Harley Davidson 2008 FLHTCUSE3 Model. Service Manual Supplement - page 9
Figure A-7.
Figure A-7.
2008 FLHTCUSE3 DOMESTIC and International Models, Indicator
2008 FLHTCUSE3 DOMESTIC and International Models, Indicator
Lamps, Fairing Cap Switches, Handlebar Switches, Garage Door
Lamps, Fairing Cap Switches, Handlebar Switches, Garage Door
Opener
Opener
et00104
ABS
Electronic Control
Module
Fuse
[166A]
[166B]
1E
2G
Block
P&A Fuse
Power Locks
15A
15A
ECU/Solenoid Ground
1
1
BK
1F
2H
Rear Brake Input
3
3
PK/BN
Rear Wheel Speed (-)
7
7
BE/V
Rear Wheel Speed (+)
8
8
BE/BN
Datalink
9
9
LGN/V
[212B] [212A]
ECU/Solenoid Power
10
10
R/V
Motor Ground
11
11
BK
GN/BK
1
1
GN/BK
Front Brake Input
13
13
R/BN
R
2
2
O/R
BE/BK
3
3
BE/BK
Front Wheel Speed (+)
17
17
BK/BE
Front Wheel Speed (-)
18
18
BK/V
Ignition Wake-Up
19
19
GY
Motor Power
20
20
R/V
R/BE
4
4
ABS
Power Locks Module
R/BE
3
3
Diode
R/BN
2
2
Pack
Battery Power
1
1
R/V
[167B]
[168B]
PK/BN
1
1
Lock Input
2
2
BE/BK
A
B
A
B
Unlock Input
3
3
GN/BK
A
B
A
B
[201B] [201A]
[167A]
[168A]
Lock Signal
6
6
BE/W
Unlock Signal
7
7
GN/W
GN/W
1
Right Saddlebag Lock
Power Ground
8
8
BK
BE/W
2
[213RB]
[231A] [231B]
[213RA]
To Main Harness
GN/W
1
Left Saddlebag Lock
Page 1
Neutral Switch,
BK
BE/W
2
[213LB]
Horn
[213LA]
GND
Tour-Pak Lock
GN/W
1
1A
[213TB]
BE/W
2
Front
Rear
Wheel
Wheel
Speed
Speed
[213TA]
Sensor
Sensor
Figure A-8. 2008 FLHTCUSE3 DOMESTIC and INTERNATIONAL Models, ABS Module, Power Locks
Figure A-8.
Figure A-8.
2008 FLHTCUSE3 DOMESTIC and INTERNATIONAL Models,
2008 FLHTCUSE3 DOMESTIC and INTERNATIONAL Models,
ABS Module, Power Locks
ABS Module, Power Locks
et00100
AM/FM
P/N 70160-06
Used With Optional
Antenna Mast
Audio
Twisted
FLHTC/U
(BK)
[41A]
XM Module
Harness
Shielded
(Violet)
Models Only
For FLHTCU
Pair
PK/W
1
GY/W
2
XM
Only
To
[185C]
V/BK
3
Antenna
Ultra
O/BK
4
Radio
(BK)
GN
5
LGN/BN
6
[28A]
[28B]
P/N 70084-96
1
GN
2
BN
Antenna Cable Part Of
Twisted
3
R
Main Harness And
4
Pair
Present On All Models
5
GY/O
P&A Non-ULTRA
6
Y/W
ACC Harness
[29A]
7
W
To Radio Antenna
BK
[76A]
Twisted
Connector
[29B]
9
++R
DIN On ULTRA
Pair
10
R
(FLHTC/U Models Only)
11
V/BK
[76B]
[51B]
[51A]
12
BN/W
BK
1
Passenger
13
Y/O
Twisted
Y/BK
2
Headset
CAV
CIR
DESCRIPTION
14
Y/V
Pair
GY/Y
3
1
BK
MIC IN SHARED (-)
15
GN/V
R
4
2
Y/BK
HDSET SPKR SHARED (-)
16
GY/BK
3
GY/O
5
GY/Y
RT REAR HDSET SPKR (+)
Twisted
17
Y/BK
4
R
FRT MIC (+)
XM
18
BK
6
5
GY/O
LFT REAR HDSET SPKR (+)
Triad
7
6
[185B]
SHIELD
8/
7
R
6
20
BK
TAB
8
ABT
MIC SHARED SHIELD
W
7
21
BK
BK
22
++BK
8
R/O
9
23
GY/W
Twisted
BK/GN
10
24
LGN/BN
Shielded
Y/O
11
25
W/BN
Y/V
12
26
BK
Pair
[185A]
27
++Twisted
28
GY/Y
XM
C.B.
(BK)
Pair
29
Y/R
30
R
[42A]
[193B]
32
++W
[185D] XM Antenna
[50B] C.B. Antenna
PK/W
1
GPS
33
++R
[184A]
GY/W
2
Antenna
34
PK/W
V/BK
3
35
O/BK
BN/W
4
BN
5
W/BN
6
++Twisted
Shielded
Triad
[28A] Ultra Only
[51B]
[27A]
++R
1
1
++R
++R
1
Used With Optional
++BK
2
2
++BK
++BK
2
Radio Pinouts
3
3
GPS Installed In Radio
R
4
4
R
R
4
RT Rear Speaker (+) - 1
(Teal)
[28A]
LFT Rear Speaker (+) - 2
BK
5
5
BK
BK
5
C.B.
(BK)
CB/GMRS Audio (+) - 3
GPS
6
BK/GN
R
6
6
R
HFM Audio (+) - 4
Antenna
[193A]
5
Y/V
W
7
7
W
[184D]
LFT Rear HDSET SPKR (+) - 5
4
Y/O
BK
8
8
BK
LFT FRT HDSET SPKR (+) - 6
3
R/O
R/O
9
9
R/O
R/O
9
LFT XM - 7
N/C- 8
2
BE/Y
BK/GN
10
10
BK/GN
BK/GN
10
FRT MIC (+) - 9
1
V/GY
Y/O
11
11
Y/O
Y/O
11
Rear MIC (+) - 10
Y/V
12
12
Y/V
Y/V
12
RR2 (RR CNTL Matrix) - 11
RC4 (RR CNTL Matrix) - 12
C.B. [184B]
[184C]
CAN (+) - 13
[6A]
Interconnect
CAN (-) - 14
LFT SDCAR HDSET SPKR (+) - 15
(BK)
RT SDCAR HDSET SPKR (+) - 16
HDSET SPKR Shared (-) - 17
XM (-) - 18
N/C- 19
C.B. Mast ASSY
MIC Shared (-) - 20
MIC Shared Shield - 21
P/N 76250-98
MIC SUM OUT (-) - 22
RR1 (RR CNTL Matrix) - 23
RT Rear SPKR (-) - 24
++Twisted
LFT Rear SPKR (-) - 25
CB/GMRS Audio (-) - 26
Shielded
HFM Audio (-) - 27
REAR CONTROL MATRIX
Triad
RT REAR HDSET SPKR (+) - 28
RT FRT HDSET SPKR (+) - 29
C3
C4
[53A]
1
2
3
4
5
67
8
9 101112
RT XM - 30
Loading Coil ASSY
(BK)
R0
REAR VOL UP
UP TUNE/FF
N/C- 31
SDCAR MIC IN (+) - 32
R1
REAR VOL DWN
DWN TUNE/REWIND
P/N 76318-98
MIC SUM OUT (+) - 33
[53B]
67
8
9 101112
RR0 (RR CNTL Matrix) - 34
R2
PUSH TO TALK
BAND
RC3 (RR CNTL Matrix) - 35
1 - RT FRT Speaker (-)
[27A]
2 - Push To Talk (MIC)
3 - R0 (Handlebar Matrix)
(BK)
[50A]
C.B. Antenna
4 - R1 (Handlebar Matrix)
5 - R2 (Handlebar Matrix)
Inside Tour-PAK
6 - C4 (Handlebar Matrix)
C.B. Antenna
7 - C3 (Handlebar Matrix)
Back Of
8 - C2 (Handlebar Matrix)
9 - Serial Bus
C.B. Module
10 - Battery
[104B]
[104A]
11 - Ground
12 - Accessory Enable
13 - Headset Speakers B
Driver
14 - N/C
CAV
CIR
DESCRIPTION
15 - SDCAR Switch Matrix In
1
Headset
HANDLEBAR MATRIX
BK
MIC IN SHARED (-)
16 - LFT FRT Speaker (+)
2
Y/BK
HDSET SPKR SHARED (-)
17 - LFT FRT Speaker (-)
C0
C1
C2
C3
C4
18 - RT FRT Speaker (+)
3
Y/R
RT FRT HDSET SPKR (+)
19 - Ground
R0
VOL UP
VOL DWN
MENU
UP TUNE / FF
4
R
FRT MIC (+)
20 - Battery
5
Y/W
RT FRT HDSET SPKR (+)
21 - Headset Speakers A
R1
DWN TUNE / REWIND
6
22 - C1 (Handlebar Matrix)
23 - C0 (Handlebar Matrix)
R2
SQUELCH UP
SQUELCH DWN
PUSH TO TALK
BAND
7
BE/Y
PUSH-TO-TALK
TAB
SHIELD
MIC SHARED SHIELD
Figure A-9. 2008 FLHTCUSE3 DOMESTIC and INTERNATIONAL Models, XM and CB Radio Interconnect Diagram
Figure A-9.
Figure A-9.
2008 FLHTCUSE3 DOMESTIC and INTERNATIONAL Models, XM
2008 FLHTCUSE3 DOMESTIC and INTERNATIONAL Models, XM
and CB Radio Interconnect Diagram
and CB Radio Interconnect Diagram
et00101
[41D]
[41C]
(BK)
[41A]
[41B]
PK/W
1
1
1
1
PK/W
Twisted
Twisted
+VOL
Right Rear
GY/W
2
2
2
2
GY/W
(BK)
Pair
Pair
V/BK
3
3
3
3
V/BK
-PTT
Speaker &
O/BK
4
4
4
4
-VOL
Controls
[28A] [28B]
O/BK
Ultra Radio Connector
GN
5
5
5
5
GN
LGN/BN
6
6
6
6
LGN/BN
RT Rear Speaker (+)
1
1
GN
LFT Rear Speaker (+)
2
2
BN
LFT FRT HDSET SPKR (+)
6
6
Y/W
FRT MIC (+)
9
9
++R
RR2 (RR CNTRL Matrix)
11
11
V/BK
Left & Right Rear
RC4 (RR CNTL Matrix)
12
12
BN/W
Passenger Controls
CAN (+)
13
13
Y/O
CAN (-)
14
14
Y/V
COLOR
ORANGE/
PINK/
VIOLET/
GRAY/
LFT SDCAR HDSET SPKR (+)
15
15
GN/V
BLACK
WHITE
BLACK
WHITE
RT SDCAR HDSET SPKR (+)
16
16
GY/BK
POSITION
HDSET SPKR Shared
17
17
Y/BK
UP /+ VOL
MODE / PTT
MIC Shared (-)
20
20
BK
DOWN / - VOL
MIC Shared Shield
21
21
BK
RR1 (RR CNTL Matrix)
23
23
GY/W
RT Rear SPKR
24
24
LGN/BN
LFT Rear SPKR
25
25
W/BN
(BK)
RT FRT HDSET SPKR (+)
29
29
Y/R
[42A]
[42B]
SDCAR Mic In (+)
32
32
++W
PK/W
1
1
1
1
PK/W
Left Rear
MIC Sum Out (+)
33
33
UP
GY/W
2
2
2
2
GY/W
RR0 (RR CNTL Matrix)
34
34
PK/W
MODE
Speaker &
V/BK
3
3
3
3
V/BK
RC3 (RR CNTL Matrix)
35
35
O/BK
DOWN
Controls
BN/W
4
4
4
4
O/BK
BN
5
5
5
5
BN
W/BN
6
6
6
6
W/BN
++Twisted
Shielded
BK/GN
6
6
BK/GN
5
5
Y/V
Triad
4
4
Y/O
3
3
BE/Y
2
2
BE/Y
V/GY
1
1
V/GY
++Twisted
Shielded
[6B]
[6A]
Triad
(BK)
[27A]
[27B]
Base Radio Connector
(BK)
RT FRT Speaker (-)
1
1
LGN/BK
1
2
3
4
5
6
7
8
9 101112
Push To Talk (MIC)
2
2
BE/Y
[53A]
Ground
11
11
BK/GN
[149B]
[149A]
SDCAR Switch Matrix In
15
15
V/GY
LFT FRT Speaker (+)
16
16
W/O
Y/O
1
1
CAN +
LFT FRT Speaker (-)
17
17
LGN/W
Y/V
2
2
CAN -
RT FRT Speaker (+)
18
18
GY/R
R
3
3
Battery
Ground
19
19
BK/GN
Battery (+)
30A
R
4
4
Battery
Twisted Pair Twisted Pair
GY/R
6
6
Right Front Out (+)
W/O
7
7
Left Front Out (+)
BN
8
8
Left Rear Out (+)
[34A]
[34D]
LGN/BK
LGN/BK
GY/R
GY/R
LGN/W
11
11
Left Front In (-)
Right
12
12
Right Front In (-)
[34B]
[34C]
LGN/BK
Front
LGN/BK
LGN/BK
13
13
Right Front Out (-)
Speaker
GY/R
LGN/W
14
14
Left Front Out (-)
W/BN
15
15
Left Rear Out (-)
[35B]
[35C]
LGN/W
LGN/W
W/O
18
18
Left Front In (+)
W/O
W/O
GY/R
19
19
Right Front In (+)
BK
20
20
Ground
[35A]
[35D]
BK
21
21
Ground
GN
22
22
Right Rear Out (+)
Left
Ground STD
LGN/BN
23
23
Right Rear Out (-)
LGN/W
Front
(Right)
W/O
Speaker
Amplifier Connector
Figure A-10. 2008 FLHTCUSE3 DOMESTIC and INTERNATIONAL Models, XM and CB Radio Audio System
Figure A-10.
Figure A-10.
2008 FLHTCUSE3 DOMESTIC and INTERNATIONAL Models, XM
2008 FLHTCUSE3 DOMESTIC and INTERNATIONAL Models, XM
and CB Radio Audio System
and CB Radio Audio System
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 FLHTCUSE3 Service: Appendix B Glossary B-1
Table B-1. Acronyms and Abbreviations
ACRONYM OR ABBREVIATION
DESCRIPTION
IA
T
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 FLHTCUSE3 Service: Appendix B Glossary
Table B-1. Acronyms and Abbreviations
ACRONYM OR ABBREVIATION
DESCRIPTION
VIN
Vehicle Identification Number
VSS
Vehicle Speed Sensor
2008 FLHTCUSE3 Service: Appendix B Glossary B-3
Tools Used in This Manual
PART NUMBER
TOOL NAME
NOTES
HD-33223-1
CYLINDER COMPRESSION GAUGE
8.16 AUTOMATIC COMPRESSION RELEASE, Compres-
sion Test
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-39361-B
SPROCKET
SHAFT OIL SEAL INSTALLER
3.6 CRANKCASE ASSEMBLY, Assembly
HD-39782-A
CYLINDER HEAD SUPPORT ST
AND
3.3 CYLINDER HEAD, Replacing Valve Guides
HD-39782-A
CYLINDER HEAD SUPPORT ST
AND
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
RA
TCHETING TAP HANDLE
3.3 CYLINDER HEAD, Replacing Valve Guides
HD-39847
RA
TCHETING 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-41404-B
TEST CONNECTOR KIT
8.6 HEATED SEAT, Diagnostics
HD-41404-B
TEST CONNECTOR KIT
8.16 AUTOMATIC COMPRESSION RELEASE, Dia-
gnostics
HD-42311
OIL FILTER WRENCH
3.8 OIL COOLER ADAPTER, Removal
HD-42326-A
CRANKSHAFT GUIDE
3.6 CRANKCASE ASSEMBLY, Assembly
HD-48498
ACR SOLENOID SOCKET
3.3 CYLINDER HEAD, Disassembly
HD-48498
ACR SOLENOID SOCKET
8.16 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
8.16 AUTOMATIC COMPRESSION RELEASE, Dia-
gnostics
HD-48644
VALVE GUIDE SEAL INSTALLER
3.3 CYLINDER HEAD, Assembly
HD-96796-47
VALVE SPRING TESTER
3.3 CYLINDER HEAD, Inspection
HD-97087-65B
HOSE CLAMP PLIERS
3.7 OIL COOLER, Removal
HD-97087-65B
HOSE CLAMP PLIERS
3.8 OIL COOLER ADAPTER, Removal
HD-97225-55C
SPROCKET
SHAFT BEARING INSTALLER
3.6 CRANKCASE ASSEMBLY, Assembly
T
A360
SNAP-ON
TORQUE ANGLE GAUGE
3.5 BORING AND HONING CYLINDERS, Inspection
I
2008 FLHTCUSE3 Model Service Manual Supplement
FASTENER
TORQUE
VALUE
NOTES
Air cleaner cover screw
36-60 in-lbs
4.1-6.8 Nm
4.1 AIR CLEANER COVER, Installation
Air cleaner decorative trim screw
27-32 in-lbs
3.1-3.6 Nm
4.1 AIR CLEANER COVER, Installation
Amplifier locknuts
96-108 in-lbs
10.8-12.2 Nm
8.14 ADVANCED AUDIO AMPLIFIER, 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
8.16 AUTOMATIC COMPRESSION
RELEASE, Installation / Apply three equally spaced
dots of LOCTITE 246 THREADLOCKER MEDIUM
STRENGTH/HIGH TEMPERATURE around lower
third of threads
Auxilary lamp/turn signal bracket screw
15-20 ft-lbs
20.3-27.1 Nm
8.4 AUXILIARY LAMPS AND
BRACKETS, Installing Lamp Bracket
Auxiliary lamp mounting nut
15-18 ft-lbs
20.3-24.4 Nm
8.4 AUXILIARY LAMPS AND
BRACKETS, Installing Lamps
Brake pedal acorn nut
25-29 ft-lbs
33.9-39.4 Nm
2.3 FOOTBOARDS AND CONTROLS, Rear Brake
Pedal
Brake pedal cover screws
20-22 in-lbs
2.3-2.5 Nm
2.3 FOOTBOARDS AND CONTROLS, Rear Brake
Pedal
Clutch actuator bleeder valve
12-15 in-lbs
1.4-1.7 Nm
1.3 BLEEDING CLUTCH FLUID LINE, Return
Motorcycle to Service
Clutch actuator bleeder valve
12-15 in-lbs
1.4-1.7 Nm
2.9 CLUTCH MASTER CYLINDER AND RESER-
VOIR, Installation
Clutch fluid line clamp bolt
96-120 in-lbs
11-13 Nm
2.11 CLUTCH FLUID LINE, Installation
Clutch fluid line flare nut
72-120 in-lbs
8.1-13.6 Nm
1.3 BLEEDING CLUTCH FLUID LINE, Draining
and Filling
Clutch fluid line flare nut
72-120 in-lbs
8.1-13.6 Nm
1.3 BLEEDING CLUTCH FLUID LINE, Return
Motorcycle to Service
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
6.2 CLUTCH RELEASE BEARING AND
PUSHROD, Installation
Clutch master cylinder/reservoir clamp
72-84 in-lbs
8.1-9.5 Nm
2.7 HANDLEBARS, Installing Handlebars
fastener
Clutch master cylinder banjo bolt
12.5-14.5 ft-lbs
16.9-19.7 Nm
1.3 BLEEDING CLUTCH FLUID LINE, Return
Motorcycle to Service
Clutch master cylinder banjo bolt
12.5-14.5 ft-lbs
16.9-19.7 Nm
2.9 CLUTCH MASTER CYLINDER AND RESER-
VOIR, Installation
Clutch master cylinder clamp fastener
72-84 in-lbs
8.1-9.5 Nm
2.8 HANDGRIPS, Replacing Handgrips
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
1.3 BLEEDING CLUTCH FLUID LINE, Return
Motorcycle to Service
Clutch reservoir cover screws
6-8 in-lbs
0.7-0.9 Nm
2.9 CLUTCH MASTER CYLINDER AND RESER-
VOIR, Installation
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
Engine guard bolt
15-20 ft-lbs
21-27 Nm
2.11 CLUTCH FLUID LINE, Installation
Fairing cap screws
25-30 in-lbs
2.8-3.4 Nm
8.8 FAIRING CAP AND SWITCHES, Installation
III
2008 FLHTCUSE3 Model Service Manual Supplement
FASTENER
TORQUE
VALUE
NOTES
Filler plug and dipstick
25-75 in-lbs
2.8-8.5 Nm
7.2 CLUTCH RELEASE COVER, Fill and Bleed
Front axle cover set screw
60-84 in-lbs
6.8-9.5 Nm
2.5 FRONT AXLE COVERS, Replacement /
LOCTITE 262 THREADLOCKER (red)
Front brake master cylinder clamp
72-84 in-lbs
8.1-9.5 Nm
2.8 HANDGRIPS, Replacing Handgrips
fastener
Front master cylinder clamp fastener
60-80 in-lbs
6.8-9.0 Nm
2.9 CLUTCH MASTER CYLINDER AND RESER-
VOIR, Installation
Gasket cover screws
6-8 in-lbs
0.7-0.9 Nm
1.2 HYDRAULIC CLUTCH FLUID, Clutch Fluid
Level
GPS antenna bracket fastener
20-30 in-lbs
2.3-3.4 Nm
8.11 GPS NAVIGATION, GPS Antenna
Handlebar control lever clamp screw
72-84 in-lbs
8.1-9.5 Nm
2.7 HANDLEBARS, Installing Handlebars
Handlebar switch housing fastener
35-45 in-lbs
4.0-5.1 Nm
2.8 HANDGRIPS, Replacing Handgrips
Handlebar switch housing fastener
35-45 in-lbs
4.0-5.1 Nm
2.8 HANDGRIPS, Replacing Handgrips
Handlebar switch housing fastener
35-45 in-lbs
4.0-5.1 Nm
2.9 CLUTCH MASTER CYLINDER AND RESER-
VOIR, Installation
Handlebar switch housing screw
35-45 in-lbs
4.0-5.1 Nm
2.7 HANDLEBARS, Installing Handlebars
Handlebar switch housing screw
35-45 in-lbs
4.0-5.1 Nm
2.7 HANDLEBARS, Installing Handlebars
Handlebar top clamp fasteners
16-20 ft-lbs
20.3-27.1 Nm
2.7 HANDLEBARS, Installing Handlebars
Headlamp door screw
9-18 in-lbs
1.0-2.0 Nm
8.3 HEADLAMP, Installation
Headlamp retaining ring screw
23-28 in-lbs
2.6-3.2 Nm
8.3 HEADLAMP, Installation
Highway peg end screw
19 ft-lbs
26 Nm
2.4 HIGHWAY PEGS, Assembly / LOCTITE 243
THREADLOCKER (blue)
Highway peg mounting screws
14 ft-lbs
19 Nm
2.4 HIGHWAY PEGS, Installing Clamp
Highway peg nut
14-19 ft-lbs
19-25 Nm
2.4 HIGHWAY PEGS, Assembly
Latch hook nut,
Tour-Pak
25-35 in-lbs
2.8-4.0 Nm
8.18 POWER LOCKS, Power Lock Lockset: Tour-
Pak
Left footboard bottom assembly
60-80 in-lbs
6.8-9.0 Nm
2.3 FOOTBOARDS AND CONTROLS, Rider
fasteners
Footboards
Left front footboard bracket cap screw
30-35 ft-lbs
41-47 Nm
2.3 FOOTBOARDS AND CONTROLS, Rider
Footboards
Left rear footboard bracket fasteners
15-20 ft-lbs
21-27 Nm
2.3 FOOTBOARDS AND CONTROLS, Rider
Footboards
Lockset retaining nut,
Tour-Pak
30-45 in-lbs
3.4-5.1 Nm
8.18 POWER LOCKS, Power Lock Lockset: Tour-
Pak
Muffler bracket screws
96-144 in-lbs
10-9-16.3 Nm
2.17 SADDLEBAG SUPPORTS, Installation
Muffler end cap fasteners
84-108 in-lbs
9.5-12.2 Nm
2.18 MUFFLER END CAP, Replacement
Muffler head shield clamps
20-40 in-lbs
2.3-4.5 Nm
2.18 MUFFLER END CAP, Replacement
Oil cooler adapter inspection cover
90-120 in-lbs
10.2-13.6 Nm
3.8 OIL COOLER ADAPTER, Assembly / Apply 1
drop LOCTITE 246 THREADLOCKER MEDIUM
STRENGH/HIGH TEMPERATURE to the fasteners
Oil cooler to mounting bracket
80-110 in-lbs
9.2-12.4 Nm
3.7 OIL COOLER, Installation
Oil filter adapter
18-22 ft-lbs
24.4-27.3 Nm
3.8 OIL COOLER ADAPTER, Installation
Passenger footboard bracket screw
30-35 ft-lbs
41-47 Nm
2.3 FOOTBOARDS AND CONTROLS, Adjustable
Passenger Footboards
Passenger footboard lower adjustment
25-30 ft-lbs
34-40 Nm
2.3 FOOTBOARDS AND CONTROLS, Adjustable
bolt
Passenger Footboards
IV TORQUE VALUES
2008 FLHTCUSE3 Model Service Manual Supplement
FASTENER
TORQUE
VALUE
NOTES
Passenger footboard upper adjustment
25-30 ft-lbs
34-40 Nm
2.3 FOOTBOARDS AND CONTROLS, Adjustable
bolt
Passenger Footboards
Power lock module bracket fastener
30-50 in-lbs
3.4-5.6 Nm
8.18 POWER LOCKS, Power Lock Module
Power lock module fastener
20-40 in-lbs
2.3-4.5 Nm
8.18 POWER LOCKS, Power Lock Module
Radio chassis mounting screws
35-45 in-lbs
4.0-5.1 Nm
8.13 ADVANCED AUDIO RADIO, Installing
Advanced Audio
Rider backrest bracket
60-96 in-lbs
6.8-10.8 Nm
2.13 RIDER BACKREST, Adjusting Front to Rear
Rider backrest bracket support strap
11-15 ft-lbs
15-20 Nm
2.13 RIDER BACKREST, Adjusting Front to Rear
Rider backrest mounting bracket screw
60-96 in-lbs
6.8-10.8 Nm
2.13 RIDER BACKREST, Adjusting Front to Rear
Right footboard bottom assembly pivot
60-80 in-lbs
6.8-9.0 Nm
2.3 FOOTBOARDS AND CONTROLS, Rider
bolts and locknuts
Footboards
Right footboard bracket cap screws
30-35 ft-lbs
41-47 Nm
2.3 FOOTBOARDS AND CONTROLS, Rider
Footboards
Saddlebag filler strip screws
15-20 ft-lbs
20.4-27.1 Nm
2.17 SADDLEBAG SUPPORTS, Installation
Saddlebag inner screws
25 in-lbs
2.8 Nm
2.16 SADDLEBAGS LATCH, Installation
Saddlebag latch cover screws
25 in-lbs
2.8 Nm
8.18 POWER LOCKS, Power Locks: Saddlebags
Saddlebag screws, upper
15-20 ft-lbs
20.4-27.1 Nm
2.17 SADDLEBAG SUPPORTS, Installation
Saddlebag support bracket screws
15-20 ft-lbs
20.4-27.1 Nm
2.17 SADDLEBAG SUPPORTS, Installation
Saddlebag support screws, front
70-100 in-lbs
7.9-11.3 Nm
2.17 SADDLEBAG SUPPORTS, Installation
Saddlebag support screws, rear
15-20 ft-lbs
20.4-27.1 Nm
2.17 SADDLEBAG SUPPORTS, Installation
Shift lever clamp bolts
18-22 ft-lbs
25-29 Nm
2.3 FOOTBOARDS AND CONTROLS, Shift Levers
Shift lever peg
Torx fastener
14-16 ft-lbs
19-21 Nm
2.3 FOOTBOARDS AND CONTROLS, Shift Levers
T
our-Pak fasteners
96-108 in-lbs
10.9-12.2 Nm
2.14 TOUR-PAK, Installation
T
ransmission drain plug
14-21 ft-lbs
19.0-28.5 Nm
7.2 CLUTCH RELEASE COVER, Fill and Bleed
T
riple clamp cover backside fasteners
70-110 in-lbs
7.9-12.4 Nm
2.6 LOWER TRIPLE CLAMP COVER, Replace-
ment
T
riple clamp lower Allen head fastener
120-180 in-lbs
13.6-20.4 Nm
2.6 LOWER TRIPLE CLAMP COVER, Replace-
ment
T
urn signal bracket screw
96-120 in-lbs
10.8-13.6 Nm
8.5 FRONT TURN SIGNALS, Installation
XM antenna bracket fastener
20-30 in-lbs
2.3-3.4 Nm
8.10 XM SATELLITE RADIO, XM Antenna
TORQUE VALUES V
Cleaning
3-6
A
Determining Service
3-5
Advanced Audio Amplifier
Disassembly
3-5
General
8-33
General
3-5
Installation
8-33
Inspection
3-8
Removal
8-33
Installation
3-15
Advanced Audio Radio
Removal
3-5
Headset Receptacle Repair
8-23
Replacing Valve Guides
3-9
Installation
8-31
D
Removal
8-31
Air Cleaner Cover
Drive
General
4-1
Specifications
6-1
Installation
4-1
E
Removal
4-1
Automatic Compression Release (ACR)
Electrical Protection
Compression Test
8-38
Fuses and Relays
8-1
Diagnostics
8-39
Engine Lubrication
General
8-37
General
1-5
Installation
8-37
Inspection
1-6
Removal
8-37
F
Auxiliary Lamps and Brackets
Fairing Cap and Switches
Installing Lamp Bracket
8-8
Installation
8-21
Installing Lamps
8-8
Removal
8-21
Removing Lamp Bracket
8-8
Footboards and Controls
Removing Lamps
8-7
Adjustable Passenger Footboards
2-6
Replacing Bulb
8-10
Rear Brake Pedal
2-6
B
Rider Footboards
2-3
Bleeding Clutch Fluid Line
Shift Levers
2-5
Bleed Fluid Line and Actuator
1-4
Foreword
Bleed Master Cylinder
1-4
Important General Information
i-I
Draining and Filling
1-3
Front Axle Covers
Return Motorcycle to Service
1-4
Replacement
2-11
Boring and Honing Cylinders
Front Turn Signal
Cylinder Bore Finished Size
3-18
Installation
8-12
Piston Orientation
3-19
Removal
8-12
Bulb Chart
G
General
8-3
Garage Door Opener
C
Receiver
8-35
Clutch Fluid Line
Remote Control Garage Door Opener
8-36
Installation
2-29
Transmitter
8-35
Removal
2-29
Glossary
Clutch Hand Lever
Acronyms and Abbreviations
B-1
Installation
2-28
GPS Navigation
Removal
2-28
General
8-27
Clutch Master Cylinder/Reservoir
GPS Antenna
8-27
Assembly
2-26
GPS Navigation Module
8-28
Clutch Fluid Level
1-2
H
Disassembly
2-25
Handgrips
General
2-24
Replacing Handgrips
2-20
Installation
2-26
Replacing Left Handgrip
2-20
Removal
2-24
Replacing Right Handgrip
2-22
Clutch Release Bearing and Push Rod
Handlebars
Installation
6-2
Assembly
2-14
Removal
6-2
Disassembly
2-14
Clutch Release Cover
Installation
2-17
Installation
7-2
Removal
2-13
Removal
7-2
Returning to Service
2-19
Connectors
Headlamp
Function and Location
A-1
General
8-4
Crankcase Assembly
Installation
8-5
Assembly
3-20
Removal
8-4
General
3-20
Heated Handgrips
Cylinder
Diagnostics
8-17
Inspection
3-17
General
8-17
Cylinder Heads
Assembly
3-13
VII
Heated Seat
S
Diagnostics
8-14
General
8-14
Saddlebag Latch
Highway Pegs
Installation
2-39
Assembly
2-10
Removal
2-39
Disassembly
2-9
Saddlebags
Installing Clamp
2-9
Installation
2-38
Removing Clamp
2-9
Removal
2-38
Hydraulic Clutch Fluid
Saddlebag Supports
Clutch Fluid Level
1-2
Installation
2-40
General
1-2
Removal
2-40
Seat
L
Cleaning and Inspection
2-32
Loctite
i-II
General
2-31
Lower Triple Clamp Cover
Installation
2-32
Replacement
2-12
Removal
2-31
Secondary Clutch Actuator
M
Replacement
7-4
Maintenance Schedule
Service Bulletins
i-I
General
1-1
Service Preparation
i-I
Muffler End Cap
Smart Security System
Replacement
2-42
Antenna
8-52
General
8-52
O
HFSM
8-52
Oil Cooler
Smart Siren
8-53
Installation
3-23
Troubleshooting
8-54
Operation
3-23
Specifications
Removal
3-23
Chassis
2-1
Oil Cooler Adapter
Engine
3-1
Disassembly
3-25
Engine Tolerances
3-1
Installation
3-25
Starter
5-1
Removal
3-25
Transmission
7-1
P
SPX Kent-Moore
i-II
Pistons
T
General
3-16
Tour-Pak
Measuring Piston
3-16
Installation
2-36
Power Lock Fob
8-48
Removal
2-35
Power Locks
Trademarks
Actuator: Saddlebag
8-46
Harley-Davidson
i-II
Actuator: Tour-Pak
8-44
Referenced Products
i-II
Diagnostics
8-49
Twist Grip Sensor
General
8-44
Installation
8-43
Lockset: Tour-Pak
8-44
Removal
8-42
Module
8-48
Power Locks: Saddlebags
8-45
V
Vehicle Identification Number (V.I.N.)
2-2
R
Radio
W
Installation
8-31
Weight Limits
2-1
Removal
8-31
Wiring Diagrams
A-2
Radio Software Update
X
Confirming Version No
8-30
General
8-29
XM Satellite Radio
Identifying Version No
8-29
Activation
8-25
Opening Diag Test Display
8-29
General
8-24
Updating Receiver Software
8-29
XM Antenna
8-24
Rider Backrest
XM Module
8-25
Adjusting Front to Rear
2-33
Adjusting Tilt Angle
2-33
General
2-33
Installation
2-33
Removal
2-33
VIII INDEX