Harley Davidson 2008 Touring Models. Service Manual - page 4

WINTER LUBRICATION

In colder climates, the engine oil should be changed often. If
motorcycle is used frequently for short trips, less than  15
miles (24 kilometers), in ambient temperatures below  60°
F (16° C), oil change intervals should be reduced to  1500
miles (2400 kilometers). Motorcycles used only for short runs
must have a thorough tank flush-out before new oil is put in.
The tank flush-out should be performed by an authorized dealer
or qualified technician.

NOTE

The further below freezing the temperature drops, the shorter
the oil change interval should be.

Water vapor is a normal by-product of combustion in any
engine. During cold weather operation, some of the water vapor
condenses to liquid form on the cool metal surfaces inside the
engine. In freezing weather this water will become slush or ice
and, if allowed to accumulate too long, may block the oil lines
and cause damage to the engine.

If the engine is run frequently and allowed to thoroughly warm
up, most of this water will become vapor again and will be
blown out through the crankcase breather.

If the engine is not run frequently and allowed to thoroughly
warm up, this water will accumulate, mix with the engine oil
and form a sludge that is harmful to the engine.

2008 Touring Service:  Maintenance  1-9

1.4

BULB REQUIREMENTS

GENERAL

Use the table to identify the bulb location and part number.
Refer to 

Table 1-6

.

NOTE

The speedometer, tachometer, odometer and indicator lamps
are illuminated with LEDs. LEDs are non-repairable. The entire
assembly must be replaced if an LED fails.

Table 1-6. Bulb Chart: 2008 Touring Models

HARLEY-DAVIDSON

PART NUMBER

CURRENT

DRAW

AMPERAGE

BULBS

REQUIRED

DESCRIPTION
(ALL LAMPS 12 VOLT)

LAMP

68329-03

4.58/5.0

1

FLHT/C/U, FLHR, FLHX

Headlamp

68329-03

4.58/5.0

2

FLTR

53438-92

0.32

1

Position lamp international

68167-04

0.59

1

Tail lamp

Tail and stop
lamp

68167-04

2.10

1

Stop lamp

68167-04

0.59

1

Tail lamp international

68167-04

2.10

1

Stop lamp international

68168-89A

2.25/0.59

2

Front/running

Turn signal lamp

68163-84

1.75

2

Front international

68572-64B

2.25

2

Rear

68163-84

1.75

2

Rear international

53788-06 (right side)

0.14

N/A

Tour-Pak side lamps

Additional lighting

53789-06 (left side)

0.14

FLHTCU*

53439-79

0.30

2

Fender tip lamps

53436-97

0.37

1

License plate lamp international

52441-95

0.35

2

License plate lamp FLHX domestic

68453-05

2.1

2

Auxiliary lamps

68851-98

2.7

2

Auxiliary lamps international

Instrument panel is illuminated with LEDs. Replace entire assembly upon
failure.

High beam indicator

Instrument panel
lamps

Oil pressure indicator

FLHT/C/U

Neutral indicator

FLHR/C
FLTR

Turn signal indicator

FLHX

N/A

N/A

N/A

speedometer

Gauge lamps
FLHR/C

N/A

N/A

N/A

Odometer

67136-85

0.19

1

Fuel gauge

N/A

N/A

N/A

Engine

N/A

N/A

N/A

speedometer

Gauge lamps
FLHT/C/U

N/A

N/A

N/A

Tachometer

FLTR

67445-00

0.24

1

Voltmeter

FLHX

67445-00

0.24

1

Oil pressure indicator
FLHT/C/U

67445-00

0.24

1

Air temperature gauge
FLHT/C/U

67445-00

0.24

1

Fuel gauge

Illuminated with LEDs. Replace entire assembly upon failure.

Items with *

1-10  2008 Touring Service:  Maintenance

1.5

ENGINE OIL AND FILTER

CHECKING OIL LEVEL: TOURING MODELS

Oil level cannot be accurately measured on a cold engine.
For pre-ride inspection, with motorcycle leaning on jiffy
stand on level ground, oil should register on dipstick
between arrows when engine is cold. Do not add oil to
bring the level to the FULL mark on a COLD engine.
(00185a)

For dipstick location, see 

Figure 1-1

.

pd00133

Figure 1-1. Engine Oil Filler Cap

Oil Level Cold Check

Perform engine oil level COLD CHECK as follows:

1.

For preride inspection, place vehicle on level ground and
rest the vehicle on its jiffy stand (unless sidecar is
attached).

2.

Turn filler plug/dipstick counterclockwise. Remove and
wipe off the dipstick. Insert the dipstick back into the oil
pan with the plug screwed completely into the fill spout.

3.

See 

Figure 1-2

. Remove the dipstick and verify the level

of the oil. The correct oil level should register between the
two marks on the dipstick. If sidecar is attached, check oil
level using the opposite side of dipstick as shown in

Figure 1-3

.

NOTE

If oil level is at or below the lower arrow, add only enough oil
to bring the level to the middle of the two marks on the dipstick.

Oil Level Hot Check

Perform engine oil level HOT CHECK as follows:

1.

Ride motorcycle until engine is at normal operating tem-
perature.

2.

Place vehicle on level ground and rest the vehicle on its
jiffy stand (unless sidecar is attached). Allow engine to
idle for 1-2 minutes. Turn engine off.

3.

Turn filler plug/dipstick counterclockwise. Remove and
wipe off the dipstick. Insert it back with the plug screwed
completely into the fill spout.

4.

See 

Figure 1-2

. Remove the dipstick and note the level

of the oil. If sidecar is attached, check oil level using the
opposite side of dipstick as shown in 

Figure 1-3

. Add only

enough oil to bring the level to the FULL mark on the dip-
stick. Do not overfill.

NOTE

Refer to 

Table 1-5

. Use only recommended oil specified in

1.3 FUEL AND OIL, Engine Lubrication

.

5.

Start engine and carefully check for oil leaks around drain
plug and oil filter.

Engine oil level should be checked only when engine is at
normal operating temperature.

NOTE

The engine will require a longer warm up period in colder
weather.

Do not allow hot oil level to fall below Add/Fill mark on
dipstick. Doing so can result in equipment damage and/or
equipment malfunction. (00189a)

Do not overfill oil tank. Doing so can result in oil carryover
to the air cleaner leading to equipment damage and/or
equipment malfunction. (00190a)

•

Check engine oil supply at each complete fuel refill.

•

Refer to 

Table 1-1

. Oil should be changed at specified

intervals in normal service at warm or moderate temperat-
ures.

•

Oil change intervals should be shorter in cold weather or
severe operating conditions. See 

1.3 FUEL AND OIL,

Winter Lubrication

.

3

1

2

om01006

1.

ADD QT (lower) mark

2.

Cold check level

3.

FULL (hot check) mark

Figure 1-2. Engine Oil Dipstick

2008 Touring Service:  Maintenance  1-11

NOTES

The engine oil dipstick has different markings on its two sides.

Figure 1-2

 shows the engine oil level when the motorcycle is

on its jiffy stand.

Figure 1-3

 shows the engine oil level with a

sidecar attached (motorcycle upright).

For cold check level, do not exceed the midpoint (2) when filling
with oil.

3

1

2

om01007

1.

ADD QT (lower) mark

2.

Cold check level

3.

FULL (hot check) mark

Figure 1-3. Engine Oil Dipstick (Sidecar Use)

CHANGING OIL AND OIL FILTER:TOURING
MODELS

TOOL NAME

PART NUMBER

OIL FILTER WRENCH

HD-42311

OIL FILTER WRENCH

HD-42311

OIL FILTER WRENCH

HD-44067A

Do not switch lubricant brands indiscriminately because
some lubricants interact chemically when mixed. Use of
inferior lubricants can damage the engine. (00184a)

Twin Cam equipped vehicles require the premium oil filter (Part
No. 63798-99A Chrome or Part No. 63731-99A Black).

Refer to 

Table 1-1

. Oil should be changed after the first  1000

miles (1600 kilometers) for a new engine and at regular inter-
vals in normal service at warm or moderate temperatures.

1.

Ride motorcycle until engine is warmed up to normal
operating temperature. Turn engine off.

2.

Locate oil filler plug/dipstick on right side of vehicle at top
of transmission case. Turn filler plug/dipstick counterclock-
wise to remove.

3.

See 

Figure 1-4

. Locate oil drain plug at front left side of

the oil pan. Remove the oil drain plug. Do not remove Allen
plug. Allow oil to drain completely.

1

2

om00311

1.

Transmission drain plug (right side)

2.

Engine oil drain plug and o-ring

Figure 1-4. Oil Pan

4.

Inspect the oil drain plug o-ring for cuts, tears or signs of
deterioration. Replace as necessary.

Be sure that no lubricants or fluids get on tires, wheels or
brakes when changing fluid. Traction can be adversely
affected, which could result in loss of control of the
motorcycle and death or serious injury. (00047d)

Use Harley-Davidson oil filter wrench for filter removal.
This tool can prevent damage to crankshaft position
sensor and/or sensor cable. (00192b)

5.

See 

Figure 1-5

. Remove the oil filter using the OIL FILTER

WRENCH (Part No. HD-42311) or OIL FILTER
WRENCH (Part No. HD-44067A). These tools allow easy
removal of the oil filter without risk of damage to the
crankshaft position sensor or cable.

6.

Place the jaws of the wrench over the oil filter with the tool
oriented vertically. Using a 3/8 inch drive with a 4 inch
extension, turn wrench in a counterclockwise direction.
Do not use with air tools.

7.

Clean the oil filter mount flange of any old gasket material.

NOTE

Dispose of oil and oil filter in accordance with local regulations.

8.

See 

Figure 1-6

. Lubricate gasket with clean engine oil and

install new oil filter on filter mount. Hand tighten oil filter
1/2-3/4 turn after gasket first contacts filter mounting sur-
face. Do not use OIL FILTER WRENCH (Part No. HD-
42311) for oil filter installation.

9.

Install engine oil drain plug and tighten to 14-21 ft-
lbs (19.0-28.5 Nm).

10. Refer to 

Table 1-5

. With vehicle resting on jiffy stand, ini-

tially add  3.5 quarts (3.3 liters) of engine oil. Use the

1-12  2008 Touring Service:  Maintenance

proper grade of oil for the lowest temperature expected
before the next oil change.

11. Verify proper oil level. See 

1.5 ENGINE OIL AND FILTER,

Checking Oil Level: Touring Models

.

a.

Check engine oil level using COLD CHECK pro-
cedure.

b.

Start engine and carefully check for oil leaks around
drain plug and oil filter.

c.

Check engine oil level using HOT CHECK procedure.

om00154

Figure 1-5. Oil Filter Wrench (Part No. HD-42311)

1

3

2

om00108

1.

Thin oil film ONLY

2.

Oil filter

3.

Mounting plate

Figure 1-6. Applying Thin Oil Film

2008 Touring Service:  Maintenance  1-13

1.6

BRAKES

FLUID INSPECTION

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)

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 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.

Check level in rear master cylinder reservoir.

a.

Stand motorcycle upright, so that master cylinder
reservoir is level.

b.

Remove two screws to release cover from master
cylinder reservoir.

c.

Check brake fluid level. If necessary, add D.O.T. 4
BRAKE FLUID until level is flush with top of ledge
cast at front of reservoir. See 

Figure 1-7

.

d.

Install master cylinder reservoir cover. Install cover
screws and tighten to 12-15 in-lbs (1.4-1.7 Nm).

2.

Check level in front master cylinder reservoir.

a.

Resting motorcycle on jiffy stand, turn front wheel
toward left fork stop until front master cylinder reser-
voir is level.

b.

Remove two screws to release cover from master
cylinder reservoir.

c.

Check brake fluid level. If necessary, add D.O.T. 4
BRAKE FLUID until level is flush with step (marked
MAX) cast at rear of reservoir. See 

Figure 1-7

.

d.

Install master cylinder reservoir cover. Install cover
screws and tighten to 7-10 in-lbs (0.8-1.1 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)

3.

Verify that front brake lever and rear brake pedal have a
firm feel when applied. Bleed appropriate system if brake
feels spongy. See 

1.14 BLEEDING BRAKES

.

1

2

sm04727

1.

Front master cylinder reservoir

2.

Rear master cylinder reservoir

Figure 1-7. Brake Fluid Level

1-14  2008 Touring Service:  Maintenance

1.7

AIR CLEANER AND EXHAUST SYSTEM

REMOVAL

1.

See 

Figure 1-8

. Remove screw from air cleaner cover.

Remove air cleaner cover with rubber seal.

2.

Remove three screws to release cover bracket from filter
element.

3.

Remove filter element pulling two breather tubes from
holes on inboard side.

4.

Remove gasket from sleeve on inboard side of filter ele-
ment. Discard gasket.

5.

Remove breather tubes from fittings on two cylinder head
breather bolts.

6.

Inspect the breather tubes and rubber seal for cuts, tears,
holes or signs of deterioration. Replace as necessary.

Do not use gasoline or solvents to clean filter element.
Flammable cleaning agents can cause an intake system
fire, which could result in death or serious injury. (00101a)

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)

7.

Clean filter element.

a.

Wash the paper/wire mesh filter element (and
breather tubes) in lukewarm water with a mild deter-
gent. Do not strike filter element on a hard surface to
dislodge dirt.

b.

Allow filter element to either air dry or blow it dry, from
the inside, with low pressure air. Do NOT use air
cleaner filter oil on the Harley-Davidson paper/wire
mesh air filter element.

c.

Hold the filter element up to a strong light source. The
element is sufficiently clean if light is uniformly visible
through the media.

d.

Replace the filter element if damaged or if filter media
cannot be adequately cleaned.

2008 Touring Service:  Maintenance  1-15

2

1

3

5

4

6

7

8

sm04764

5.

1.

Cover bracket

Cover screw

2.

6.

Air cleaner cover

Filter element

7.

3.

Gasket

Rubber seal

4.

8.

Cover bracket screw (3)

Breather tube (2)

Figure 1-8. Air Cleaner Assembly

INSTALLATION

1.

Slide new gasket over sleeve on inboard side of filter
element.

2.

Insert breather tubes about  0.25 inch (6.4 mm) into holes
on inboard side of filter element.

3.

Install breather tubes onto fittings of two cylinder head
breather bolts.

NOTE

Air cleaner mounting without installation of the breather tubes
allows crankcase vapors to be vented into the atmosphere in
violation of legal emissions standards.

4.

Place filter element onto backplate with the flat side down.

5.

Align holes in cover bracket with those in filter element
and start three screws. Alternately tighten screws to 40-60
in-lbs (4.5-6.8 Nm).

6.

Verify that rubber seal is properly seated around perimeter
of air cleaner cover.

7.

Fit air cleaner cover into backplate. Apply a small dab of
LOCTITE MEDIUM STRENGTH THREADLOCKER 243
(BLUE) to threads of cover screw. Install screw and tighten
to 36-60 in-lbs (4.1-6.8 Nm).

EXHAUST SYSTEM LEAK CHECK

Check the exhaust system for leaks at every scheduled service
interval as follows:

1.

Check entire exhaust system for loose or missing
fasteners, broken pipe clamps or brackets, and obvious
signs of leakage (carbon tracks at pipe joints, etc.).

2.

Check for loose or broken heat shields. Repair or replace
as necessary.

3.

Start engine, cover muffler ends with clean, dry shop
towels and listen for audible signs of exhaust leakage.

4.

Correct any leaks detected. See 

4.18 EXHAUST SYSTEM

for exhaust system removal and installation procedures.

1-16  2008 Touring Service:  Maintenance

5

2

3

1

4

sm05039

Figure 6-29. Sealing Fastener Torque Sequence

2008 Touring Service:  Drive  6-13

6.5

CLUTCH

REMOVAL AND INSTALLATION

To remove the clutch without disassembly or for installation
instructions, see 

6.3 DRIVE COMPONENTS, Removal

.

CLUTCH PACK ONLY

Partial Disassembly

This procedure can be performed on the motorcycle without
removing the clutch shell or hub.

1.

Remove primary chaincase cover. See 

6.2 PRIMARY

CHAINCASE COVER, Removal

.

2.

See 

Figure 6-30

. Remove six bolts (1) (metric) to release

diaphragm spring retainer (2) from clutch hub. Loosen
each bolt gradually and in a star sequence around the
hub.

3.

Remove diaphragm spring retainer, diaphragm spring (3)
and pressure plate (4) from clutch hub.

4.

Remove friction plates (5, 7), steel plates (6), damper
spring (8) and damper spring seat (9) from clutch hub (11).
Continue with Cleaning And Inspection.

Cleaning And Inspection

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)

1.

Wash all parts in cleaning solvent, except for friction plates
and bearing, if removed. Blow parts dry with low pressure
compressed air.

2.

Check friction plates as follows:

a.

Blow off all lubricant from the friction plates. Do not
wipe off with a rag.

b.

Measure the thickness of each plate with a dial caliper
or micrometer.

c.

If the thickness of any plate is less than  0.143
in. (3.62 mm), discard all friction plates and replace
with an entirely new set.

d.

Look for worn or damaged fiber surface material (both
sides).

NOTE

Replace all nine friction plates with an entirely new set if any
individual plate shows evidence of wear or damage. Submerge
and soak all friction plates in FORMULA+ TRANSMISSION
AND PRIMARY CHAINCASE LUBRICANT (Part No. 99851-
05, qt.) for at least five minutes.

3.

Check the steel plates as follows:

a.

Discard any plate that is grooved or bluish in color.
Blue plates are likely warped or distorted.

b.

Check each plate for distortion. Lay the plate on a
precision flat surface. Insert a feeler gauge between
the plate and the flat surface in several places.
Replace any steel plate that is warped more than

0.006 in. (0.15 mm).

4.

Holding the clutch hub, rotate the clutch shell to check
bearing for smoothness. Replace the bearing if it runs
rough, binds or has any end play.

5.

Check the primary chain sprocket and the starter ring gear
on the clutch shell. Replace the clutch shell if either
sprocket or ring gear are badly worn or damaged.

6.

Check the slots that mate with the clutch plates on both
the clutch shell and hub. Replace shell or hub if slots are
worn or damaged.

7.

Check the diaphragm spring and diaphragm spring retainer
for cracks or bent tabs. Obtain a new diaphragm spring
or diaphragm spring retainer if either condition exists.

6-14  2008 Touring Service:  Drive