not remove four bolts from the Tour-Pak until it is called

Figure 8-45. Connector [149] Release Latch

out in a numbered procedure.

•

Do not remove or loosen the rearmost locknut. This will

hold the Tour-Pak in place while replacing the amplifier.

ed01618

4. To protect finish, place a clean shop cloth between the

2

3

fender and amplifier.

NOTE

See Figure 8-46. Amplifier has two closed holes (3) in mounting

flange toward front of vehicle, and two open slots (2) toward

rear.

2

5. See Figure 8-48. Remove two nylon cap locknuts (1) and

flat washers (2) from two forward Tour-Pak mounting

positions.

6. Loosen, but do not remove, nylon locknuts from two rear

mounting locations. Do not remove center-rear locknut

1

3

(5).

7. Push two forward-most mounting bolts (7) up to clear the

1. Connector [149] pin housing

front amplifier mounting holes.

2. Rear mounting slots

3. Front mounting holes

8. Carefully slide amplifier toward front of motorcycle enough

to clear two rear mounting bolts and license plate bracket.

Figure 8-46. Amplifier

Slide amplifier out right side of motorcycle.

INSTALLATION

ed01616

1. See Figure 8-47. Engage slots in rear of amplifier mounting

flange with rear mounting bolts (1), with amplifier flange

(5) between spacer (4) and license plate bracket (6).

2. See Figure 8-48. Place spacers (4) (concave side up)

between amplifier flange and top support tube (10) in the

forward mounting locations, aligning them with mounting

holes in Tour-Pak bottom.

3. Install forward bolts (7) with washers (8) through Tour-Pak,

top support tube, spacers and amplifier front mounting

flange.

4. Install washer (2) and nylon locknut (1) on each mounting

bolt.

NOTE

Figure 8-44. Amplifier Connector [149]

Make sure that concave section of each spacer remains in line

with top support tube rail and does not rotate out of position.

2008 FLHTCUSE3 Service: Electrical 8-33

5. In a crosswise pattern, alternately tighten mounting bolts

ed01620

and locknuts to 96-108 in-lbs (10.8-12.2 Nm).

6. Plug wiring harness connector [149] into amplifier socket.

7. Install liner in Tour-Pak.

6

8

8. Test sound system for proper operation.

5

ed01619

1

2

9

7

3

4

3

2

10

1

4

1. Locknut

2. Washer

6

5

3. Amplifier

4. Spacer (4)

7

5. Center-rear locknut

6. Antenna ground lead

7. Bolt

8

8. Large washer

1. Bolt

9. License plate bracket

2. Washer

10. Top support tube

3. Tour-Pak bottom

Figure 8-48. Tour-Pak/Amplifier Components

4. Spacer

5. Amplifier bracket

6. License plate bracket

7. Washer

8. Locknut

Figure 8-47. Fastener Stack

8-34 2008 FLHTCUSE3 Service: Electrical

GARAGE DOOR OPENER

8.15

TRANSMITTER

RECEIVER

Removal

Installation

1. Remove MAXIFUSE.

1. Unplug power cord from garage door drive unit to prevent

door activation during installation.

2. Remove outer fairing. See Touring Models Service Manual.

2. Find an unswitched 110V power outlet in garage that is

3. See Figure 8-49. Locate transmitter (1) on inner left side

located either highest in the garage, or closest to front of

of fairing.

garage, or both. Locate the Harley-Davidson remote-con-

4. Disconnect wiring harness connector [132+] (2).

trol garage-door opener receiver here.

5. Remove transmitter from adhesive tape mount.

NOTE

With some brands of garage door opener systems, it may be

Installation

necessary to plug in the Harley-Davidson receiver at a location

some distance away from the door opener. If the Harley-

NOTE

Davidson receiver is plugged in too close to the original opener

Be certain to apply pressure to adhesive tape when installing

receiver, effective transmission range may be significantly

transmitter.

reduced on both systems.

1. Clean surface with isopropyl alcohol and allow to dry.

3. Find two garage-door-activation switch terminals at one

Apply new transmitter.

of these locations:

2. Connect wires to harness.

a. The existing wall-mounted, hard wired garage door

opener button.

3. Verify correct function by verifying that the LED light on

transmitter blinks when the high-low beam switch is

b. The garage-door drive unit to which the garage-door-

activated.

opener button is connected.

4. Install outer fairing according to procedure in Touring

4. Fasten stripped end of Harley-Davidson garage-door

Models Service Manual.

opener receiver wires to door-opener terminals that

activate door opener drive unit. Refer to door-opener

5. Install MAXIFUSE.

manufacturer's documentation for terminal locations and

connections.

ed01621

NOTE

Do not remove original wires from original connections on the

door-opener button or on drive-unit terminals.

5. Assemble and install garage-door opener button in its

original location.

6. Route the plug end of the Harley-Davidson garage-door

opener wires to the Harley-Davidson garage-door opener

receiver location.

7. See Figure 8-50. Plug connector on Harley-Davidson

garage-door opener receiver wires into the receptacle (1)

2

back of Harley-Davidson garage-door opener receiver.

8. Plug garage-door opener receiver into selected power

outlet.

9. Plug power cord from garage-door drive unit into power

1

outlet.

10. Press wall-mounted garage-door-opener button to test

button operation.

1. Transmitter

2. Connector [132+]

Figure 8-49. Garage Door Opener Transmitter

2008 FLHTCUSE3 Service: Electrical 8-35

try to correct the interference by one or more of the following

ed01622

measures.

•

Reorient or relocate the receiving antenna.

1

•

Increase the distance between the equipment and the

receiver.

•

Connect the equipment to an outlet on a circuit different

2

from that to which the receiver is connected.

•

Consult the dealer or an experienced radio/TV technician

for help.

3

Program the Receiver and Transmitter

The receiver must be programmed to receive the transmitter

frequency. This process may require two people, depending

on how far apart the receiver and transmitter are during the

1. Wire connector/plug receptacle

programming process.

2. LED

3. Set button

1. Check that a red light is visible on the front of the Harley-

Davidson garage door opener receiver, indicating power

Figure 8-50. Garage Door Opener Receiver: FLHTCUSE3

to the receiver.

2. See Figure 8-50. Press and hold the Set button (3) the

REMOTE CONTROL GARAGE DOOR

Harley-Davidson garage door opener receiver. The LED

(2) blinks continuously while the Set button is pressed.

OPENER

3. Set the motorcycle ignition switch to IGN. Switch the

FCC Notices

headlamp beam switch using one of these sequences:

NOTE

a. Starting from Low beam, switch High, then Low.

Changes or modifications to this unit not expressly approved

b. Starting from high beam, switch Low, then High.

by the manufacturer could void the user's authority to operate

the equipment.

NOTE

When the receiver receives a signal from the transmitter, the

This equipment has been tested and

found to comply with the

LED on the transmitter turns off.

limits for Class B digital devices pursuant to Part 15, Subpart

B of the FCC Rules. These limits are designed to provide

4. Release the Set button on the receiver.

reasonable protection against harmful interference in a resid-

ential environment. This equipment generates, uses, and can

radiate radio frequency energy, and if not installed and used

in accordance with the instruction manual, may cause harmful

Be sure that all lights and switches operate properly before

interference to radio communications. However, there is no

operating motorcycle. Low visibility of rider can result in

guarantee that interference will not occur in a particular

death or serious injury. (00316a)

installation. If this equipment does cause harmful interference

NOTE

to radio or television reception, which can be determined by

Clear all obstructions away from between the transmitter and

turning the equipment off and on, the user is encouraged to

receiver before testing the operation of the garage door opener.

5. Test the garage door opener, high beam, and low beam

headlamp operation.

NOTE

When the transmitter is activated by toggling the headlamp

switch, the red LED on the transmitter illuminates for one

second to indicate that the transmitter is functioning correctly.

6. Turn the motorcycle ignition switch OFF.

8-36 2008 FLHTCUSE3 Service: Electrical

AUTOMATIC COMPRESSION RELEASE

8.16

GENERAL

ed01625

See Figure 8-51. The Automatic Compression Release (ACR)

is opened and closed by the ECM to assist starting.

See Figure 8-52. 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 8-53. ACR in Head

3. See Figure 8-56. 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 8-54. Identify a location around the threads of

the ACR approximately 1/3 of the way up from the end.

3. See Figure 8-55. 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 8-56. 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 8-51. 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 8-52. ACR Exhaust Port Release

2008 FLHTCUSE3 Service: Electrical 8-37

ed01626

ed01628

Figure 8-56. 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 8-54. Bottom Third

1. Operate engine to normal operating temperature.

2. Disconnect spark plug wires.

3. Clean around plug base and remove front cylinder spark

plug.

ed01627

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 8-10 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 8-10. Readings should be within specified

range. If readings are higher than normal, suspect a

Figure 8-55. 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.

8-38 2008 FLHTCUSE3 Service: Electrical

3. If V/GY wire is shorted to ground, the ACR's will remain

Table 8-10. 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

em00235

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

19

19

V/GN

E

30

3

S

85

2

HD-48637

BREAK-OUT BOX

U

86

1

Diagnostic Tips

Refer to flow charts that follow for troubleshooting.

Diagnostic Notes

NOTES

•

The reference numbers in Table 8-11 correlate with the

circled numbers in Figure 8-57.

1

2

1

2

•

The step numbers below correlate with the circled numbers

[203FB]

[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 8-57. ACR Circuit

Table 8-11. Connectors/Fuse in ACR Circuit

NUMBER

DESCRIPTION

TYPE

LOCATION

[78]

ECM

73-place Delphi

Under seat

[203F]

ACR

2-place Amp (T

yco)

Between cylinders

[203R]

ACR

2-place Amp (T

yco)

Between cylinders

[119]

System relay

Lugs

Fuse block

2008 FLHTCUSE3 Service: Electrical 8-39

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.

1

During the first 2 seconds after turning the

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 “19”.

[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

“19” on breakout box and ground.

ECM connector [78B] terminal “19”.

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

(Part 2 of 2).

YES

NO

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

fc01777_en

terminal “19” and replace both ACRs.

7078

8-40 2008 FLHTCUSE3 Service: Electrical

ACR Diagnostics (Part 2 of 2)

Continued from ACR Diagnostics

(Part 1 of 2).

Measure voltage at breakout box terminal “19”

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 “19”.

7079

YES

NO

Reconnect breakout box and ECM; and

ACRs to the engine wiring harness. Measure

Replace defective

voltage at terminal “19” 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

fc01778_en

2008 FLHTCUSE3 Service: Electrical 8-41

TWIST GRIP SENSOR (TGS)

8.17

5. Remove terminals and wire leads from connector housing.

REMOVAL

See APPENDIX B, MOLEX and DEUTSCH ELECTRICAL

NOTE

CONNECTORS in Touring Models Service Manual.

The twist grip sensor also contains the leads for the handgrip

6. Securely attach a piece of mechanic's wire approximately

heater.

3 ft (1 m) long to the bundle of terminals using electrical

1. Remove outer fairing. See Touring Models Service Manual.

tape. This will be used as a harness leader.

2. Remove MAXIFUSE.

7. Remove the right handgrip. See Remove Right Handgrip

in 2.8 HANDGRIPS.

3. Remove cable ties as necessary.

8. Lubricate harnesses with glass cleaner, and carefully pull

4. See Figure 8-58. Disconnect twist grip sensor (TGS)

TGS from end of handlebar. Continue to pull until tape

connector [204] (5) and handgrip heater interconnect

securing wire leaders to harnesses can be removed.

harness connector [206] (4).

9. Remove leaders from harness terminals.

ed01629

5

1

2

4

3

1. Left handlebar switch connector [24]

2. Right handlebar switch connector [22]

3. Handgrip heater power connector [189]

4. Handgrip heater interconnect [206]

5. Twist grip sensor connector [204]

Figure 8-58. Handlebar Control Connector Locations

INSTALLATION

NOTES

•

Attach wire lead bundles to mechanic's wire to draw wire

leads back through handlebars, and out center of

8-42 2008 FLHTCUSE3 Service: Electrical

POWER LOCKS

8.18

GENERAL

ed01632

Power locks are installed on the Tour-Pak and on both

saddlebags. The cables and actuators can be replaced without

removing the protective box or the entire assemblies can be

removed and replaced.

2

POWER LOCK LOCKSET: TOUR-PAK

Removal

1

1. Remove the MAXIFUSE.

2. Remove the felt liner from Tour-Pak cover.

3. See Figure 8-59. Remove the fastener (1) holding the latch

cover in place.

4. See Figure 8-60. Remove retaining ring (1) and disconnect

cable end from latch.

5. Remove nut and washer (2).

3

6. Remove latch components (3).

7. Remove nut (4) and remove lockset from cover.

Installation

1. See Figure 8-60. Insert the lockset and install nut (4).

4

Tighten to 30-45 in-lbs (3.4-5.1 Nm).

2. Install latch components (3) and secure with nut and

washer (2). Tighten to 25-35 in-lbs (2.8-4.0 Nm)

3. Connect cable end to latch hook

and retain with retaining

ring (1).

4. See Figure 8-59. Install the latch cover and secure with

1.

Retaining ring

fastener (1).

2.

Nut and washer

3.

Latch components

5. Install felt liner.

4.

Nut

6. Install MAXIFUSE and test power lock operation.

Figure 8-60. Tour-Pak Lockset

ed01631

ACTUATOR: TOUR-PAK

Removal

NOTE

The actuator and/or cable can be replaced without removing

the protective box from the Tour-Pak.

1. Remove MAXIFUSE.

2. Remove upper and lower felt liners.

2

3. Separate the connector [213T] located in the Tour-Pak

1

bottom.

4. Remove the cover from the latch assembly.

1. Fastener

5. Remove two fasteners and remove the actuator box cover.

2. Latch cover

NOTE

Figure 8-59. Tour-Pak Latch Cover

To prevent locking the Tour-Pak without a release mechanism,

do not close the Tour-Pak cover until repairs are complete.

6. See Figure 8-61. Remove harness from retaining clips (1).

8-44 2008 FLHTCUSE3 Service: Electrical

7. Remove retaining ring

(2) securing cable to latch

ed01633

assembly.

2

8. Loosen jam nut (3) from each end of cable. Remove cable

1

6

from latch bracket and actuator box slots.

9. Pull the actuator (4) off of its thin plastic mounting studs

while disengaging the harness and grommet (5) from the

actuator box.

10. Remove the fastener and locknut (6) from the end of the

3

actuator to remove the cable.

4

11. If necessary, remove the actuator box (7) from the inside

5

7

wall of the Tour-Pak cover.

Assembly

NOTE

1. Harness retaining clip

Be certain to apply pressure to adhesive tape when installing

2. Retaining ring, latch

actuator box.

3. Jam nuts

4. Actuator

1.

If removed, attach the actuator box to the inside of Tour-

5. Harness and grommet

Pak cover:

6. Fastener and locknut

a. See Figure 8-61. Clean mounting surface of Tour-Pak

7. Actuator box

with isopropyl alcohol. Allow to dry.

Figure 8-61. Tour-Pak Power Lock Actuator

b. Use double sided tape and mount actuator box (7) to

inside wall of Tour-Pak cover.

POWER LOCKS: SADDLEBAGS

2.

Assemble the cable to the end of the actuator with fastener

and locknut (6). Tighten securely.

Removal

3.

Slide the actuator (4) over the plastic mounting studs.

1. Remove the MAXIFUSE.

4.

Press the harness and grommet (5) into the slot

in the

2. Open the saddlebag and lift out the felt liner.

box.

3. Separate the power

lock connector [213] and remove the

5.

Slide the cable into the slots in the box and latch bracket.

saddlebag.

Tighten the jam nuts (3) securely.

4. Remove the wire terminals from the connector housing

6.

Install the actuator box cover.

and pull the wire leads through the cord grip exit hole in

the side of the saddlebag.

7.

Connect the cable to the latch assembly and secure with

retaining ring (2).

NOTES

8.

Route harness through retainers (1) and mate connector

•

Squeeze the cord grip together on the inside of the

[213T] to harness connector located in Tour-Pak bottom.

saddlebag and push the cord grip out.

9.

Install latch cover.

•

See APPENDIX B DEUTSCH ELECTRICAL CON-

NECTORS in the Touring Models Service Manual for

10.

Install felt liners.

connector service procedures.

11.

Install MAXIFUSE and test power lock operation.

5. Remove the two screws from the check strap and the latch

cover.

6. See Figure 8-62. Loosen the lock nut on the cable end

and remove the cable ball end from the latch inner cam.

If the inner cam and latch require service, see

2.16 SADDLEBAGS LATCH for procedures.

7. Remove harness from the retaining clips.

8. Remove the actuator box and harness from the bottom of

saddlebag.

Installation

1. Clean inside mounting surface of saddlebag with isopropyl

alcohol. Allow to dry.

2. Use double sided tape to fix box to mounting surface.

3. Slip barrel end of cable into saddlebag locking arm.

Assemble cable into slot on bracket. Tighten locknut.

2008 FLHTCUSE3 Service: Electrical 8-45

4. Thread wire leads through exit hole in side of saddlebag

ed01635

and under harness retaining clips. Replace clips if neces-

sary.

5. See Figure 8-64. Snap cord grip over the wire lead conduit

and press the small end of the cord grip into exit hole from

the outside of saddlebag.

6. Install terminals in connector housing. The cavity numbers

are embossed on the sides of the connector. Refer to

Table 8-13.

NOTE

See APPENDIX B DEUTSCH ELECTRICAL CONNECTORS

in the Touring Models Service Manual for connector service

procedures.

7. Mate power lock connector [213] halves while installing

the saddlebag.

8. Install latch cover. Tighten screws to 25 in-lbs (2.8 Nm).

9. Install felt liner.

10. Install MAXIFUSE and test power lock.

Table 8-13. Connectors [213R] and [213L]

Figure 8-63. Actuator Box

TERMINAL

WIRE LEAD COLOR

1

GN

2

BE

ed01636

ed01634

Figure 8-64. Cord Grip

Figure 8-62. Cable Ball End in Inner Cam

ACTUATOR: SADDLEBAG

Disassembly

NOTE

The actuator and/or cable can be replaced without removing

the protective box from the saddlebag.

1. To remove the actuator assembly from a saddlebag, see

8.18 POWER LOCKS, Power Locks: Saddlebags.

2. Remove two fasteners to open the actuator box cover.

3. Loosen the cable jam nut.

4. Pull the actuator off from its thin plastic mounting studs

and slide the grommet and wire leads out of the slot in the

box.

5. Remove the Torx head screw and lock nut from the end

of the actuator to remove the cable and elbow.

8-46 2008 FLHTCUSE3 Service: Electrical

4. Install the cable elbow in the slot in the box and tighten

Assembly

the locknut.

1. Fasten the cable eyelet over the actuator with the Torx

head screw and tighten the lock nut.

5. Install the cover with two fasteners.

2. Orient the actuator to the cable and grommet slots in the

6. Install the power lock assembly into the saddlebag. See

box, and slide the actuator over the plastic mounting studs.

INSTALL under 8.18 POWER LOCKS, Power Locks:

Saddlebags.

3. Press the wire lead grommet into the slot in the box.

em01300

Fuse

1E

2G

Block

P&A fuse

Power locks

15A

15A

1F

2H

[212B] [212A]

GN/BK

1

1

GN/BK

R

2

2

O/R

BE/BK

3

3

BE/BK

Power Locks module

Battery power

1

1

R/V

Lock input

2

2

BE/BK

Unlock input

3

3

GN/BK

Lock signal

6

6

BE/W

Right Saddlebag Lock

Unlock signal

7

7

GN/W

GN/W

1

Power ground

8

8

BK

BE/W

2

[213RB]

[231A] [231B]

[213RA]

Left Saddlebag Lock

GN/W

1

Neutral Switch,

BE/W

2

[213LB]

Horn

[213LA]

GND

Tour-Pak Lock

GN/W

1

1A

BE/W

2

[213TB]

[213TA]

Figure 8-65. Power Locks Circuit

Table 8-14. Power Locks Circuit

NUMBER

DESCRIPTION

TYPE

LOCATION

[212]

Lock/Unlock Switch

3-place amp (T

yco)

In fairing cap

[213R]

Saddlebag Lock

2-place Deutsch

Behind RH saddlebag

[213L]

Saddlebag Lock

2-place Deutsch

Behind LH saddlebag

[213T]

T

our-Pak Lock

2-place Deutsch

Inside Tour-Pak liner

[231]

Power Locks Module

8-place

Inside outer fairing

2008 FLHTCUSE3 Service: Electrical 8-47

POWER LOCK MODULE

POWER LOCK FOB

See Figure 8-66. The lock module is located inside the outer

General

fairing and attached to the right fairing bracket.

See Figure 8-67. The fob remotely operates the power locks

Removal

in the saddlebags and Tour-Pak. The key on the fob may be

used to manually lock/unlock the ignition switch, saddlebags,

1. Remove the MAXIFUSE.

and Tour-Pak on the vehicle.

2. Remove outer fairing. See FAIRING CAP in Touring Ser-

Entering Program Mode

vice Manual.

NOTE

3. Disconnect harness connector from module (1).

To program a fob, it is necessary to put the receiver on the

4. Remove fastener (2). Remove module.

bike into program mode.

5. If necessary, remove fastener (3) and remove bracket (4).

1. Turn ignition knob to IGNITION or ACCESSORY.

Installation

NOTES

•

Verify that both saddlebags and the tour-pak power locks

1. If removed, install bracket (4) and tighten fastener (3) to

are functioning correctly when using the saddlebag/Tour-

30-50 in-lbs (3.4-5.6 Nm)

Pak lock switch.

2. Install module and tighten fastener (2) to 20-40 in-lbs (2.3-

•

Leave the Tour-Pak lid open during programming to see

4.5 Nm).

the Tour-Pak power lock hook move during lock and unlock

3. Install connector to module (1).

events.

4. Install outer fairing and connect MAXIFUSE.

2. See Figure 8-69. Press UNLOCK on the saddlebag/Tour-

Pak lock switch to set locks to the unlocked position. Wait

NOTE

5 seconds.

If the power lock module is replaced, it must be programmed

to the fobs.

3. Press LOCK once on the saddlebag/Tour-Pak lock switch.

5. New power lock module must be programmed to operate

4. Press UNLOCK on the saddlebag/Tour-Pak lock switch 3

with the fobs. See 8.18 POWER LOCKS, Power Lock Fob.

times in a row.

5. Press LOCK on the saddlebag/Tour-Pak lock switch 3

ed01637

times in a row.

6. Press

and hold

UNLOCK for 5 seconds. After 5 seconds,

the actuators will cycle the locks to locked then back to

unlocked. The receiver is now beginning its program cycle.

7. Wait 11 more seconds. The actuators will once again cycle

to lock then back to unlock. The receiver is now in program

mode.

3

ed01638

4

88.7

FM 1

101.1

91.3

91.3 MHz

90.7

2

95.5

CB

INT

12:27

SCAN

More

1

CRUISE

SPKR

ACC

SPOT

1. Power lock module

2. Fastener

3. Module bracket

Figure 8-67. Saddlebag/Tour-Pak Lock Switch

4. Fastener

Figure 8-66. Power Lock Module

Program Mode

NOTE

Pressing lock or unlock on the saddlebag/Tour-Pak lock switch

during program mode will cause program mode to end.

8-48 2008 FLHTCUSE3 Service: Electrical

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