Harley Davidson 2008 Touring Models. Service Manual - page 5

1.8

TIRES AND WHEELS

TIRES

Match tires, tubes, air valves and caps to the correct wheel
rim. Contact a Harley-Davidson dealer. Mismatching can
result in damage to the tire bead, allow tire slippage on
the rim or cause tire failure, which could result in death
or serious injury. (00023a)

Use only Harley-Davidson approved tires. See a Harley-
Davidson dealer. Using non-approved tires can adversely
affect stability, which could result in death or serious
injury. (00024a)

Use inner tubes on laced (wire spoked) wheels. Using
tubeless tires on laced wheels can cause air leaks, which
could result in death or serious injury. (00025a)

NOTES

•

Tubeless tires are used on all Harley-Davidson cast and
disc wheels.

•

Tire sizes are molded on the tire sidewall. Inner tube sizes
are printed on the tube.

•

New tires should be stored on a horizontal tire rack. Avoid
stacking new tires in a vertical stack. The weight of the
stack compresses the tires and closes down the beads.

Check tire pressure and tread:

•

As part of the pre-ride inspection.

•

At every scheduled service interval.

1.

Inspect each tire for punctures, cuts and breaks.

2.

Inspect each tire for wear. Replace tires before they reach
the tread wear indicator bars.

NOTE

Missing indicator wear bars represent less than   1/32 in. (0.8
mm) tread pattern depth remaining.

3.

Check for proper front and rear tire pressures when tires
are cold. Compare results against 

Table 1-7

.

Table 1-7. Tire Pressures: 2008 Touring Models

TIRE PRESSURE (COLD)

LOAD

MODEL

REAR

FRONT

kPa

PSI

kPa

PSI

248

36

248

36

Solo rider

All

276

40

248

36

Rider and passenger

TIRE REPLACEMENT

Inspection

Harley-Davidson tires are equipped with wear bars that
run horizontally across the tread.When wear bars become
visible and only 1/32 in. (0.8 mm) tread depth remains,
replace tire immediately. Using a worn tire can adversely
affect stability and handling, which could result in death
or serious injury. Use only Harley-Davidson approved
replacement tires. (00090b)

See 

Figure 1-9

. Arrows on tire sidewalls pinpoint location of

wear bar indicators.

Tread wear indicator bars will appear on tire tread surfaces
when  1/32 in. (0.8 mm) or less of tire tread remains. See

Figure 1-10

. Always replace tires before the tread wear indic-

ator bars appear.

When To Replace Tires

New tires are needed if any of the following conditions exist:

1.

Tread wear indicator bars become visible on the tread
surfaces.

2.

Tire cords or fabric become visible through cracked side-
walls, snags or deep cuts.

3.

A bump, bulge or split in the tire.

4.

Puncture, cut or other damage to the tire that cannot be
repaired.

2008 Touring Service:  Maintenance  1-17

om00846

Figure 1-9. Tire Sidewall Wear Bar Locator

om00845

Figure 1-10. Wear Bar Appearance

WHEEL BEARINGS

Service wheel bearings:

1.

Replace wheel bearings if end play exceeds  0.002
in. (0.051 mm). See 

2.8 SEALED WHEEL BEARINGS

.

2.

If wheel is already removed, check wheel bearings as fol-
lows:

a.

Insert finger into wheel bearing and rotate the inner
race in both directions. Repeat step on opposite side
of wheel. See 

Figure 1-11

.

b.

Replace the wheel bearings if there is drag, rough
rotation, abnormal noise or anything unusual.

3.

Check axle spacers for wear and corrosion. Replace as
necessary.

sm04767

Figure 1-11. Inspect Wheel Bearings

WHEEL SPOKES

Spokes that are too tight can draw nipples through the rim
or distort hub flanges. Spokes that are too loose can
continue to loosen when put in service. Either condition
can adversely affect stability and handling, which could
result in death or serious injury. (00286a)

If nipples require more than one full turn to tighten spoke,
remove tire to check that spoke protrusion has not dam-
aged tube. (00526b)

4.

Raise motorcycle wheel off the ground.

NOTE

Perform the entire procedure for each spoke, one at a time.

5.

Mark one of the spokes with a reference mark to the rim.

6.

Loosen spoke 1/4 turn.

NOTES

•

Use a spoke torque wrench to tighten spokes.

•

Do not tighten spoke more than 1/4 turn past reference
mark. If more tension is needed, label spoke and check
after completing rest of wheel.

7.

Tighten spoke to reference mark. If torque is less then the
value listed in 

Table 1-8

, continue to tighten spoke until it

reaches the listed torque.

8.

Once the entire wheel has been checked, repeat pro-
cedure for each labeled spoke.

1-18  2008 Touring Service:  Maintenance

9.

If more than a few spokes were loose, true the entire wheel
following procedure under 

2.9 TRUING LACED WHEELS

.

Table 1-8. Spoke Nipple Torque Specification

MINIMUM TORQUE

RIM TYPE

55 in-lbs (6.2 Nm)

All

2008 Touring Service:  Maintenance  1-19

1.9

PRIMARY CHAIN

GENERAL

All models have an automatic chain tensioner. For primary
chain service procedures, see 

6.3 DRIVE COMPONENTS

.

CHAINCASE LUBRICANT: TOURING
MODELS

General

Refer to 

Table 1-1

. The primary chaincase lubricant should be

drained and refilled with fresh lubricant at specified intervals.

Check Lubricant Level

1.

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

2.

Stand motorcycle upright, so that primary chaincase is
level.

3.

See 

Figure 1-12

. Remove five screws to free clutch

inspection cover from primary chaincase cover.

4.

Remove seal ring from clutch inspection cover and discard.

5.

If the fluid level can be seen, it is adequate. Otherwise,
pour enough GENUINE Harley-Davidson FORMULA+
TRANSMISSION AND PRIMARY CHAINCASE LUB-
RICANT (Part No. 99851-05, U.S. quart) in through the
clutch inspection cover opening until it is visible along the
bottom portion of the clutch assembly.

6.

Refer to Changing Chaincase Lubricant to install seal ring
and clutch inspection cover.

Do not overfill the primary chaincase with lubricant.
Overfilling can cause rough clutch engagement, incom-
plete disengagement, clutch drag and/or difficulty in
finding neutral at engine idle. (00199b)

4

3

5

2

1

1

3

2

4

om04765

1.

Primary chaincase cover

2.

Drain plug

3.

Clutch inspection cover

4.

Torque sequence

Figure 1-12. Primary Chaincase

Changing Chaincase Lubricant

When draining or adding lubricant, do not allow dirt, debris
or other contaminants to enter the engine. (00198a)

1.

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

2.

Remove five screws to free clutch inspection cover from
primary chaincase cover.

3.

Remove drain plug at bottom of primary chaincase. Drain
lubricant into suitable container.

NOTE

Dispose of chaincase lubricant in accordance with local regu-
lations.

4.

Clean drain plug magnet. If plug has accumulated a lot of
debris, inspect the condition of chaincase components.

5.

Inspect drain plug O-ring for cuts, tears or signs of deteri-
oration. Replace as necessary.

6.

Install drain plug into primary chaincase and tighten to 14-
21 ft-lbs (19.0-28.5 Nm).

7.

Pour  38 fl. oz. (1124 ml) of GENUINE Harley-Davidson
FORMULA+ TRANSMISSION AND PRIMARY CHAIN-
CASE LUBRICANT (Part No. 99851-05 quart) through the
clutch inspection cover opening.

NOTE

Only add  45 fl. oz. (1331 ml) after service that involves removal
of the primary chaincase or primary chaincase cover.

Do not overfill the primary chaincase with lubricant.
Overfilling can cause rough clutch engagement, incom-
plete disengagement, clutch drag and/or difficulty in
finding neutral at engine idle. (00199b)

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)

8.

Swab all lubricant from seal ring groove in clutch inspection
cover. Install new seal ring in groove with nubs contacting
ring groove walls.

9.

Install five screws to fasten clutch inspection cover to
primary chaincase cover. Alternately tighten screws to 84-
108 in-lbs (9.5-12.2 Nm) in the sequence shown in

Figure 1-12

.

1-20  2008 Touring Service:  Maintenance

NOTE

See 

Figure 6-36

. Notice damper spring (4) orientation with

respect to damper spring seat (3).

3.

See 

Figure 6-30

. Install damper spring (8) on clutch hub

with the concave side out (facing away from damper spring
seat).

4.

Install a steel plate (6) with round edge outward and then
a friction plate (5) on the clutch hub. Install seven
remaining sets in the same manner, alternating between
steel plates and friction plates.

5.

Install pressure plate (4) on clutch hub aligning holes in
plate with threaded bosses on hub.

6.

Seat diaphragm spring (3) in recess of pressure plate with
the concave side inward.

7.

Align holes in diaphragm spring retainer (2) with threaded
bosses on clutch hub. Tabs on spring retainer contact flats
on inboard side of bosses.

8.

Install six bolts (1) (metric) to secure diaphragm spring
retainer to clutch hub. Alternately tighten the bolts to 90-
110 in-lbs (10.2-12.4 Nm).

NOTE

The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.

9.

Install primary chaincase cover and gasket. See

6.2 PRIMARY CHAINCASE COVER, Installation

.

10. Fill primary chaincase with lubricant. See 

1.9 PRIMARY

CHAIN, Chaincase Lubricant: Touring Models

.

1

2

sm02417

1.

Narrow plate

2.

Regular plate

Figure 6-31. Friction Plates

CLUTCH PACK AND BEARING

Complete Disassembly

1.

Remove the primary chaincase cover. See 

6.2 PRIMARY

CHAINCASE COVER, Removal

.

2.

Remove clutch assembly. See 

6.3 DRIVE COMPONENTS,

Removal

.

3.

Follow all partial disassembly information under

6.5 CLUTCH, Clutch Pack Only

.

NOTE

To avoid possible bearing damage, do not disassemble the
clutch shell and hub assembly unless the bearing, hub or shell
require replacement. Replace the bearing if disassembled.

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
serious eye injury. (00312a)

4.

See 

Figure 6-32

. With the transmission side up, remove

retaining ring from clutch hub groove.

5.

See 

Figure 6-33

. Supporting clutch shell in same orienta-

tion, use arbor press and a suitable press plug to press
hub from bearing in clutch shell.

6.

See 

Figure 6-34

. With the transmission side up, remove

retaining ring from groove in clutch shell bore.

7.

See 

Figure 6-35

. Turn clutch shell over so that transmis-

sion side is down. Using arbor press and a suitable press
plug, press on inner race to remove bearing from clutch
shell bore.

8.

Continue with Cleaning and Inspection found under

6.5 CLUTCH, Clutch Pack Only

.

sm02419

Figure 6-32. Clutch Hub Retaining Ring

6-16  2008 Touring Service:  Drive

sm02421

Figure 6-33. Pressing Clutch Hub From Bearing

Assembly

1.

Orient clutch shell in arbor press with transmission side
up. Be sure to support clutch shell bore on sprocket side
to avoid damage to ears on clutch basket. Using a suitable
press plug, press against outer race until bearing contacts
shoulder in clutch shell bore.

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
serious eye injury. (00312a)

2.

See 

Figure 6-34

. Install retaining ring in groove of clutch

shell bore so that flat side of retaining ring is towards
bearing.

3.

Turn clutch shell over so sprocket side is up. Center hub
in bearing. Be sure that bearing inner race is supported
with sleeve on transmission side. Press hub into bearing
until hub shoulder contacts bearing inner race.

4.

See 

Figure 6-32

. Turn assembly over so that the transmis-

sion side is up. Install retaining ring in groove of clutch
hub.

5.

Place clutch assembly on bench oriented with the trans-
mission side down.

6.

Soak all friction and steel plates in FORMULA+ TRANS-
MISSION AND PRIMARY CHAINCASE LUBRICANT (Part
No. 99851-05, qt.) for at least five minutes.

7.

See 

Figure 6-36

. Install the narrow friction plate on the

clutch hub engaging tabs on plate with slots in clutch shell.

8.

Install damper spring seat on clutch hub so that it seats
inboard of narrow friction plate.

9.

Install damper spring on clutch hub with the concave side
up (facing opposite damper spring seat).

10. Install a steel plate and than a friction plate on the clutch

hub. Install seven remaining sets in the same manner,
alternating between steel plates and frictions plates.

11. Install pressure plate on clutch hub aligning holes in plate

with threaded bosses on hub.

12. See 

Figure 6-37

. Seat diaphragm spring (1) in recess of

pressure plate with the concave side down.

13. Align holes in diaphragm spring retainer with threaded

bosses on clutch hub. Tabs on spring retainer contact flats
on inboard side of bosses.

14. Install six bolts (5) (metric) to secure diaphragm spring

retainer to clutch hub. Alternately tighten 90-110 in-
lbs (10.2-12.4 Nm).

15. Install clutch. See 

6.3 DRIVE COMPONENTS, Installation

.

NOTE

The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.

16. Install primary chaincase cover and gasket. See

6.2 PRIMARY CHAINCASE COVER, Installation

.

17. Fill primary chaincase with lubricant. See 

1.9 PRIMARY

CHAIN, Chaincase Lubricant: Touring Models

.

sm02422

Figure 6-34. Install Clutch Shell Retaining Ring with Flat

Side Against Bearing

2008 Touring Service:  Drive  6-17

sm02424

Figure 6-35. Pressing Bearing From Clutch Shell

5

2

7

6

1

3

4

sm02426

1.

Steel plate

2.

Clutch hub

3.

Damper spring seat

4.

Damper spring

5.

Starter ring gear

6.

Primary chain sprocket

7.

Narrow friction plate

Figure 6-36. Clutch Stackup

5

4

3

2

1

sm02427

1.

Diaphragm spring

2.

Jam nut

3.

Adjuster screw

4.

Retaining ring

5.

Bolt (6) (metric)

Figure 6-37. Assembled Clutch

6-18  2008 Touring Service:  Drive