Harley Davidson 2008 Touring Models. Service Manual

2.18

AIR DAM: FLTR

AIR DAM (FLTR)

Removal

NOTE

By allowing the flow of air to pass under the fuel tank and over
the cylinder heads, removing the air dam evacuates heated
air and provides some relief to the rider in warmer temperat-
ures: 70°F. (21°C.) or above.

Moving to the back of the lower fork bracket, remove two
hex screws (with flat washers) to release air dam. See

Figure 2-65

Reinstall two hex screws (with flat washers) to keep dirt
and debris out of holes in lower fork bracket. Tighten
screws to 120-144 in-lbs (13.6-16.3 Nm).

Installation

NOTE

Reinstall air dam in colder weather.

With the concave side down, align holes in air dam with
holes at back of the lower fork bracket. Start two hex
screws (with flat washers).

sm02906

Figure 2-65. Air Dam

NOTE

Plastic plug(s) at back of lower fork bracket will prevent proper
cover installation. Remove and discard plug(s), if present.

Alternately tighten hex screws to 120-144 in-lbs (13.6-
16.3 Nm).

2008 Touring Service: Chassis 2-57

2.19

STEERING HEAD BEARINGS

REMOVAL

TOOL NAME

PART NUMBER

UNIVERSAL DRIVER

HD-33416

STEERING HEAD BEARING CUP
REMOVER

HD-39301A

Disassemble motorcycle as follows:

FLHR/C: Remove headlamp nacelle. See

2.45 HEADLAMP NACELLE: FLHR/C

FLHX, FLHT/C/U: Remove the auxiliary lamp bracket,
outer fairing and radio (storage box on FLHT). See

8.11 AUXILIARY LAMPS AND BRACKETS

2.35 UPPER FAIRING AND WINDSHIELD: FLHX,
FLHT/C/U

and

8.32 ADVANCED AUDIO SYSTEM

respectively.

FLTR: Remove instrument nacelle. See

2.41 INSTRUMENT NACELLE: FLTR

Remove front forks. See

2.17 FRONT FORK

sm04955

Fork stem nut

Roll pin

Lock plate

Upper fork bracket

Spade contact

Bearing adjuster nut

Dust shield

Bearing cone

Bearing cup

10. Dust shield
11. Lower fork bracket

Figure 2-66. Steering Head/Fork Bracket Assembly

sm02909

Remover

Collet

Figure 2-67. Steering Head Bearing Cup Remover (Part

No. HD-39301A)

sm02910

Figure 2-68. Universal Driver (Part No. HD-33416)

Remove screw at bottom of lower fork bracket to release
brake line bracket.

FLTR: Remove two screws (with flat washers) to release
air dam at back of lower fork bracket.

Bend tab on lock plate away from flat of fork stem nut.
Remove fork stem nut. See

Figure 2-66

Remove roll pin and lock plate.

Disconnect ignition switch [33], left handlebar switch [24],
right handlebar switch [22] and twist grip sensor jumper
harness [204] connectors. On fairing equipped motor-
cycles, remove interconnect harness ground socket ter-
minal from spade contact at front of upper fork bracket
(left side).

Remove upper fork bracket.

Remove bearing adjuster nut from stem of lower fork
bracket.

10. Using a rubber mallet, tap on stem of lower fork bracket

to free from upper bearing cone. Draw stem of lower fork
bracket out through bottom of steering head.

11. Remove dust shield and upper bearing cone at top of

steering head.

12. Remove lower bearing cone and dust shield from stem of

lower fork bracket.

2-58 2008 Touring Service: Chassis

NOTE

Bearing cones are a slip fit on stem of lower fork bracket. If
necessary, gently pry bearing cones off stem with a pair of flat
blade screwdrivers.

13. See

Figure 2-67

and

Figure 2-68

. Obtain STEERING

HEAD BEARING CUP REMOVER (Part No. HD-39301A)
and UNIVERSAL DRIVER (Part No. HD-33416). Proceed
as follows:

With the tapered side down, seat the two-piece
remover tool on the upper bearing cup leaving a gap
in the middle. See

Figure 2-69

Install collet on driver.

Insert driver up through bottom of steering head, and
while holding remover tool on upper bearing cup,
center collet in gap. Tap driver to remove upper
bearing cup.

Reverse tool and repeat procedure to remove lower
bearing cup.

sm02911

Install remover on upper cup

Install collet on driver

Install driver in remover and remove upper cup

Remove lower cup

Figure 2-69. Remove Steering Head Bearing Cups

INSPECTION

Check the bearing races in the steering head. If pitted or
grooved, replace both the bearings and races.

Turn bearings in races. Replace the bearings if they do
not move freely and smoothly. Always replace both races
and bearings even if one race and bearing appears good.

2008 Touring Service: Chassis 2-59

INSTALLATION

TOOL NAME

PART NUMBER

STEERING HEAD BEARING CUP
INSTALLER

HD-39302

See

Figure 2-70

. Obtain STEERING HEAD BEARING

CUP INSTALLER (Part No. HD-39302). Proceed as fol-
lows:

Start upper bearing cup into top of steering head with
the beveled side facing outboard.

Fit smaller OD of installer tool into upper bearing cup.

Slide forcing screw through installer tool and bearing
cup until threaded end exits bottom of steering head.

Sparingly apply graphite lubricant to threads of forcing
screw.

With the beveled side facing outboard, slide lower
bearing cup up forcing screw.

Slide second half of installer tool up forcing screw fit-
ting smaller OD into lower bearing cup.

Install Nice bearing, flat washers and hex nut onto
forcing screw.

Tighten hex nut by hand until assembly is square and
snug.

While holding head of forcing screw, turn hex nut to
simultaneously draw both upper and lower bearing
cups into steering head. Continue turning hex nut until
cups makes contact with counterbores. See

Figure 2-71

Disassemble and remove tool.

Slide new dust shield down stem until contact is made
with top of lower fork bracket.

Pack new bearing cones with Harley-Davidson SPECIAL
PURPOSE GREASE, Part No. 99857-97.

With the tapered side up, place bearing cone over stem
of lower fork bracket. Using the thumbs of both hands,
lightly press on bearing cone until it bottoms against dust
shield.

Insert stem of lower fork bracket up into steering head.

At top of steering head, push upper bearing cone onto
stem with the tapered side down.

Slide new dust shield down stem until flush with top of
steering head.

Install bearing adjuster nut onto stem.

Snug adjuster nut until bearing play is taken up and stem
turns freely. Overtightening nut will cause excessive
bearing wear.

10. Install upper fork bracket.

11. Install lock plate and roll pin.

12. Install fork stem nut and tighten to 60-80 ft-lbs (81-109

Nm).

13. Bend tab on lock plate against flat of fork stem nut.

sm04979

Figure 2-70. Steering Head Bearing Cup Installer (Part No.

HD-39302)

sm04980

Figure 2-71. Install Steering Head Bearing Cups

14. Connect ignition switch [33], left handlebar switch [24],

right handlebar switch [22] and twist grip sensor jumper
harness [204] connectors. On fairing equipped motor-
cycles, connect interconnect harness ground socket ter-
minal to spade contact at front of upper fork bracket (left
side).

15. Install front forks. See

2.17 FRONT FORK

16. Start screw to fasten brake line bracket at bottom of lower

fork bracket. Verify that brake lines to calipers, as viewed
at the rear, are equal distance from the left and right fork
sliders, and then tighten screw to 120-180 in-lbs (13.6-
20.3 Nm).

17. FLTR: Install two screws (with flat washers) to fasten air

dam at back of lower fork bracket. Alternately tighten
screws to 120-144 in-lbs (13.6-16.3 Nm).

2-60 2008 Touring Service: Chassis

18. Assemble motorcycle as follows:

FLHR/C: Install headlamp nacelle. See

2.45 HEAD-

LAMP NACELLE: FLHR/C

FLHX, FLHT/C/U: Install radio (storage box on FLHT),
outer fairing and auxiliary lamp bracket. See

8.32 ADVANCED AUDIO SYSTEM

2.35 UPPER

FAIRING AND WINDSHIELD: FLHX, FLHT/C/U

and

8.11 AUXILIARY LAMPS AND BRACKETS

, respect-

ively.

FLTR: Install instrument nacelle. See

2.41 INSTRU-

MENT NACELLE: FLTR

Properly adjust fork stem bearings. Improper adjustments
affect stability and handling, which could result in death
or serious injury. (00301a)

19. Check swing-by and adjust as necessary. See

1.19 STEERING HEAD BEARINGS

2008 Touring Service: Chassis 2-61

2.20

REAR AIR SUSPENSION

REMOVAL AND INSTALLATION

TOOL NAME

PART NUMBER

AIR SUSPENSION PUMP AND
GAUGE

HD-34633A

Remove and replace components as necessary. Check for air
leaks as follows:

Remove left side saddlebag. See

2.27 SADDLEBAGS

Remove protective cap from air valve. Install AIR SUSPEN-
SION PUMP AND GAUGE (Part No. HD-34633A)and set
to correct pressure. See

1.17 SUSPENSION ADJUST-

MENTS

. Remove the gauge and wait overnight.

Recheck air pressure. If no leakage is observed, move to
step 8. If a loss of 5-10 psi (34.5-68.9 kPa) is noted, then
proceed to step 4.

Pressurize rear air suspension system and check for leaks
as described below.

sm02914

Figure 2-72. Air Suspension Pump and Gauge (Part No.

HD-34633A)

Compression Fitting

Spray or brush a light film of soapy water on the compres-
sion fitting at the top of each shock absorber. If no leakage

is observed, move to step 6. If leakage is noted, proceed
as follows:

Depress pin in valve to bleed air from shocks. To
purge lines of any oil, add 3-5 psi (20.7-34.5 kPa)
before releasing air.

Depress collar on compression fitting and pull out air
tube. See inset of

Figure 2-74

. Inspect the tube end

for burrs or damage. If either condition is observed,
snip off the end of the tube and insert it back into the
compression fitting until it bottoms. Gently tug on tube
to verify that it is locked in place.

Pressurize rear air suspension system and check for
leaks. If leakage continues, proceed to step 5(d).

Depress collar on compression fitting and pull out air
tube. Remove compression fitting from shock
absorber.

Apply PIPE SEALANT WITH TEFLON to the threads
of a new compression fitting and install in shock
absorber.

Insert air tube into the compression fitting until it bot-
toms. Gently tug on tube to verify that it is locked in
place.

Pressurize rear air suspension system and check for
leaks. If no leakage is observed, move to step 8. If
leakage continues, proceed to step 6.

Air Valve Assembly

Spray or brush a light film of soapy water into the valve
head and where the air tubes exit the air inlet tee. If

2-62 2008 Touring Service: Chassis

leakage is not observed at either location, move to step
7. If leakage is noted, proceed as follows:

If leakage is at the air inlet tee, proceed to step 6(b).
If leakage is at the valve head, proceed to step 6(e).

Depress pin in valve to bleed air from shocks. To
purge lines of any oil, add 3-5 psi (20.7-34.5 kPa)
before releasing air.

Depress collar on air inlet tee and pull out air tube.
Inspect the tube end for burrs or damage. If either
condition is observed, snip off the end of the tube and
insert it back into the air inlet tee until it bottoms.
Gently tug on tube to verify that it is locked in place.
Repeat step with remaining tube.

Pressurize rear air suspension system and check for
leaks. If no leakage is observed, move to step 8. If
leakage continues, proceed to step 6(e).

Using a valve core tool, verify that valve core is
properly tightened. If leakage continues, proceed to
step 6(f).

Depress pin in valve to bleed air from shocks. To
purge lines of any oil, add 3-5 psi (20.7-34.5 kPa)
before releasing air.

Remove hex nut from valve head. See

Figure 2-74

Push on valve head to free air valve assembly from
mounting bracket. See

Figure 2-73

Depress collars on air inlet tee and pull out air tubes.

Insert air tubes into air inlet tee of new air valve
assembly.

From inboard side, insert valve head through hole in
mounting bracket. Install hex nut on valve head (flat
side facing inboard). Tighten nut to 40-50 in-lbs (4.5-
5.6 Nm).

Pressurize rear air suspension system and check for
leaks.

m. If no leakage is observed, move to step 8. If leakage

continues, reinstall old air valve assembly and pro-
ceed to step 7.

sm02915

Air inlet tee

Valve head

Figure 2-73. Air Valve Assembly

Air Tubes

Inspect air tubes for kinks, cuts, holes, chafing or other
damage that may result in air leaks. If tube replacement
is necessary, proceed as follows:

Remove seat. See

2.26 SEAT

Depress pin in valve to bleed air from shocks. To
purge lines of any oil, add 3-5 psi (20.7-34.5 kPa)
before releasing air.

Depress collars on air inlet tee and pull out air tubes.
Remove opposite end of tubes from compression fit-
tings. See

Figure 2-74

Cut bulk tube to proper length.

Insert new tubes into air inlet tee. Install opposite end
of tubes into compression fittings.

Pressurize rear air suspension system.

Install seat. See

2.26 SEAT

Install protective cap on air valve.

Install left side saddlebag. See

2.27 SADDLEBAGS

2008 Touring Service: Chassis 2-63

sm02913

Protective cap

Hex nut

Air valve and mounting bracket

Air inlet tee

Shock air inlet tube

Compression fitting

Left shock

Right shock

Figure 2-74. Rear Air Suspension System

2-64 2008 Touring Service: Chassis

2.21

REAR SHOCK ABSORBERS

ADJUSTMENT

For the correct air pressure, see

1.17 SUSPENSION

ADJUSTMENTS

REMOVAL

TOOL NAME

PART NUMBER

AIR SUSPENSION PUMP AND
GAUGE

HD-34633

NOTE

If replacing both shock absorbers, remove and install one shock
at a time. Remove and install the second shock only after the
first shock is installed, but before the air suspension system is
pressurized.

Place the motorcycle on a hydraulic center stand with the
rear wheel raised off the ground.

Remove saddlebags. See

2.27 SADDLEBAGS

Use caution when bleeding air from the suspension.
Moisture combined with lubricant may leak onto the rear
wheel, tire and/or brake components and adversely affect
traction, which could result in death or serious injury.
(00084a)

Remove protective cap from air valve. Using the no-loss
AIR SUSPENSION PUMP AND GAUGE (Part No. HD-
34633), add 3-5 psi (20.7-34.5 kPa) to purge lines of any
oil.

Depress pin in valve to bleed air from shocks.

Depress collar on compression fitting to release air tube.
See

Figure 2-75

Remove the upper shock mounting bolt with lockwasher
and flat washer. See lower frame of

Figure 2-76

Remove the lower shock mounting bolt with lockwasher
and flat washer. Remove the shock absorber assembly
from the motorcycle.

NOTE

Never lay the shock absorber down. Always keep the shock
absorber upright in a fully vertical position. Laying the shock
absorber down with the air line removed can cause the oil to
drain out through the compression fitting. Any loss of oil
requires replacement of the shock absorber.

sm02916

Figure 2-75. Depress Collar on Fitting and Pull Out Air Inlet

Tube

sm02917

Compression fitting

Air inlet tube

Shock absorber

Frame boss

Figure 2-76. Remove Upper Shock Mounting Bolt (Left

Side View)

CLEANING AND INSPECTION

Examine the rubber mounting bushings for cracks or wear.
Examine the shock for leaks. The unit should not leak and
should compress slightly easier than it extends. Compare
the action of the shock with a new one to judge if it is worn.
Replace the shock if necessary.

2008 Touring Service: Chassis 2-65

Clean and examine the shock mounting hardware. Replace
parts that are worn or damaged.

DISASSEMBLY AND ASSEMBLY

NOTES

•

Air shocks are not repairable. Replace the shocks if dam-
aged, worn or any sign of leakage is observed.

•

If the compression fittings were removed, apply PIPE
SEALANT WITH TEFLON to the threads before assembly.

INSTALLATION

NOTE

Install lockwasher and flat washer on the lower shock
mounting bolt. Insert bolt through the shock bottom
bushing.

Apply two or three drops of LOCTITE MEDIUM
STRENGTH THREADLOCKER 243 (blue) to threads.

Start bolt into rear swingarm mount. Tighten bolt to 35-40
ft-lbs (47-54 Nm).

Install lockwasher and flat washer on the upper shock
mounting bolt. Insert bolt through the shock upper bushing.

Apply two or three drops of LOCTITE MEDIUM
STRENGTH THREADLOCKER 243 (blue) to threads.

Start bolt into frame boss. Tighten bolt to 33-35 ft-lbs (45-
48 Nm).

Insert air tube into compression fitting until it bottoms.
Gently tug on tube to verify that it is locked in place.

NOTE

If replacing both shock absorbers, remove and install the other
shock at this time.

Pressurize rear air suspension system and check for leaks.
See

1.17 SUSPENSION ADJUSTMENTS

and

2.20 REAR

AIR SUSPENSION

, respectively.

Install saddlebags. See

2.27 SADDLEBAGS, Installation

2-66 2008 Touring Service: Chassis

2.22

REAR FORK

REMOVAL

Place the motorcycle on a hydraulic center stand. Slide a
block of wood beneath the oil pan to support the weight
of the transmission once the pivot shaft is removed.

Remove rear wheel. See

2.4 REAR WHEEL

Remove caliper bracket from anchor weldment on rear
swingarm.

Remove belt guard from bottom of left side swingarm. First
remove two rear screws, and then loosen front screw.
Push belt guard toward the front of the motorcycle until
screw engages large end of slot, and then remove.

Remove lower shock mounting bolt (with lockwasher and
flat washer) to release shock absorber from rear swingarm
mount. Repeat step on opposite side of motorcycle.

Remove socket screw with lockwasher to remove pas-
senger footboard from rear swingarm bracket. Repeat step
on opposite side of motorcycle.

Remove two bolts (with lockwashers) to free rear swingarm
bracket from left side of motorcycle frame. See

Figure 2-77

Moving to right side of motorcycle, leave rear swingarm
bracket installed, but remove decorative chrome plug.

Open two cable clips on T-studs at top of right side
swingarm. Free rear brake line hose and rear wheel speed
sensor (if ABS equipped) from cable clips.

NOTE

For best results, insert blade of small screwdriver into gap at
side of clip and gently rotate end of screwdriver to pop open.

10. Holding left side nut within rubber mount, remove right

side locknut from end of pivot shaft. Remove cup washer.

11. Using a suitable drift, tap pivot shaft toward left side of

motorcycle.

12. See

Figure 2-82

. Moving to left side, pull pivot shaft

assembly (pivot shaft, locknut, cup washer, rubber mount
and outer spacer) out of transmission mount and left side
swingarm.

13. Standing at rear of motorcycle, work rear swingarm free

of transmission mount and rear swingarm brackets.

14. Remove outer spacer from right side swingarm tube.

15. Remove rubber mount from behind right side swingarm

bracket.

sm02929

Pivot shaft

Locknut

Rubber mount

Slot

Figure 2-77. Remove Rear Swingarm Bracket (Left Side

View)

DISASSEMBLY AND ASSEMBLY

TOOL NAME

PART NUMBER

REAR SWINGARM BEARING
INSTALLER

HD-45327

Bearing Removal

Move rear swingarm to an hydraulic press.

Place swingarm on its side, so that the brake side is on
top. The brake side is easily recognized by the anchor
weldment for mounting of the brake caliper.

Support the swingarm with a block of wood and a large
socket as shown in

Figure 2-78

. Verify that assembly is

square and the bearing bore is completely vertical.

Slide driver handle (or long socket extension) through the
brake side swingarm tube and bearing until it contacts
driver (or smaller socket) placed on inboard side of drive
side bearing.

2008 Touring Service: Chassis 2-67

sm03534

Anchor weldment

Wood block

Large socket

Socket extension

Smaller socket

Ram

Figure 2-78. Press Out Drive Side Bearing

Center driver handle (or long socket extension) under ram
and press drive side bearing from rear swingarm.

Remove tools from rear swingarm. Turn swingarm over
and previous steps to press out brake side bearing.

Bearing Installation

Obtain new rear swingarm bearings. Bearings and spacers
must be assembled before installation. Proceed as follows:

Place bearing flat on suitable press plate.

With the collar topside, start spacer into bearing. See

Figure 2-79

Center assembly under ram of hydraulic press.

Apply pressure to spacer until it bottoms against press
plate.

Repeat step to assemble second swingarm bearing.

sm02930

Spacer

Bearing

Figure 2-79. Press Spacer into Bearing

2-68 2008 Touring Service: Chassis

sm03535

Drive side driver

Brake side driver

Figure 2-80. Rear Swingarm Bearing Installer (HD-45327)

sm02931

Brake side driver

Anchor weldment

Figure 2-81. Press in Brake Side Bearing

Install assembled bearings into rear swingarm. Proceed
as follows:

Obtain REAR SWINGARM BEARING
INSTALLER (Part No. HD-45327). See

Figure 2-80

Place swingarm on its side, so that the brake side is
on top. The brake side is easily recognized by the
anchor weldment for mounting of the brake caliper.

With the spacer inboard, insert bearing into outboard
side of brake side swingarm tube.

Insert driver stamped "Brake Side" into swingarm tube
until it contacts installed bearing. Center driver under
ram and press on brake side bearing until shoulder
on tool makes contact with casting of swingarm. See

Figure 2-81

Remove tool and turn rear swingarm over. With the
spacer inboard, insert bearing into outboard side of
drive side swingarm tube.

Insert driver stamped "Drive Side" into swingarm tube
until it contacts installed bearing. Center driver under
ram and press on drive side bearing until it bottoms.
Shoulder on tool will not make contact with casting
of swingarm.

Remove tool from swingarm. Remove swingarm from
hydraulic press.

Pivot Shaft Disassembly

Partially install locknut on right side of pivot shaft. Install
second locknut on right side until it contacts the first.
Holding first locknut to prevent rotation of shaft, remove
left side locknut. See

Figure 2-82

Remove cup washer, rubber mount and outer spacer.

Remove right side locknuts from pivot shaft.

Pivot Shaft Assembly

With larger OD outboard, slide outer spacer onto left side
of pivot shaft until counterbore contacts shoulder on shaft.

Install rubber mount with the flat side inboard toward outer
spacer.

Install cup washer with the concave side facing in toward
the rubber mount.

Apply two drops of Loctite Medium Strength Threadlocker
243 (blue) to threads of left side locknut, and then start on
shaft.

Partially install locknut on right side of pivot shaft. Install
second locknut on right side until it contacts the first.
Holding second locknut to prevent rotation of shaft, tighten
left side locknut to 40-45 ft-lbs (54-61 Nm).

Remove right side locknuts from pivot shaft.

2008 Touring Service: Chassis 2-69

sm02932

Pivot shaft (right side)

Locknut

Cup washer

Rubber mount

Outer spacer

Figure 2-82. Pivot Shaft Assembly

INSTALLATION

With the slot on the outboard side between the twelve and
one o'clock positions, install rubber mount behind rear
swingarm bracket on right side of motorcycle. Be sure that
index tab cast on inboard side of bracket fully engages
slot in rubber mount.

Place outer spacer into right side swingarm tube.

With the belt on the inboard side of the left side swingarm,
work the rear swingarm into position between the transmis-
sion mount and the rear swingarm brackets. Use a rubber
mallet and carefully tap swingarm into position, if neces-
sary.

The pivot shaft secures the rear swingarm and transmis-
sion to the motorcycle frame. See

Figure 2-82

. Install the

pivot shaft as follows:

Coat pivot shaft with Loctite Anti-Seize Lubricant.

From left side of motorcycle, slide pivot shaft
assembly (pivot shaft, locknut, cup washer, rubber
mount and outer spacer) through left side swingarm
and transmission mount. After exiting right side
swingarm, guide end of pivot shaft through holes in
rubber mount and right side swingarm bracket.

With the concave side inboard, slide cup washer onto
end of pivot shaft.

Install locknut on pivot shaft. Holding left side nut on
pivot shaft, tighten locknut to 40-45 ft-lbs (54-61 Nm).
Now hold right side nut and tighten left side locknut
using the same torque value.

Carefully raise swingarm up and down slightly to verify
movement (and that assembly is not in a bind).

Install decorative chrome plug in right side rear
swingarm bracket.

Moving to left side of motorcycle, rotate the rubber
mount so that the slot is between the eleven and
twelve o'clock positions. Install left side swingarm
bracket fitting index tab into rubber mount slot. See

Figure 2-77

Install two bolts (with lockwashers) to secure left side
swingarm bracket to motorcycle frame. Tighten bolts
to 34-42 ft-lbs (46-57 Nm).

Install socket screw with lockwasher to fasten passenger
footboard to rear swingarm bracket. Tighten screw to 30-
35 ft-lbs (40.7-47.5 Nm). Repeat step on opposite side of
motorcycle.

Install lockwasher and flat washer on the lower shock
mounting bolt. Insert bolt through the shock bottom
bushing. Apply two or three drops of Loctite Medium
Strength Threadlocker 243 (blue) to threads. Start bolt
into rear swingarm mount. Tighten bolt to 35-40 ft-lbs (47-
54 Nm). Repeat step on opposite side of motorcycle.

Install belt guard at bottom of left side swingarm. Push
belt guard toward the rear of the motorcycle until front
screw engages small end of slot. Install two rear screws,
and then tighten front screw.

Seat caliper bracket on anchor weldment of rear swingarm.

Capture rear brake line hose in two cable clips at top of
right side swingarm. Rear cable clip also captures rear
wheel speed sensor cable on ABS equipped motorcycles.
Snap cable clips closed.

10. Install rear wheel. See

2.4 REAR WHEEL

NOTE

At the required service interval (see

1.2 MAINTENANCE

SCHEDULE

), remove the decorative chrome plugs in the rear

swingarm brackets and check the torque on the pivot shaft
locknuts. See

Figure 2-83

. Holding right side nut on the pivot

shaft, tighten left side locknut to 40-45 ft-lbs (54-61 Nm). Then
hold left side nut and tighten right side locknut using the same
torque value.

2-70 2008 Touring Service: Chassis

2.23

CLUTCH CABLE

REMOVAL

Remove maxi-fuse. See

8.5 SYSTEM FUSES AND

RELAYS

Remove right side exhaust system. See

4.18 EXHAUST

SYSTEM

Slide rubber boot off clutch cable adjuster. Holding cable
adjuster with 1/2 inch wrench, loosen jam nut using 9/16
inch wrench. Back jam nut away from cable adjuster. Move
adjuster toward jam nut to introduce free play at hand
lever. See

Figure 2-84

Remove retaining ring from pivot pin groove at bottom of
clutch lever bracket. Remove pivot pin. See

Figure 2-85

Remove clutch hand lever from clutch lever bracket. If
necessary, remove two T27 TORX screws (with flat
washers) to release handlebar clamp from clutch lever
bracket.

Remove anchor pin and clutch cable eyelet from clutch
hand lever.

Remove the magnetic drain plug at the bottom right side
of the oil pan and drain the transmission lubricant into a
suitable container. Remove the filler plug/dipstick.

Remove six socket head screws (with captive washers)
to free clutch release cover from two dowel pins on trans-
mission side door flange. Remove and discard gasket.

sm02219

Rubber boot

Cable adjuster

Jam nut

Cable end

Figure 2-84. Clutch Cable Adjuster

sm04655

Retaining ring

Pivot pin

Clutch lever bracket

Hand lever

Bushing

Anti-rattle spring and screw

Screw

Flat washer

Handlebar clamp

10. Anchor pin
11. Clutch cable
12. O-ring

Figure 2-85. Clutch Hand Lever Assembly

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)

Remove retaining ring securing ball and ramp mechanism
to clutch release cover. See

Figure 2-86

10. Lift inner ramp out of clutch release cover and turn the

assembly over so that ball sockets are facing outboard.
Remove hook of ramp from button on coupling. Remove
clutch cable barrel from recess in coupling.

11. Remove balls from outer ramp sockets. Remove outer

ramp from clutch release cover.

12. Unscrew the clutch cable fitting from the clutch release

cover. Remove clutch release cover from motorcycle.

2-72 2008 Touring Service: Chassis

Harley Davidson 2008 Touring Models. Service Manual - page 14