Harley Davidson 2008 Touring Models. Service Manual

sm03582

Saddlebag mounting bracket screws

Saddlebag support to fender screws

Rail to saddlebag support screws

Guard to frame screws

Support rail to guard screw

Rail mount to guard screws

Rail clamp screws

Figure 2-112. Multi-Rail Saddlebag Guard (FLHTC/U)

Table 2-14. Multi-Rail Saddlebag Guard (FLHTC/U):

Fastener Torque Specifications

TORQUE

ITEM

60-96 in-lbs (7.0-11.0 Nm)

15-20 ft-lbs (20.0-27.0 Nm)

70-100 in-lbs (8.0-11.0 Nm)

72-120 in-lbs (8.0-14.0 Nm)

30-50 in-lbs (3.0-6.0 Nm)

sm03583

Rail to saddlebag support screws

Guard to frame screws

Support rail to guard screw

Figure 2-113. Saddlebag Guard (FLHR/C, FLHT)

2008 Touring Service: Chassis 2-89

Table 2-15. Saddlebag Guard (FLHR/C, FLHT): Fastener

Torque Specifications

TORQUE

ITEM

15-20 ft-lbs (20.0-27.0 Nm)

70-100 in-lbs (8.0-11.0 Nm)

sm03584

Rail to saddlebag support screws

Support rail to frame screws

Figure 2-114. Saddlebag Support Rail (FLHX, FLTR)

Table 2-16. Saddlebag Support Rail (FLHX, FLTR):

Fastener Torque Specifications

TORQUE

ITEM

15-20 ft-lbs (20.0-27.0 Nm)

2-90 2008 Touring Service: Chassis

2.29

TOUR-PAK

FLHTC

Removal

Open Tour-Pak. Remove rubber mat.

Rotate knurled lock ring in a counter-clockwise direction
to separate pin and socket halves of radio antenna cable
connector [51]. Release cable from two adhesive clips at
bottom of Tour-Pak.

Disconnect Tour-Pak lights connector [12], 3-place Multi-
lock. See

Figure 2-115

Pull grommet into Tour-Pak and remove from main har-
ness conduit.

Feed main harness conduit and connectors through hole
in Tour-Pak. See

Figure 2-116

Holding nylon cap locknuts at bottom of luggage rack rail,
remove four hex head bolts (with flat washers) from inside
Tour-Pak. Luggage rack spacers will become free as
locknuts are removed.

Holding button head bolt at rear center hole, remove
locknut (and flat washer) from inside Tour-Pak to release
Tour-Pak from luggage rack. Be sure to have a firm grasp
on the Tour-Pak as the bolt is removed. See

Figure 2-117

Installation

Place Tour-Pak on luggage rack and open lid.

Align rear center hole in Tour-Pak with same hole in lug-
gage rack. Slide button head bolt through spacer (concave
side up), luggage rack and Tour-Pak holes. From inside
Tour-Pak, install flat washer, radio antenna ground ring
terminal and locknut on bolt. With concavity on spacer
inline with the rail, hold locknut and tighten bolt until snug.

NOTE

Always install hex head bolts from inside Tour-Pak. If hex head
bolts are installed upside down, then loss of a nylon cap could
cause the end of a bolt to tear the molded liner and scratch
objects, such as helmets, stored inside the Tour-Pak.

From inside Tour-Pak, install two hex head bolts (with flat
washers) in two front Tour-Pak and luggage rack holes
(one each side). At bottom of luggage rack, install spacer
(concave side up) and nylon cap locknut on each bolt.
With concavity on spacer inline with the rail, hold locknut
and tighten each bolt until snug.

Position two spacers between bottom of luggage rack and
tabs of license plate bracket. Slide two hex head bolts
(with flat washers) through two center holes in Tour-Pak
and luggage rack, and then through spacers and tabs of
license plate bracket. If necessary, loosen two hex head
bolts at back of license plate bracket to align holes in tabs
with bolts. Install flat washers and nylon cap locknuts on
bolts and tighten until snug. See inset of

Figure 2-117

sm03544

Radio antenna cable

Adhesive clip

Tour-pak lights connector [12]

Grommet

Figure 2-115. Disconnect Tour-Pak Lights Connector

sm03545

Adhesive clip

Radio antenna cable connector [51D]

Grommet

Tour-pak hole

Figure 2-116. Feed Main Harness Through Tour-Pak Hole

In a crosswise pattern, alternately tighten five bolts to 96-
108 in-lbs (10.8-12.2 Nm). Be sure that concavity on each
spacer is inline with the rail and has not rotated out of
position.

Standing on left side of motorcycle, feed socket connectors
and main harness conduit through hole in Tour-pak. Cap-
ture conduit in grommet. Install grommet in hole with the
larger OD facing inside.

Connect Tour-pak lights connector [12], 3-place Multilock.
See

Figure 2-115

2008 Touring Service: Chassis 2-91

2,6

sm03546

Button head bolt - rear center hole (cap down)

Hex head bolts (4), 1-3/4 inch (cap up)

Spacers (5)

Flat washers (7)

Locknut

Nylon cap locknuts (4)

Figure 2-117. Install Tour-Pak Mounting Bolts

Rotate knurled lock ring in a clockwise direction to mate
pin and socket halves of radio antenna cable connector
[51]. Capture cable in two adhesive clips at bottom of Tour-
Pak.

Install rubber mat. Close Tour-Pak.

FLHTCU

Removal

Open Tour-Pak. Open map pocket and remove acorn nuts
(with flat washers). Remove map pocket and molded liner
from Tour-Pak.

Depress external latch and rotate housing to release bulb
socket from left side of Tour-Pak.

Rotate knurled lock ring in a counterclockwise direction
to separate pin and socket halves of radio antenna cable
connector [51]. Release cable from two adhesive clips at
bottom of Tour-Pak.

Disconnect Tour-Pak lights connector [12], 3-place Multi-
lock. See

Figure 2-115

Pull grommet into Tour-Pak and remove from main har-
ness conduit.

Feed main harness conduit and connectors through hole
in Tour-Pak. See

Figure 2-116

Release rear headset receptacle from bracket at bottom
of left side speaker box.

Remove trim ring and gently pull on wire harness to draw
rear speaker/passenger controls connector [42], 6-place
Deutsch, out of left side speaker box. Depress external
latch and use a rocking motion to separate pin and socket
halves.

Moving to right side of motorcycle, disconnect CB antenna
cable connector [50]. Release cable from two adhesive
clips at bottom of Tour-Pak. See

Figure 2-118

10. Pull right side grommet into Tour-Pak and remove from

CB antenna cable. Feed CB antenna cable through hole
in Tour-Pak.

11. Remove trim ring and gently pull on wire harness to draw

rear speaker/passenger controls connector [41], 6-place
Deutsch, out of right side speaker box. Depress external
latch and use a rocking motion to separate pin and socket
halves.

12. Holding nylon cap locknuts at bottom of luggage rack rail,

remove four hex head bolts (with flat washers) from inside
Tour-Pak. Luggage rack spacers will become free as
locknuts are removed.

13. Holding button head bolt at rear center hole, remove

locknut (and flat washer) from inside Tour-Pak to release
Tour-Pak from luggage rack. Be sure to have a firm grasp
on the Tour-Pak as the bolt is removed. See

Figure 2-117

2-92 2008 Touring Service: Chassis

sm03547

CB antenna cable connector [50]

Adhesive clip

Grommet

Figure 2-118. Disconnect CB Antenna Cable Connector

Installation

Place Tour-Pak on luggage rack and open lid.

NOTE

Figure 2-117

In a crosswise pattern, alternately tighten five bolts to 96-
108 in-lbs (10.8-12.2 Nm). Be sure that concavity on each
spacer is inline with the rail and has not rotated out of
position.

Connect rear speaker/passenger controls connector [41],
6-place Deutsch. Feed connector back up into right side
speaker box pressing trim ring into hole.

Pass CB antenna cable through hole in Tour-Pak. Capture
cable in grommet. Install grommet in hole with the larger
OD facing inside.

Connect CB antenna cable connector [50]. Capture cable
in two adhesive clips at bottom of Tour-Pak. See

Figure 2-118

Moving to opposite side of motorcycle, connect rear
speaker/passenger controls connector [42], 6-place
Deutsch. Feed connector back up into left side speaker
box pressing trim ring into hole.

10. Capture rear headset receptacle in bracket at bottom of

left side speaker box.

11. Feed socket connectors and main harness conduit through

hole in Tour-pak. Capture conduit in grommet. Install
grommet in hole with the larger OD facing inside.

12. Connect Tour-pak lights connector [12], 3-place Multilock.

See

Figure 2-115

13. Rotate knurled lock ring in a clockwise direction to mate

pin and socket halves of radio antenna cable connector
[51]. Capture cable in two adhesive clips at bottom of Tour-
Pak.

14. Install bulb socket on left side of Tour-pak.

15. Install molded liner in Tour-Pak. Install map pocket and

secure using acorn nuts (with flat washers). Close Tour-
Pak.

ADJUSTMENT

NOTE

The Tour-Pak can be moved forward/rearward approximately
one inch for best passenger comfort.

Proceed as follows:

FLHTC: Open Tour-Pak. Remove rubber mat.

FLHTCU: Open Tour-Pak. Open map pocket and
remove acorn nuts (with flat washers). Remove map
pocket and molded liner from Tour-Pak.

From inside Tour-Pak, remove plastic plug from unused
rear center hole.

Holding nylon cap locknuts at bottom of luggage rack rail,
remove four hex head bolts (with flat washers) from inside
Tour-Pak. Luggage rack spacers will become free as
locknuts are removed.

Figure 2-117

Move Tour-Pak to the forward/rearward position. See

Figure 2-119

Align rear center hole in Tour-Pak with same hole in lug-
gage rack. Slide button head bolt through spacer (concave
side up), luggage rack and Tour-Pak holes. From inside
Tour-Pak, install flat washer, radio antenna ground ring
terminal and locknut on bolt. With concavity on spacer in-
line with the rail, hold locknut and tighten bolt until snug.

NOTE

2008 Touring Service: Chassis 2-93

sm03548

Forward

Rearward

Figure 2-119. Adjust Position of Tour-Pak for Passenger Comfort

Verify that two spacers are in position between bottom of
luggage rack and tabs of license plate bracket. Slide two
hex head bolts (with flat washers) through two center holes
in Tour-Pak and luggage rack, and then through spacers
and tabs of license plate bracket. Install flat washers and
nylon cap locknuts on bolts and tighten until snug. See
inset of

Figure 2-117

In a crosswise pattern, alternately tighten five bolts to 96-
108 in-lbs (10.8-12.2 Nm).

10. Verify that wire harness to Tour-pak is not bunched or

stretched at any point. Rearrange wire harness slightly if
necessary. Install new cable straps capturing wire harness
and luggage rack rails if rearrangement required cutting
of existing cable straps. See

Figure 2-120

11. From inside Tour-Pak, install plastic plug in unused rear

center hole. See

Figure 2-119

12. Proceed as follows:

FLHTC: Install rubber mat. Close Tour-Pak.

FLHTCU: Install molded liner in Tour-Pak. Install map
pocket and secure using acorn nuts (with flat
washers). Close Tour-Pak.

sm03549

Figure 2-120. Right Side Luggage Rack Rail (FLHTCU)

2-94 2008 Touring Service: Chassis

2.30

TOUR-PAK SERVICE

LOCKSET

Removal

NOTE

For replacement of the lockset catch, see

2.30 TOUR-PAK

SERVICE, Latches/Lockset Catch

At inside of Tour-Pak lid, remove hex nut, internal tooth
lockwasher, cam hook and cam washer. Remove jam nut
and lock guide. See

Figure 2-121

At outside of Tour-Pak, remove lockset. Remove thin
washer from threaded body of lockset. See

Figure 2-122

sm03550

Lock guide

Jam nut

Lockset

Cam washer

Cam hook

Lockwasher

Hex nut

Figure 2-121. Lockset Assembly

sm04804

Lockset

Thin washer

Cam stop

Threaded stud

Cam washer

Cam hook

Figure 2-122. Lockset Mechanism

Installation

Slide thin washer down threaded body of lockset. See

Figure 2-122

With cam stop facing toward front of Tour-Pak lid, install
lockset into hole.

Install lock guide over threaded body of lockset oriented
with finger at rear and pointing toward bottom of Tour-Pak
lid. See

Figure 2-121

Install jam nut and tighten to 30-45 in-lbs (3.4-5.1 Nm).

Verify that groove in threaded stud of lockset is facing rear
of Tour-Pak lid. Use key to rotate threaded stud, if neces-
sary.

Align cam hook and cam washer as shown in

Figure 2-122

With the cam hook toward the front of Tour-Pak lid and
cam washer on the inboard side, slide assembly down
threaded stud.

Install internal tooth lockwasher and hex nut onto threaded
stud. Tighten hex nut to 25-35 in-lbs (2.8-4.0 Nm).

HINGES

TOOL NAME

PART NUMBER

RIVET TOOL

HD-39787A

Removal

Remove tether. See

2.30 TOUR-PAK SERVICE, Tether

Holding hinge pin with a T25 TORX bit (inboard side),
remove T15 TORX screw (outboard side).

Remove hinge pin from hinge.

Repeat previous steps to remove second hinge pin.
Remove Tour-Pak lid.

Using a 3/16 inch drill bit, drill out eight rivets from inside
Tour-Pak.

Remove hinge and backplates.

Installation

With the head of the new rivet on the outboard side of the
Tour-Pak, slide rivet through holes in hinge, Tour-Pak and
backplate.

Obtain RIVET TOOL (Part No. HD-39787A). See

Figure 2-123

Orient tool so that head of rivet is seated in depression of
drive head. Turn adjuster thumbscrew in or out of handle
until both ends of rivet are captured.

Slowly squeeze handle of tool to compress rivet. Turn
adjuster thumbscrew slightly in a clockwise direction and
then squeeze handle again to further compress rivet.
Repeat step as necessary until rivet is fully installed.

NOTE

Compress rivet in small increments only. This method provides
for best retention and alignment of parts and avoids possible
damage to tool and painted surfaces of Tour-Pak.

2008 Touring Service: Chassis 2-95

Repeat previous steps to install remaining rivets.

Install lid onto Tour-Pak engaging upper and lower hinges.

Install hinge pin with the T25 TORX bit recess on the
inboard side of the hinge.

Apply a small dab of Loctite High Strength Threadlocker
262 (red) to threads of T15 TORX screw.

Install T15 TORX screw into hinge pin and tighten to 20-25
in-lbs (2.3-2.8 Nm).

10. Repeat previous steps to install second hinge pin.

11. Install tether. See

2.30 TOUR-PAK SERVICE, Tether

sm03552

Adjuster thumbscrew

Drive head

Figure 2-123. Rivet Tool (HD-39787A)

LATCHES/LOCKSET CATCH

Removal

Remove two T15 TORX screws (with flat washers) to
release rear latch and spacer from right side of Tour-Pak.

Remove two T15 TORX screws to release front latch,
spacer and lockset catch from Tour-Pak. See

Figure 2-124

Installation

From inside Tour-Pak, slide two short T15 TORX screws
(with flat washers) through rear holes on right side of Tour-
Pak.

With open side of spacer facing Tour-Pak and rib at
bottom, slide spacer over ends of screws.

Apply a small dab of Loctite Medium Strength Threadlocker
243 (blue) to threads of screws and start into threaded
bosses on latch. Properly oriented, portion of latch not
mated with spacer should be at the top.

Alternately tighten screws to 20-25 in-lbs (2.3-2.8 Nm).

Slide two long T15 TORX screws through holes in lockset
catch. From inside Tour-Pak, slide screws through front
holes on right side of Tour-Pak. Properly oriented, flat side
of lockset catch should be topside. See

Figure 2-124

With open side of spacer facing Tour-Pak and rib at
bottom, slide spacer over ends of screws.

Alternately tighten screws to 20-25 in-lbs (2.3-2.8 Nm).

sm03553

Lockset catch

T15 TORX screw

Front latch

Figure 2-124. Front Latch Assembly

CATCHES

Removal

Using a 3/16 inch drill bit, drill out two rivets from inside
Tour-Pak lid.

Remove catch and backplate.

Installation

With the head of the new rivet on the outboard side of the
Tour-Pak, slide rivet through holes in catch, Tour-Pak lid
and backplate.

Install rivets. See

2.30 TOUR-PAK SERVICE, Hinges

TETHER

Removal

NOTE

Exercise caution to keep lid from opening beyond the normal
90° of travel or damage to painted surfaces can occur.

Remove T15 TORX screw from threaded boss on tether
bracket. See

Figure 2-125

Remove tether eyelet and wave spring from threaded
boss.

Repeat previous steps to remove opposite end of tether
from second tether bracket.

2-96 2008 Touring Service: Chassis

Installation

With the concave side toward the tether bracket, install
wave spring onto threaded boss.

Install tether eyelet onto threaded boss.

Apply a small dab of Loctite High Strength Threadlocker
262 (red) to threads of T15 TORX screw.

Install screw into threaded boss and tighten to 20-25 in-
lbs (2.3-2.8 Nm). See

Figure 2-125

Repeat previous steps to fasten opposite end of tether to
second tether bracket.

sm03554

Tether bracket (lid)

T15 TORX screw

Tether eyelet

Wave spring

Black nylon rivet

Flange nut

Figure 2-125. Tour-Pak Tether Bracket Assembly

TETHER BRACKETS

Removing Tether Bracket from Tour-Pak

Remove tether. See

2.30 TOUR-PAK SERVICE, Tether

Using a 3/16 inch drill bit, drill out four rivets from inside
Tour-Pak.

Remove tether bracket and backplate.

Removing Tether Bracket from Tour-Pak Lid

Remove tether. See

2.30 TOUR-PAK SERVICE, Tether

From inside Tour-Pak lid, center a 3/32 inch punch on pin
at center of black nylon rivet. Using a small hammer, gently
tap pin out of rivet. At outside of Tour-Pak, pull rivet from
holes in tether bracket, Tour-Pak lid and passenger
backrest bracket. Repeat step to remove second nylon
rivet. See

Figure 2-125

Remove two flange nuts from studs of passenger backrest
bracket and remove tether bracket.

Installing Tether Bracket on Tour-Pak Lid

From inside Tour-Pak lid, install tether bracket on studs
of passenger backrest bracket and start flange nuts. See

Figure 2-125

At outside of Tour-Pak, insert black nylon rivet through
holes in passenger backrest bracket, Tour-Pak lid and
tether bracket. Insert pin into head of rivet until flush. Install
second rivet in the same manner.

Alternately tighten flange nuts to 40-60 in-lbs (4.5-6.8
Nm).

Install tether. See

2.30 TOUR-PAK SERVICE, Tether

Installing Tether Bracket on Tour-Pak

With the head of the new rivet on the outboard side of the
Tour-Pak, slide rivet through holes in backplate, Tour-Pak
and tether bracket (with the threaded boss topside).

Install rivets. See

2.30 TOUR-PAK SERVICE, Hinges

Install tether. See

2.30 TOUR-PAK SERVICE, Tether

2008 Touring Service: Chassis 2-97

2.31

TOUR-PAK LIGHTS

GENERAL

All domestic model Ultra Tour-Paks are equipped with side
marker lights. Ultra models also have rear wrap-around lights,
each of which contains a 2-filament lamp. One filament is a
supplemental brake light and the other a supplemental tail
lamp.

SIDE MARKER LIGHTS (FLHTCU)

Removal

Open Tour-Pak. Open map pocket and remove acorn nuts
(with flat washers). Remove map pocket and molded liner
from Tour-Pak.

Disconnect side marker lights connector, 2-place Multilock.

Remove two T15 TORX screws and feed socket through
hole in Tour-Pak to release side marker lights. See

Figure 2-126

Installation

Feeding socket through hole in Tour-Pak, place side
marker lights into position. See

Figure 2-126

Align threaded bosses in side marker lights with holes in
Tour-Pak. Install two T15 TORX screws and alternately
tighten to 20-25 in-lbs (2.3-2.8 Nm).

Connect side marker lights connector, 2-place Multilock.

Install molded liner in Tour-Pak. Install map pocket and
secure using acorn nuts (with flat washers). Close Tour-
Pak.

sm03555

Figure 2-126. Side Marker Lights Assembly (FHLTCU)

TOUR-PAK LIGHTS HARNESS

Removal

Remove Tour-Pak. See

2.29 TOUR-PAK

Open Tour-Pak. Holding hex head screw inside Tour-Pak
(rear right corner), remove flange nut at bottom to release
loading coil bracket. Remove hex head screw with external
tooth lockwasher.

Depress external latch and remove bulb socket of both
left and right side wrap-around lights. See

Figure 2-127

Disconnect two side marker lights connectors, 2-place
Multilocks. Release conduit from two adhesive clips at
rear of Tour-Pak.

Close Tour-Pak. Turn Tour-Pak over and remove five
remaining flange nuts at bottom.

Place Tour-Pak topside up and open lid. Reach inside
Tour-Pak and remove metal plate pulling threaded studs
from holes at bottom.

Remove masking tape as necessary to release Tour-Pak
lights harness.

Installation

Place Tour-Pak lights harness at bottom of Tour-Pak as
shown in

Figure 2-127

Adjust harness so that Multilock connectors are outboard
of the metal plate, when installed. Note that conduit to
Tour-Pak lights harness connector [12] is the only length
routed through gaps in ribbing. All other conduit is outboard
of ribbing. Use masking tape as necessary to fix position
of conduit and connectors.

NOTE

If conduit overlaps ribbing or connectors are not outboard of
the metal plate, tightening flange nuts on threaded studs of
metal plate can pinch wires or crack connectors.

Install metal plate at bottom of Tour-Pak so that threaded
studs exit holes at bottom.

Connect two side marker lights connectors, 2-place Multi-
locks. Capture conduit in two adhesive clips at rear of
Tour-Pak.

Install bulb socket of both left and right side wrap-around
lights.

Align hole in loading coil bracket with holes in rear right
corner of metal plate and Tour-Pak. Slide hex head screw
(with external tooth lockwasher) through holes. At bottom
of Tour-Pak, install flange nut.

Close lid and turn Tour-Pak over. Install five remaining
flange nuts on threaded studs of metal plate. Alternately
tighten six flange nuts to 65-70 in-lbs (7.3-7.9 Nm).

Install Tour-Pak on motorcycle. See

2.29 TOUR-PAK

2-98 2008 Touring Service: Chassis

sm03556

Tour-pak lights harness [12]

Left wrap-around light

Right wrap-around light

Left side marker lights [12-3]

Right side marker lights [12-2]

Rib gap

Masking tape

Figure 2-127. Tour-Pak Lights Harness (FLHTCU)

WRAP-AROUND LIGHTS (FLHTCU)

Bulb Replacement

Open Tour-Pak. Open map pocket and remove acorn nuts
(with flat washers). Remove map pocket and molded liner
from Tour-Pak.

Depress external latch and remove bulb socket of left or
right side wrap-around light. See

Figure 2-127

Remove bulb from socket. Install new bulb.

Install bulb socket of left or right side wrap-around light.

Install molded liner in Tour-Pak. Install map pocket and
secure using acorn nuts (with flat washers). Close Tour-
Pak.

Removal

Open Tour-Pak. Open map pocket and remove acorn nuts
(with flat washers). Remove map pocket and molded liner
from Tour-Pak.

Depress external latch and remove bulb socket of both
left and right side wrap-around lights. See

Figure 2-127

Disconnect CB antenna cable connector [50] on right side
of Tour-Pak. Release cable from rear adhesive clip at
bottom of Tour-Pak.

Remove Keps nut, ring terminal and flat washer from
loading coil stud.

Holding hex head screw, remove flange nut at bottom of
Tour-Pak to release loading coil bracket. Remove hex
head screw (with external tooth lockwasher) and loading
coil from motorcycle.

Using a 2.5 mm allen head wrench, remove loading coil
stud. Remove CB antenna mast from lamp housing.

On left side of Tour-Pak, rotate knurled lock ring in a
counter-clockwise direction to disconnect radio antenna
cable connector [51]. Release cable from rear clip at
bottom of Tour-Pak.

Remove jam nut from radio antenna cable connector at
back of Tour-Pak. Remove internal tooth lockwasher, ring
terminal and large flat washer from connector.

2008 Touring Service: Chassis 2-99

sm03557

Tour-pak

Caulking

Bulb housing

Metal clip

Figure 2-128. Wrap-around Light Assembly

Install jam nut back onto connector. Thread a 1/2 in.-20
UNF nut onto connector until contact is made with jam
nut. Turn jam nut to in a counter-clockwise direction to
remove connector stud from radio antenna mast. Remove
mast from lamp housing.

10. Remove caulking from around light bar. Remove four

flange nuts and metal clips to free light bar from Tour-Pak.
See

Figure 2-128

Installation

Install light bar, metal clips and flange nuts to secure light
bar to Tour-Pak. Inside Tour-Pak, use RTV silicone sealer

(Part No. 99710-88) to seal perimeter of light bar. See

Figure 2-128

Install radio antenna mast into lamp housing. Thread
connector stud into mast. Turn 1/2 in.-20 UNF nut (installed
on connector during removal) in a clockwise direction to
tighten.

Remove 1/2 in.-20 UNF nut and jam nut. Install large flat
washer, ring terminal and internal tooth lockwasher onto
connector. Reinstall jam nut and tighten.

Rotate knurled lock ring in a clockwise direction to mate
pin and socket halves of radio antenna cable connector
[51]. Capture cable in rear clip at bottom of Tour-Pak.

On right side of Tour-Pak, install CB antenna mast into
lamp housing. Install stud into mast and tighten with 2.5
mm allen head wrench.

Place loading coil into position aligning hole in bracket
with hole in rear right corner of Tour-Pak. Slide hex head
screw (with external tooth lockwasher) through holes. At
bottom of Tour-Pak, install flange nut on hex head screw.

Install flat washer, ring terminal and Keps nut onto loading
coil stud. Tighten Keps nut.

Connect CB antenna cable connector [50]. Capture
antenna cable in rear adhesive clip at bottom of Tour-Pak.

Install bulb socket of both left and right side wrap-around
lights.

10. Install molded liner in Tour-Pak. Install map pocket and

secure using acorn nuts. Close Tour-Pak.

11. Check SWR and adjust if necessary. Follow the SWR

Adjustment procedure in ELECTRICAL DIAGNOSTIC
MANUAL. Remove SWR meter, install antenna connector
and tighten antenna connector stud.

2-100 2008 Touring Service: Chassis

2.32

TOUR-PAK BACKREST

PASSENGER BACKREST

Removal

Open Tour-Pak.

Remove two flange nuts and backplate to release center
backrest from Tour-Pak lid. See

Figure 2-129

Remove two flange nuts to release left side backrest.

NOTE

Be sure that black nylon rivets are in place before removing
flange nuts to release right side backrest or tether bracket will
come free. Unexpected release of the tether bracket can allow
the Tour-Pak lid to swing fully open, which may result in
damage to hinges and painted surfaces. If black nylon rivets
are missing, be sure to hold Tour-Pak lid as the second flange
nut is removed.

sm03558

Center flange nuts and backplate

Left side flange nuts

Right side flange nuts, tether bracket and black
nylon rivets

Passenger backrest

Figure 2-129. Tour-Pak Lid (Underside)

Remove two flange nuts to release right side backrest.

Carefully pull studs on backrest brackets from holes in
Tour-Pak lid.

Installation

Slide studs on center backrest cushion plate through holes
in Tour-Pak lid. With the nylon side facing the Tour-Pak,
install backplate on studs and start flange nuts.

Slide studs on left side backrest "L" bracket through holes
in Tour-Pak lid and start flange nuts.

Slide studs on right side backrest "L" bracket through holes
in Tour-Pak lid and tether bracket and start flange nuts.

Alternately tighten six flange nuts to 40-60 in-lbs (4.5-6.8
Nm).

Close Tour-Pak.

RUBBER ISOLATORS

Removal

Remove passenger backrest. See

2.32 TOUR-PAK

BACKREST, Passenger Backrest

Center isolator: Remove flange nut with lockwasher to
release cushion plate from rubber isolator stud. Remove
flange nut with lockwasher to release other stud from
backrest support bracket. See

Figure 2-130

Outside isolator: Remove flange nut with lockwasher to
release "L" bracket from rubber isolator stud. Rotate rubber
isolator to remove other stud from threaded hole in back-
rest. See

Figure 2-131

Installation

Center isolator: Insert stud of new rubber isolator into
hole of backrest support bracket and install lockwasher
and flange nut. Tighten flange nut until snug. Install
cushion plate, lockwasher and flange nut on other stud.
Orient cushion plate so that it is parallel to backrest and
then finger tighten flange nut only. See

Figure 2-130

Outside isolator: Install stud of new rubber isolator into
threaded hole in backrest until snug. Install "L" bracket,
lockwasher and flange nut on other stud. Finger tighten
flange nut only. See

Figure 2-131

NOTE

Always hold rubber isolator on end to be installed. Do not grasp
middle of rubber isolator or opposite end as excessive twisting
can result in separation of molded parts or other damage.

Install passenger backrest. See

2.32 TOUR-PAK BACK-

REST, Passenger Backrest

Gently pull back cover material of backrest to expose
underside and final tighten flange nuts only finger tightened
in step 1.

Verify that each side of rubber isolator is not twisted or
under any torsional load. Loosen flange nuts and adjust
rubber isolator if necessary.

2008 Touring Service: Chassis 2-101

sm03559

Cushion plate

Rubber isolator

Backrest support bracket

Figure 2-130. Center Isolator

sm03561

"L" bracket

Rubber isolator

Figure 2-131. Outside Isolator

PASSENGER BACKREST FLAP (FLHTCU)

Removal

Open Tour-Pak. Open map pocket and remove two acorn
nuts (with flat washers). Remove map pocket and molded
liner from Tour-Pak.

Holding acorn nuts inside Tour-Pak, remove two T25
TORX screws (with flat washers) at front.

Remove backrest flap.

Installation

Align holes in backrest flap with those at front of Tour-Pak.

Slide two T25 TORX screws (with flat washers) through
holes in backrest flap and Tour-Pak. Inside Tour-Pak,
install acorn nuts.

Holding acorn nuts, alternately tighten screws to 21-24 in-
lbs (2.4-2.7 Nm).

Install molded liner in Tour-Pak. Install map pocket and
secure using acorn nuts (with flat washers). Close Tour-
Pak.

2-102 2008 Touring Service: Chassis

2.33

TOUR-PAK SPEAKER BOX: FLHTCU

SPEAKER BOX (FLHTCU)

Removal

Remove trim ring and gently pull on wire harness to draw
rear speaker/passenger controls connector [41/42], 6-place
Deutsch, out of speaker box. Depress external latch and
use a rocking motion to separate pin and socket halves.

Open Tour-Pak. Open map pocket and remove acorn nuts
(with flat washers). Remove map pocket and molded liner
from Tour-Pak.

Remove three bolts with flat washers to free speaker box
from Tour-Pak.

Installation

Install three bolts with flat washers to secure speaker box
to Tour-Pak. Alternately tighten bolts to 25-35 in-lbs (2.8-
4.0 Nm).

Install molded liner in Tour-Pak. Install map pocket and
secure using acorn nuts (with flat washers). Close Tour-
Pak.

Connect rear speaker/passenger controls connector
[41/42], 6-place Deutsch. Feed connector back up into
speaker box pressing trim ring into hole.

2008 Touring Service: Chassis 2-103

2.34

LOWER FAIRING AND ENGINE GUARD

LOWER FAIRING (FLHTCU)

Removal

Unfasten snaps to release glove box door flap. Release
anchor on draw string from hole in glove box door. Set
door flap aside.

Reaching into glove box, remove two flange nuts from clip
studs and remove fairing cap. If necessary, push ends of

studs through holes in glove box tray and fairing lower to
release fairing cap. Do not twist or rotate fairing cap or
damage may result. See

Figure 2-132

Hold locknut at bottom of fairing lower and turn inside T40
TORX screw to free assembly from engine guard clamp.
Discard rubber washer.

Repeat procedure on other side of motorcycle.

sm03562

11.

T20 TORX screw (5)

Fairing lower

12.

Engine guard clamp

Glove box tray

13.

Glove box door

T40 TORX screw

14.

Rubber washer

Locknut

15.

Flat washer

Locknut

16.

Door flap

Compression spring

17.

Serrated washer (1 black, 1 white)

Snap, push-in (4)

18.

Flange nut (2)

Pivot screw

19.

Vent door

Clip stud (2)

10. Fairing cap

Figure 2-132. Lower Fairing Assembly

2-104 2008 Touring Service: Chassis

Harley Davidson 2008 Touring Models. Service Manual - page 16