Harley Davidson 2008 Touring Models. Service Manual - page 17

Disassembly

1.

Remove three T20 TORX screws to release glove box
door and glove box tray from fairing lower.

2.

Remove two T20 TORX screws to release glove box door
from glove box tray.

3.

Remove locknut, flat washer, compression spring (rubber
sleeve), glove box tray and two serrated washers from
pivot screw in vent door arm.

4.

Remove pivot screw from vent door arm.

Assembly

1.

Slide threaded end of pivot screw up through hole in center
of vent door arm.

2.

With the teeth facing upward, slide serrated washer over
end of pivot screw. Square shaped boss at bottom of ser-
rated washer should engage square recess in vent door
arm.

3.

Slide second serrated washer over pivot screw so that
teeth engage those on first serrated washer.

NOTE

Use one black and one white serrated washer. Using two
washers of the same color may result in a chirping noise when
the fairing lowers are adjusted.

4.

Slide square hole on glove box tray over end of pivot screw
until it engages square shaped boss at top of second
serrated washer.

5.

Install compression spring (rubber sleeve), flat washer
and locknut on pivot screw. Verify that pin at front of glove
box tray engages slot at top of vent door.

6.

Tighten locknut only until flat washer is snug (does not
rotate) and then tighten an additional 1-1/2 turns. Verify
proper vent door operation.

NOTE

For best results, the  0.50 in. (12.7 mm) compression spring
must be compressed to a height of  0.420 to 0.460 in. (10.7-
11.7 mm).

7.

Align bottom two holes in glove box tray with bosses on
glove box door and start two T20 TORX screws. Altern-
ately tighten screws to 20-25 in-lbs (2.3-2.8 Nm).

8.

Fit glove box tray into top of fairing lower and align three
holes in fairing lower with holes in glove box tray and
bosses in glove box door. Install three T20 TORX screws.
Alternately tighten screws to 20-25 in-lbs (2.3-2.8 Nm).

9.

Install anchor on draw string of glove box door flap into
hole in glove box door. Fasten snaps to install glove box
door flap.

Installation

1.

Place fairing lower into position at front of engine guard.

2.

Holding screw inside fairing lower, install new rubber
washer, clamp and locknut to attach bottom of fairing lower
to engine guard. Do not tighten locknut.

3.

Verify that two clip studs are fully installed on fairing cap.

4.

Position fairing cap at front of engine guard and against
fairing lower so that clip studs engage holes in fairing lower

and glove box tray. Reaching into glove box, start two
flange nuts on clip studs.

5.

Verify that fairing lower is square, and then alternately
tighten flange nuts on clip studs to 35-40 in-lbs (4.0-4.5
Nm).

6.

Hold locknut at bottom of fairing lower and turn inside T40
TORX screw to fasten assembly to engine guard clamp.
Tighten screw to 90-100 in-lbs (10.2-11.3 Nm).

7.

Repeat procedure on other side of motorcycle.

SERRATED WASHER REPLACEMENT

Removal

1.

Unfasten snaps to release glove box door flap.

2.

Reaching into glove box, remove locknut, flat washer and
compression spring (rubber sleeve) from pivot screw in
vent door arm. Remove pivot screw.

3.

Carefully extract first serrated washer at top of vent door
arm. Remove second washer at bottom of glove box tray.
Discard washers.

Installation

1.

Obtain two new serrated washers.

NOTE

Use one black and one white serrated washer. Using two
washers of the same color may result in a chirping noise when
the fairing lowers are adjusted.

2.

With the teeth up, carefully install first serrated washer at
top of vent door arm. Be sure that square shaped boss on
washer engages square recess in arm.

3.

With the teeth down, carefully install second serrated
washer at bottom of glove box tray. Be sure that square
shaped boss on washer engages square hole in tray.

4.

Slide threaded end of pivot screw up through hole in center
of vent door arm.

5.

Reaching into glove box, install compression spring (rubber
sleeve), flat washer and locknut on pivot screw.

6.

Tighten locknut only until flat washer is snug (does not
rotate) and then tighten an additional 1-1/2 turns. Verify
proper vent door operation.

NOTE

For best results, the  0.50 in. (12.7 mm) compression spring
must be compressed to a height of  0.420 to 0.460 in. (10.7-
11.7 mm).

ENGINE GUARD

Removal

1.

Remove fairing lowers, if present. See 

2.34 LOWER

FAIRING AND ENGINE GUARD, Lower Fairing (FLHTCU)

.

Remove fairing lower clamps from engine guard.

2.

Remove T40 TORX screws (with flanged locknuts) to
release ends of engine guard from frame weldments.

3.

Remove hex socket screw (with flat washer) to release
tab at top of engine guard from slot at base of steering
head.

2008 Touring Service:  Chassis  2-105

Installation

1.

Insert tab at top of engine guard into slot at base of
steering head. Start hex socket screw (with flat washer)
to hang engine guard.

2.

Position ends of engine guard outboard of frame weld-
ments on each side of motorcycle. Install T40 TORX

screws positioning flanged locknuts on inboard side of
frame weldments.

3.

Alternately tighten three screws to 15-20 ft-lbs (20.3-27.1
Nm).

4.

Install fairing lowers, if present, but first install fairing lower
clamps on each side of engine guard. See 

2.34 LOWER

FAIRING AND ENGINE GUARD, Lower Fairing (FLHTCU)

.

2-106  2008 Touring Service:  Chassis

2.35

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

OUTER FAIRING AND WINDSHIELD

Removal

1.

Remove maxi-fuse. See 

8.5 SYSTEM FUSES AND

RELAYS

.

2.

Loosen the three screws (with flat washers) just below
the windshield. See 

Figure 2-133

.

3.

Raise and remove the windshield from between the inner
and outer fairings.

4.

Remove the two screws outboard of the speakers on the
left and right side.

5.

Turn the handlebar to the right fork stop and remove screw
by reaching in below the left side of the fairing cap. Turn
the handlebar to the left fork stop and remove screw below
right side of the fairing cap.

NOTE

On FLHX models, be sure to hold the outer fairing in position
as the last screw is removed. Without auxiliary lamps to hold
it in position, the outer fairing will drop, possibly resulting in
fairing or fender damage.

6.

Remove the three screws below the windshield.

7.

Tilting the outer fairing forward, remove headlamp con-
nector [38] at the back of the headlamp assembly.

8.

Lift the outer fairing off the motorcycle.

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sm02862

Figure 2-133. Outer Fairing Screws

Installation

1.

Place the outer fairing on the motorcycle and install
headlamp connector [38] at the back of the headlamp
assembly.

2.

Start the three screws (with flat washers) just below the
windshield. See 

Figure 2-133

.

3.

Start the two screws outboard of the speakers on the left
and right side.

4.

Turn the handlebar to the left fork stop and start screw by
reaching in below the right side of the fairing cap. Turn
the handlebar to the right fork stop and start screw below
left side of the fairing cap.

5.

Alternately tighten the four screws on the inner fairing side
to 20-30 in-lbs (2.3-3.4 Nm).

6.

Place the windshield into position between the inner and
outer fairings engaging the slotted holes in the windshield
with the threaded bosses on the inner fairing.

7.

Alternately tighten the three screws below the windshield
to 25-30 in-lbs (2.8-3.4 Nm).

8.

Install maxi-fuse. See 

8.5 SYSTEM FUSES AND RELAYS

.

2008 Touring Service:  Chassis  2-107

2.36

FAIRING CAP: FLHX, FLHT/C/U

FAIRING CAP

Removal

1.

Partially disassemble ignition switch: remove ignition
switch knob, spring, nut, collar, spacer and switch position
plate. See 

8.17 IGNITION/LIGHT KEY SWITCH AND

FORK LOCK

.

2.

Remove two screws (with flat washers) to release fairing
cap from left and right sides of inner fairing.

3.

With the front forks turned to the left fork stop, reach
behind right side of fairing cap and disconnect fairing cap
switch connector [105], 12-place Multilock (black).

4.

Remove fairing cap from motorcycle. See 

Figure 2-134

.

Installation

1.

Verify that rubber grommets are installed on each side of
fairing cap. Barbs on cap fit into holes in grommets. See

Figure 2-134

.

2.

Connect fairing cap switch connector [105], 12-place
Multilock (black).

3.

Install fairing cap over ignition switch housing. Verify that
grommets in fairing cap fully capture handlebar, handlebar
switch conduit, and brake line from front master cylinder
reservoir (right side).

2

1

sm02863

1.

Rubber grommet

2.

Fairing cap switch connector [105]

Figure 2-134. Fairing Cap Assembly

4.

Start two screws (with flat washers) to fasten fairing cap
to left and right sides of inner fairing. Alternately tighten
screws to 25-30 in-lbs (2.8-3.4 Nm).

5.

Assemble ignition switch: install switch position plate,
spacer, collar, nut, spring and knob. See

8.17 IGNITION/LIGHT KEY SWITCH AND FORK LOCK

.

2-108  2008 Touring Service:  Chassis

2.37

INNER FAIRING: FLHX, FLHT/C/U

REMOVAL

NOTE

To avoid scratches or other damage, place protective material
over front fender, fuel tank and fairing lowers, if present.

1.

Remove outer fairing. See 

2.35 UPPER FAIRING AND

WINDSHIELD: FLHX, FLHT/C/U, Outer Fairing and
Windshield

.

2.

Disconnect left and right front turn signal/auxiliary lamp
connectors [31L/R], 4-place Multilocks, on T-studs at top
of left and right fairing support braces (outboard side). See

Figure 2-135

.

3.

Remove four screws to release auxiliary lamp bracket from
upper and lower fork brackets.

4.

Remove fairing cap. See 

2.36 FAIRING CAP: FLHX,

FLHT/C/U, Fairing Cap

.

5.

Pull chrome skirt from inner fairing. See 

Figure 2-135

.

6.

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.

7.

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

8.

Remove two screws (with flat washers) to release
handlebar clamp from clutch lever bracket. Remove clutch
hand lever from clutch lever bracket.

9.

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

Figure 2-136

.

10. Feed clutch cable through inner fairing grommet to front

of motorcycle.

11. See 

Figure 2-137

. Remove cigarette lighter from socket.

Pull socket terminals [132] from spade contacts on socket
and outer shell. Holding socket to prevent rotation,
unscrew outer shell. Remove socket from inner fairing.

12. Pull socket terminals [35] from left side speaker spade

contacts. Remove three screws to release speaker adapter
from inner fairing. Repeat step on right side of motorcycle.

13. Unthread rubber boot from odometer reset switch. Pull

switch from hole in inner fairing.

14. Disconnect speedometer [39] and tachometer [108] gauge

connectors. See 

Figure 2-137

. Leaving anchors on inter-

connect harness installed in ears of brackets, if present,
remove screws to release brackets from gauges. Remove
gauges from inner fairing.

2

3

1

sm02864

1.

Right front turn signal/auxiliary lamp [31R]

2.

Left front turn signal/auxiliary lamp [31L]

3.

Chrome skirt

Figure 2-135. Inner Fairing (Front View)

1

2

3

5

4

6

7

9

8

sm04881

1.

Retaining ring

2.

Pivot pin

3.

Screw (with flat washer)

4.

Handlebar clamp

5.

Clutch lever bracket

6.

Anchor pin

7.

Clutch cable eyelet

8.

Hand lever

9.

Bushing

Figure 2-136. Disconnect Clutch Cable From Hand Lever

2008 Touring Service:  Chassis  2-109

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4

5

3

10

1

6

9

8

7

sm02865

6.

1.

Voltmeter gauge [111] and lamp [110]

Indicator lights [21]

2.

7.

Right front speaker [34]

Oil pressure gauge [113] and lamp [112]

8.

3.

Air temperature gauge [115] and lamp [114]

Left front speaker [35]

4.

9.

Speedometer [39]

Fuel gauge [117] and lamp [116]

10.

5.

Cigarette lighter [132]

Tachometer [108]

Figure 2-137. Inner Fairing Connectors (FLHX, FLHT/C/U)

15. Disconnect indicator lights connector [21], 10-place Multi-

lock. See 

Figure 2-137

. Release each paddle on lens from

between pair of index tabs on indicator lights assembly.
Remove lens from inner fairing.

16. Disconnect voltmeter gauge [111] and lamp [110] con-

nectors. Disconnect fuel gauge [117] and lamp [116] con-
nectors.

17. Remove four screws to free inner fairing from fairing

bracket. See 

Figure 2-138

.

18. Spread bottom of inner fairing to free from threaded dowels

in lower fork bracket. Spread bottom of fairing bracket to
release from same dowels. Raise inner fairing and fairing
bracket slightly to prevent re-engagement with dowels.

19. Classic and Ultra models: Disconnect oil pressure gauge

[113] and lamp [112] connectors. Disconnect air temper-
ature gauge [115] and lamp [114] connectors.

20. Raise inner fairing and fairing bracket together and then

separate by pulling fairing bracket toward the front and
inner fairing toward the rear.

21. When inner fairing becomes free of the radio, remove from

motorcycle and move to bench area.

22. Install fairing bracket (with radio and interconnect harness)

back onto motorcycle aligning holes with threaded dowels
in lower fork bracket. Loosely install screws to secure
fairing bracket to lower fork bracket.

23. At bench area, remove hex nuts from studs at back of

voltmeter and fuel gauges. Remove mounting brackets
from gauges and remove gauges from inner fairing. On
Classic and Ultra models, repeat step to remove oil pres-
sure and air temperature gauges.

24. Remove clutch cable grommet from inner fairing.

2-110  2008 Touring Service:  Chassis

sm02868

Figure 2-138. Remove Fairing Bracket Screws

INSTALLATION

1.

Install clutch cable grommet in inner fairing.

2.

Install voltmeter and fuel gauges in inner fairing. Slide
mounting brackets over studs. Verify that tabs on top and
bottom of brackets engage slots in inner fairing. Loosely
install hex nuts on studs. Verify that gauge is properly
aligned and tighten nuts to 10-20 in-lbs (1.1-2.3 Nm). See

Figure 2-139

.

3.

Classic and Ultra models: Repeat last step to install air
temperature and oil pressure gauges.

NOTE

To avoid scratches or other damage, place protective material
over front fender, fuel tank and fairing lowers, if present.

4.

Remove screws to free fairing bracket (with radio and
interconnect harness) from lower fork bracket. Raise fairing
bracket and then tilt forward at a 45° angle.

5.

Position inner fairing at rear of fairing bracket. Tilting inner
fairing rearward at a 45° angle, align upper and lower fork
bracket thru holes with those in fairing bracket. Draw fairing
bracket and inner fairing together fitting radio into slot of
inner fairing.

6.

Align upper thru holes in fairing bracket and inner fairing
with threaded holes in bosses of upper fork bracket and
start two screws. Align lower thru holes in fairing bracket
and inner fairing with threaded dowels in lower fork bracket
and start two screws. Alternately tighten four screws until
snug.

7.

Install four screws to fasten inner fairing to fairing bracket.
See 

Figure 2-138

.

8.

Connect voltmeter gauge [111] and lamp [110] connectors.
Connect fuel gauge [117] and lamp [116] connectors.

9.

Classic and Ultra models: Connect oil pressure gauge
[113] and lamp [112] connectors. Connect air temperature
gauge [115] and lamp [114] connectors.

10. Install lens of indicator lights, so that bottom slot engages

index tab in inner fairing. With the word "TOP" facing up,
engage each paddle on lens between pair of index tabs
on indicator lights assembly. Connect indicator lights
connector [21], 10-place Multilock. See 

Figure 2-140

.

11. Install speedometer and tachometer gauges in inner

fairing. Align holes in brackets with those in gauges and
start two screws. Rotate brackets until top and bottom tabs
engage slots in inner fairing. Verify that gauges are prop-
erly aligned and tighten screws to 10-20 in-lbs (1.1-2.3
Nm). Connect speedometer [39] and tachometer [108]
gauge connectors.

12. Slide odometer reset switch through hole in inner fairing

and install rubber boot.

13. With the widest edge at the top, align holes in speaker

adapter with those in inner fairing. Install two long screws
at top of speaker adapter. Capturing fairing support brace,
install short screw in lower outboard hole (positioning flat
washer between adapter and support brace).Tighten lower
screw to 22-28 in-lbs (2.5-3.2 Nm). Tighten two upper
screws to 35-50 in-lbs (4.0-5.7 Nm).

NOTE

The screw hole on the lower inboard side of the speaker
adapter is not used.

14. Install socket terminals onto speaker spade contacts. Dif-

ferent size spade contacts prevent improper assembly.

15. Repeat last two steps on opposite side of motorcycle.

16. Slide socket of cigarette lighter through hole in inner

fairing. Thread outer shell onto socket until tight. Install
cigarette lighter in socket. Connect the orange/white wire
terminal to the socket spade contact, the black wire ter-
minal to the outer shell contact.

17. Feed clutch cable through inner fairing grommet.

18. Insert clutch cable eyelet into groove of clutch hand lever

aligning eyelet with hole without bushing. Insert anchor
pin through lever and eyelet.

19. Insert lever into groove of clutch lever bracket fitting sleeve

at end of cable housing into bore on inboard side of
bracket.

20. Align hole in hand lever with hole in bracket and install

pivot pin. Install retaining ring in pivot pin groove.

21. Install two screws (with flat washers) to secure handlebar

clamp to clutch lever bracket. Starting with the top screw,
tighten screws to 72-108 in-lbs (8-12 Nm).

22. Adjust clutch. See 

1.11 CLUTCH

.

23. Install fairing cap. See 

2.36 FAIRING CAP: FLHX,

FLHT/C/U

.

24. Remove two screws from lower fork bracket. Install chrome

skirt aligning thru holes with those in lower fork bracket.
Reinstall screws. See 

Figure 2-135

.

25. Loosen two screws in upper fork bracket.

2008 Touring Service:  Chassis  2-111

1

3

6

4

2

5

sm02866

1.

Pin housing

2.

Hex nut

3.

Stud

4.

Mounting bracket

5.

Tab

6.

Gauge

Figure 2-139. 2 Inch Diameter Gauges

N

2

1

5

6

3

4

sm02867

1.

Indicator lights connector [21]

2.

Indicator lights assembly

3.

Lens

4.

Paddles

5.

Index tabs

6.

Orientation stamp

Figure 2-140. Indicator Lights Assembly

26. Slide slots of auxiliary lamp bracket onto upper and lower

fork bracket screws. Alternately tighten four screws to 15-
20 ft-lbs (20-27 Nm) in a crosswise pattern.

27. Mate left and right front turn signal/auxiliary lamp con-

nectors [31L/R], 4-place Multilocks. Install on T-studs at
top of left and right fairing support braces (outboard side).
Verify that conduit is routed inboard using relief in upper
outboard corner of chrome skirt.

28. Install outer fairing. See 

2.35 UPPER FAIRING AND

WINDSHIELD: FLHX, FLHT/C/U

.

2-112  2008 Touring Service:  Chassis

2.38

AIR DEFLECTORS: FLHTCU

AIR DEFLECTORS (FLHTCU)

Removal

1.

Remove four screws to release air deflector at side of inner
fairing. See 

Figure 2-141

.

2.

Repeat step to remove air deflector on opposite side of
motorcycle.

Installation

1.

Install four screws to fasten air deflector at side of inner
fairing. Alternately tighten screws to 25-30 in-lbs (2.8-3.4
Nm).

2.

Repeat step to install air deflector on opposite side of
motorcycle.

sm04885

Figure 2-141. Air Deflector (Adjustable)

2008 Touring Service:  Chassis  2-113

2.39

UPPER FAIRING AND WINDSHIELD: FLTR

WINDSHIELD

Removal

1.

Alternately loosen and then remove five screws (with
plastic flat washers) at base of windshield.

2.

Remove windshield from outer fairing.

3.

Carefully remove wellnuts (with rubber flat washers) from
holes in outer fairing. See 

Figure 2-142

.

NOTE

Exercise caution to avoid pushing wellnuts into fairing during
removal. Inspect wellnuts and rubber flat washers for cuts,
tears or signs of deterioration. Replace as necessary.

sm02871

Figure 2-142. Remove Wellnuts from Outer Fairing

Installation

1.

Preinstall hardware on windshield as follows:

a.

Slide plastic flat washers onto screws.

b.

Slide screws through slots in windshield.

c.

Slide rubber flat washers onto wellnuts.

d.

Start wellnuts onto screws.

2.

Push wellnuts into holes in outer fairing. See 

Figure 2-143

.

3.

Starting with center screw, alternately tighten five screws
to 6-13 in-lbs (0.7-1.5 Nm).

1

3

2

5

4

sm02872

1.

Screw

2.

Plastic flat washer

3.

Windshield

4.

Wellnut

5.

Rubber flat washer

Figure 2-143. Install Windshield

OUTER FAIRING

Removal

NOTE

Windshield may be left in place during outer fairing removal.

1.

Place protective material on top of front fender to protect
paint from scratches or other damage.

2.

Remove screw at edge of fairing outboard of left speaker.
See 

Figure 2-144

. Remove screw outboard of right

speaker.

3.

Loosen top left and right screws just outboard of the fuel
and volt gauges, respectively.

4.

Remove screw just below left side glove compartment.
Remove screw below right side glove compartment.

5.

On inboard side of right fairing support, remove rear acorn
nut (with flat washer) from stud of front turn signal lamp
bracket. Remove front acorn nut with flat washer.

Pull front turn signal lamp assembly from motorcycle and
allow to hang at front of engine guard. Repeat step to
remove front turn signal lamp assembly on left side. See

Figure 2-145

.

2-114  2008 Touring Service:  Chassis

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100

MPH

H

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HARLEY-DAVID SON

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-DAV

I DSON MOTOR

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sm02873

3.

1.

Long screw

Short screw

2.

Short screw

Figure 2-144. Remove/Install Six Outer Fairing Screws

6.

Remove top left and right screws just outboard of the fuel
and volt gauges, respectively (previously loosened).

7.

Raise outer fairing slightly and then rest on protective
fender pad.

8.

Squeeze two external tabs to disconnect headlamp jumper
harness connector.

9.

To avoid possible wire damage, disconnect front turn
signal lamp connectors [31L] and [31R], 3-place Multilocks,
and move to bench area. See 

Figure 2-146

.

Installation

1.

Place protective material on top of front fender to protect
paint from scratches or other damage.

2.

Connect front turn signal lamp connectors [31L] and [31R],
3-place Multilocks. Capture conduit in adhesive clips on
inner fairing. Allow front turn signal lamp assemblies to
hang at front of engine guard until outer fairing installation
is complete.

NOTE

The front turn signal lamp assemblies are not interchangeable.
Note that the letters R(ight) or L(eft) are stamped on the inboard

side of the turn signal lamp bracket to help ensure proper
assembly.

3.

To avoid chafing wires of interconnect harness, verify that
trim strips are installed inboard of hooks on radio bracket.

4.

Rest outer fairing on front fender pad and connect head-
lamp jumper harness connector.

5.

Place outer fairing against inner fairing. Two slots in outer
fairing must engage hooks on radio bracket. Move harness
conduit and wiring as necessary to ensure full engagement
between outer and inner fairings.

NOTE

If windshield is attached during outer fairing installation, exer-
cise caution to avoid scratching or damaging inner fairing with
windshield screws and wellnuts.

6.

Move to side of outer fairing to verify that alignment tabs
are properly engaged. Alignment tabs on inner fairing must
be positioned outboard of those on the outer fairing.
Repeat step on opposite side of motorcycle.

NOTE

Although the tightening sequence described below begins on
the left side of the motorcycle, if the left side of the outer fairing

2008 Touring Service:  Chassis  2-115

fits the inner fairing better than the right, then start the first
screw on the right side. In other words, install the first screw
on the side that does not have the best fit.

7.

Install screw at edge of fairing outboard of the left speaker.
Install screw outboard of the right speaker. Mounting
bosses on inner fairing are painted white for easier align-
ment of holes.

8.

Install the top left and right screws just outboard of the
fuel and volt gauges, respectively.

9.

Moving to left side of motorcycle, install the first of two
long screws just below the glove compartment. Install the
second long screw below the right side glove compartment.

10. Alternately tighten four short fairing screws to 6-12 in-

lbs (0.7-1.4 Nm). Alternately tighten two long fairing
screws to 10-15 in-lbs (1.1-1.7 Nm). Use the torque pat-
tern shown in 

Figure 2-144

.

11. Slide studs on front turn signal lamp bracket through holes

in fairings and fairing support. Loosely install acorn nuts
with flat washers. Alternately tighten acorn nuts to 40-50
in-lbs (4.5-5.7 Nm).

12. Repeat last step to install front turn signal lamp assembly

on opposite side of motorcycle.

sm02874

Figure 2-145. Remove Acorn Nuts to Release Turn Signal

Lamp and Bracket

sm02875

Figure 2-146. Front Turn Signal Lamp

2-116  2008 Touring Service:  Chassis

2.40

INSTRUMENT BEZEL: FLTR

BEZEL

Removal

1.

Remove screw on each side of bezel. See 

Figure 2-147

.

2.

Use thumbs to push tab at rear of bezel from slot in front
of ignition switch. Gently raise free side of bezel until tabs
at front of instrument nacelle become disengaged from
slot at front of bezel (concealed behind decorative
adhesive strip).

0

20

30

70

80

40

50

60

10

RPM x100

0

10

30

20

50

40

110

120

60 70

80

90

100

MPH

H

A

RL

EY

-DAV

I DSON MOTOR

CO

M

PA

N

Y

CERTIFIED

H

A

RL

EY

-DAV

I DSON MOTOR

CO

M

PA

N

Y

1

3

2

sm02876

1.

Screw (2)

2.

Bezel

3.

Instrument nacelle

Figure 2-147. Remove Bezel Screws

2008 Touring Service:  Chassis  2-117

2

5

3

1

4

6

sm02877

4.

1.

Speaker switch [105C/D]

Indicator lights [21]

2.

5.

Speedometer gauge [39]

Tachometer gauge [108]

6.

3.

Clutch cable

Instrument nacelle switches [105A/B]

Figure 2-148. Instrument Nacelle (Bezel Removed)

3.

See 

Figure 2-148

. Raising bezel slightly, disconnect

instruments and indicator lights from interconnect harness
as follows:

a.

Speedometer connector [39], 12-place Packard.

b.

Tachometer connector [108], 12-place Packard.

c.

Indicator lights connector [21], 10-place Multilock.

4.

Remove bezel from motorcycle.

Installation

1.

See 

Figure 2-148

. Looking into the instrument nacelle,

connect instruments and indicator lights to interconnect
harness as follows:

a.

Speedometer connector [39], 12-place Packard.

b.

Tachometer connector [108], 12-place Packard.

c.

Indicator lights connector [21], 10-place Multilock.

2.

Verify that left and right sides of instrument nacelle are
properly mated. Pins on left side of nacelle must fully
engage holes on right.

3.

Insert tab at rear of bezel into slot of instrument nacelle
(just in front of ignition switch). Holding left and right sides
of nacelle together, place bezel over instrument nacelle
flange. When properly mated, tabs at front of instrument
nacelle engage lip in slot at front of bezel (behind decor-
ative adhesive strip).

NOTE

If tabs do not properly engage slot at front of bezel, then a
loose fit will result. Remove decorative adhesive strip by gently
prying up outer edges, and using a flat bladed screwdriver,
carefully raise tabs so that they engage lip in slot. If damaged,
install new decorative adhesive strip.

4.

Install screw on each side of bezel. Alternately tighten
screws to 25-35 in-lbs (2.8-4.0 Nm). See 

Figure 2-147

.

2-118  2008 Touring Service:  Chassis

2.41

INSTRUMENT NACELLE: FLTR

INSTRUMENT NACELLE

Removal

1.

Partially disassemble ignition switch: remove ignition
switch knob, spring, nut, collar, spacer and switch position
plate. See 

8.17 IGNITION/LIGHT KEY SWITCH AND

FORK LOCK

.

2.

Remove bezel. See 

2.40 INSTRUMENT BEZEL: FLTR

.

3.

Disconnect speaker switch connector [105C/D], 4-place
Multilock, from instrument nacelle switch harness. See

Figure 2-148

.

4.

Pull clutch cable clip from hole on left side of instrument
nacelle.

5.

Remove two screws (with flat washers) to release left side
of instrument nacelle from upper and lower fork brackets.
See 

Figure 2-150

.

6.

Unthread rubber boot from odometer reset switch, and
while carefully removing left side instrument nacelle from
motorcycle, pull odometer reset switch from hole.

7.

Disconnect instrument nacelle switch connector [105A/B],
12-place Multilock, from interconnect harness. See

Figure 2-148

.

8.

Remove two screws (with flat washers) to release right
side of instrument nacelle from upper and lower fork
brackets. See 

Figure 2-150

.

1

2

sm04889

1.

Speaker switch [105C/D]

2.

Instrument nacelle switches [105A/B]

Figure 2-149. Instrument Nacelle Connectors

2008 Touring Service:  Chassis  2-119

2

1

4

3

5

6

sm03585

4.

1.

Right side nacelle

Left side nacelle

2.

5.

Clutch cable clip hole

Speaker switch connector [105C]

6.

3.

Instrument nacelle switch connector [105B]

Speaker switch connector [105D]

Figure 2-150. Instrument Nacelle Halves

Installation

1.

Install right side of instrument nacelle on motorcycle.

2.

Connect instrument nacelle switch connector [105A/B],
12-place Multilock, to interconnect harness. See

Figure 2-148

.

3.

While carefully placing left side of instrument nacelle on
motorcycle, slide odometer reset switch through hole and
install rubber boot.

4.

Connect speaker switch connector [105C/D], 4-place
Multilock, to instrument nacelle switch harness. See

Figure 2-148

.

5.

Verify that left and right sides of nacelle are properly
mated. Four pins on left side of nacelle must fully engage
holes on right.

6.

Install two screws (with flat washers) to fasten left side
instrument nacelle to upper and lower fork brackets.
Alternately tighten screws to 15-20 ft-lbs (20-27 Nm).

7.

Capture clutch cable in cable clip. Insert cable clip into
hole in left side of instrument nacelle.

8.

Install two screws (with flat washers) to fasten right side
instrument nacelle to upper and lower fork brackets.
Tighten screws to 15-20 ft-lbs (20-27 Nm).

9.

Install bezel. See 

2.40 INSTRUMENT BEZEL: FLTR

.

2-120  2008 Touring Service:  Chassis