Harley Davidson 2008 Touring Models. Service Manual

2.42

INNER FAIRING: FLTR

REMOVAL

TOOL NAME

PART NUMBER

IGNITION SWITCH CONNECTOR
REMOVER

HD-45961

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

Remove outer fairing. See

2.39 UPPER FAIRING AND

WINDSHIELD: FLTR

Carefully cut two cable straps to free wire bundles and
conduit from convoluted tubing of interconnect harness
and allow to hang naturally.

See

Figure 2-151

. Disconnect main harness from intercon-

nect harness as follows:

Main to interconnect harness connector [1], 16-place
Molex (black); below radio (right side).

Main to interconnect harness connector [2], 12-place
Molex (gray); below radio (right side).

Main to interconnect harness connector [15], 4-place
Packard (black); below radio (right side).

Disconnect radio antenna cable connector [51] at back of
radio (left side).

Disconnect twist grip sensor jumper harness connector
[204], 6-place Molex (black), from main harness.

sm02878

Left turn signal [31L]

Main to interconnect harness [1]

Main to interconnect harness [2]

Right turn signal [31R]

Headlamp [38]

Main to interconnect harness [15]

Right handlebar switches [22]

Radio antenna [51]

10.

Twist grip sensor jumper harness [204]

Left handlebar switches [24]

Figure 2-151. Inner Fairing Connectors (FLTR)

2-122 2008 Touring Service: Chassis

See

Figure 2-151

. Disconnect handlebar switches from

interconnect harness. Proceed as follows:

Left handlebar switch connector [24], 16-place Molex
(gray); T-stud on left side of radio bracket.

Right handlebar switch connector [22], 12-place Molex
(black); T-stud on left side of radio bracket.

Remove interconnect harness ground socket terminal from
spade contact at front of upper fork bracket (left side).

Draw the main harness conduit, radio antenna cable, twist
grip sensor jumper harness conduit, and handlebar switch
conduit as far forward as possible. Rest the connectors
of the longer harnesses on the front fender.

10. Remove left side of instrument nacelle. See

2.41 INSTRUMENT NACELLE: FLTR

11. Disconnect instrument nacelle switch connector [105A/B],

12-place Multilock, from interconnect harness.

12. Disconnect ambient temperature sensor connector [107],

3-place Multilock, from sensor anchored in hole on left
side of steering head. Feed connector and conduit in
through opening on left side of fairing bracket.

13. See

Figure 2-148

. Draw branches of interconnect harness

(terminating in odometer reset switch and speedometer,
tachometer, indicator lights, instrument nacelle switches
and ambient temperature sensor connectors) through
tunnel of fairing bracket to front of inner fairing.

sm02879

Main harness

Interconnect harness

Figure 2-152. Wrap Main Harness in Shop Towels

14. Disconnect ignition switch connector [33], 3-place Packard,

at front of ignition switch housing. Proceed as follows:

Obtain the IGNITION SWITCH CONNECTOR
REMOVER (Part No. HD-45961).

Gently insert end of tool into slot in ignition switch
housing until it stops.

Grasping main harness conduit and tool, pull both at
the same time to release socket housing from ignition
switch housing.

15. Draw branch of main harness terminating in ignition switch

connector from instrument nacelle through tunnel of fairing
bracket to front of inner fairing.

16. Separate any branches of the interconnect harness that

may be intermingled with the main harness conduit. Allow
the interconnect harness to hang along the left side of the
front fender.

17. Capturing all connectors, tightly wrap clean shop towels

around the main harness conduit, radio antenna cable,
twist grip sensor jumper harness conduit, and handlebar
switch conduit, and secure with masking tape. See

Figure 2-152

18. Remove four locknuts to release radio bracket and inner

fairing from studs of fairing bracket. See

Figure 2-153

19. Lift inner fairing (with attached radio bracket and intercon-

nect harness) from fairing bracket studs and move to
bench area.

NOTE

To remove the fairing bracket, proceed with remaining steps.

20. Remove right side instrument nacelle. See

2.41 INSTRU-

MENT NACELLE: FLTR

21. Remove shop towels and masking tape from around the

harness bundle. Separate main harness conduit, radio
antenna cable, twist grip sensor jumper harness conduit,
and handlebar switch conduit.

22. Pull main harness conduit, terminating in the radio antenna

cable [51], twist grip sensor jumper harness [204], ignition
switch [33], and main to interconnect harness connectors,
[1] and [15], out through opening on right side of fairing
bracket. Hang conduit and connectors over top of engine
guard.

23. Pull cable to draw front wheel speed sensor connector

[167], 2-place Amp (Tyco), out through opening on left
side of fairing bracket. Disconnect from main harness if
ABS equipped.

24. Continue pulling main harness conduit to draw main to

interconnect harness connector [2] out left side of fairing
bracket. Hang conduit and connectors over top of engine
guard.

25. Pull handlebar switch conduit and twist grip sensor jumper

harness conduit out through opening at top of fairing
bracket.

26. Remove locknuts and bolts to release fairing bracket from

holes at rear of steering head.

2008 Touring Service: Chassis 2-123

2.47

REAR FENDER

REMOVAL

NOTE

Skip first step for all models except FLHX.

FLHX: Remove rear fascia and rear fascia lamp. See

2.48 REAR FACIA: FLHX

Remove rear wheel. See

2.4 REAR WHEEL

Remove seat. See

2.26 SEAT

Disconnect rear fender lights connector [7] anchored at
front of rear fender. Release anchor from fender hole. See

Figure 2-164

Remove left and right side covers.

Remove four screws with lockwashers (two each on
FLHR/C and FLTR) to release license plate bracket from
luggage rack.

sm04825

Figure 2-164. Rear Fender Lights Connector

sm04749

Figure 2-165. Rear Bumper Screws

sm04750

Figure 2-166. Rear Fender Side Mounting Screw (Left Side)

sm04754

Figure 2-167. Rear Fender Side Mounting Screw (Right

Side)

At rear of motorcycle, remove inside screw (and flange
nut) to release rear bumper bracket from saddlebag sup-
port bracket and saddlebag support rail. Repeat step on
opposite side of motorcycle. See

Figure 2-165

Reaching under rear bumper, remove flange nut (with flat
washer) to free rear bumper bracket from weld stud on
fender. Remove bumper from motorcycle.

2008 Touring Service: Chassis 2-133

Remove fender side mounting screw located just below
side cover grommet. Repeat step on opposite side of
motorcycle. See

Figure 2-166

and

Figure 2-167

10. Remove upper rear screw from saddlebag support bracket.

Repeat step on opposite side of motorcycle. See

Figure 2-168

11. Remove upper front screw from saddlebag support

bracket. Be aware that rear fender will drop when both
forward screws are removed. Repeat step on opposite
side of motorcycle.

12. Exercising caution to avoid scratching fender paint on

luggage rack or other bracketry, carefully roll the fender
out. See

Figure 2-169

. If necessary, have one person

spread the saddlebag support brackets while the fender
is rolled out.

INSTALLATION

Exercising caution to avoid scratching fender paint on
luggage rack or other bracketry, carefully roll the fender
in. See

Figure 2-169

. If necessary, have one person

spread the saddlebag support brackets while the other
rolls the fender in.

Engaging hole of fender rear spacer nut, start upper front
screw in saddlebag support bracket. Repeat step on
opposite side of motorcycle. See

Figure 2-168

Start upper rear screw in saddlebag support bracket.
Repeat step on opposite side of motorcycle.

Engaging hole in frame and fender front spacer nut, start
fender side mounting screw located just below side cover
grommet. Repeat step on opposite side of motorcycle.
See

Figure 2-166

and

Figure 2-167

sm04755

Figure 2-168. Saddlebag Support Bracket Screws

sm04756

Figure 2-169. Carefully Roll Out Rear Fender

Reaching under rear fender, hang rear bumper bracket
on weld stud. Install flat washer and start flange nut on
weld stud.

Start inside screw (with flange nut) to fasten rear bumper
bracket to saddlebag support bracket and saddlebag
support rail. Repeat step on opposite side of motorcycle.
See

Figure 2-165

Alternately tighten all rear fender mounting screws to 15-
20 ft-lbs (20-27 Nm).

Reaching under rear fender, tighten flange nut on weld
stud to 45-85 in-lbs (5.1-9.6 Nm).

Install four hex screws with lockwashers (two each on
FLHR/C and FLTR) to secure license plate bracket to
luggage rack. Alternately tighten screws to 15-20 ft-lbs (20-
27 Nm).

10. Connect rear fender lights connector [7] and snap anchor

in rear fender hole. See

Figure 2-164

11. Align barbed studs in side cover with grommets in frame

downtubes and push firmly into place (no tools required).
Repeat step on opposite side of motorcycle.

12. Install rear wheel. See

2.4 REAR WHEEL

13. Install seat. See

2.26 SEAT

14. FLHX: Install rear fascia lamp and rear fascia. See

2.48 REAR FACIA: FLHX

REAR FENDER LIGHTS CONDUIT

Removal

Remove rear fender.

Remove rear fender lights harness. See

8.12 TAIL LAMP,

Rear Fender Lights Harness

Carefully cut adhesive conduit and remove wire harness.

Remove terminals from socket housing of rear fender lights
connector [94], 6-place Multilock.

2-134 2008 Touring Service: Chassis

NOTE

For instructions on properly removing wire terminals, see

A.2 AMP MULTILOCK CONNECTORS

Installation

Draw rear fender lights harness through new adhesive
conduit until progress is halted by installed cable strap. If
absent, install new cable strap as follows:

Adjust conduit so that end is 0.25 in. (6.35 mm) or
less from wire end of connector [7B].

Install cable strap 8.75 in. (222.25 mm) from mating
end of connector as shown in

Figure 2-170

. Cut any

excess cable strap material.

NOTE

Proper placement of the cable strap prevents rearward move-
ment of the rear fender lights harness. Gradual accumulation
or bunching of the harness rear of the adhesive conduit can
result in damage through contact with rear tire.

Install terminals into socket housing of rear fender lights
connector [94], 6-place Multilock.

Table 2-17. Rear Fender Lights [94]

CHAMBER

NUMBER

WIRE

COLOR

CHAMBER

NUMBER

WIRE

COLOR

Red/Yellow

Orange/White

Violet

Brown

Black

Blue

NOTE

For instructions on properly installing wire terminals, see

A.2 AMP MULTILOCK CONNECTORS

Install rear fender lights harness. See

8.12 TAIL LAMP,

Rear Fender Lights Harness

Install rear fender.

sm04757

Connector [7B]

Conduit

Cable Strap

Adhesive Conduit

0.25 in. (6.35 mm)

8.75 in. (222.25 mm)

Figure 2-170. Install Cable Strap on Conduit

REAR FENDER CLOISONNE

TOOL NAME

PART NUMBER

ROBINAIR HEAT GUN

HD-25070

Removal

Apply 3M general purpose adhesive remover (Part No.
051135) to edge of adhesive backing visible behind clois-
onne. Allow to soak.

NOTE

Avoid excess heat which will damage the painted surface.

Carefully apply heat directly onto cloisonne with ROBINAIR
HEAT GUN (Part No. HD-25070).

Lift the cloisonne from fender.

NOTE

Dental floss can be used to gently saw the heated cloisonne
free of the rear fender.

Remove remaining adhesive with 3M general Purpose
adhesive remover (Part No. 051135).

Installation

Peel paper backing off cloisonne.

Place cloisonne into position over recess in rear fender.

NOTE

The cloisonne is centered left to right over the dimpled recess
in the rear fender with the bottom edge of the cloisonne 1.75
in. (44.45 mm) above the bottom edge of the fender.

Press firmly to affix cloisonne.

sm04759

Figure 2-171. Rear Fender Cloisonne (FLTR)

2008 Touring Service: Chassis 2-135

2.48

REAR FACIA: FLHX

REMOVAL

Remove saddlebags. See

2.27 SADDLEBAGS

Remove six flange nuts from studs at sides of rear fender.
See

Figure 2-172

On left side of motorcycle, loosen set screw and unthread
radio antenna mast.

Gently open adhesive conduit at split line to release rear
facia lamp wires.

At rear of motorcycle, spread top of facia to release from
top studs at sides of fender and then pull bottom in a
downward direction to release facia from fender. If
necessary, gently wiggle facia while pulling.

Remove two T20 TORX screws to release lamp assembly
from facia.

INSTALLATION

Install two T20 TORX screws to fasten lamp assembly to
facia. Alternately tighten screws to 18-22 in-lbs (2.0-2.5
Nm).

At rear of motorcycle, insert flange at top of facia between
flap and fender. Notch in flange engages locator bump on
flap when facia is fully installed. Spread top of facia to
engage top studs at sides of fender.

See

Figure 2-172

. Start six flange nuts on studs at sides

of fender. Apply a small dab of Loctite Medium Strength
Threadlocker 243 (blue) to threads of studs. Alternately
tighten flange nuts to 30-45 in-lbs (3.4-5.1 Nm).

NOTE

As it is necessary to overcome the resistance of the lock patch
on the stud threads, note that the flange nut torque specification
is higher when using a new stud plate.

On left side of motorcycle, gently open adhesive conduit
at split line and insert rear facia lamp wires.

Install radio antenna mast and tighten set screw.

Install saddlebags. See

2.27 SADDLEBAGS

STUD PLATE

Removal

Remove rear wheel as necessary to gain access to fender
well. See

2.4 REAR WHEEL

Remove flange nuts from studs at sides of rear fender.
See

Figure 2-172

Reaching into fender well, carefully pry stud plate away
from rear fender.

NOTE

Stud plates installed in production use adhesive strips as an
assembly aid. Beginning at the edges, carefully work stud plate
free using a small putty knife or gasket scraper.

sm02923

Figure 2-172. Remove Flange Nuts

Installation

Install new stud plate.

Install flange nuts on studs and alternately tighten to 80
in-lbs (9.0 Nm). See

Figure 2-172

NOTE

As it is necessary to overcome the resistance of the lock patch
on the stud threads, note that the flange nut torque specification
is higher when using a new stud plate.

Install rear wheel. See

2.4 REAR WHEEL

REAR FACIA LAMP

Removal

Remove rear facia. See

2.48 REAR FACIA: FLHX

On left side of motorcycle, remove bolt (with flat washer)
to remove passenger seat strap and saddlebag front
mounting bracket from chrome frame tube cover.

Remove Phillips screw and chrome frame tube cover.

Release rear facia lamp wires from cable clip at top of
radio antenna bracket. See

Figure 2-173

Cut cable strap to release rear facia lamp wires and radio
antenna cable from slotted hole in rear fender support.

Cut cable strap to release rear facia lamp wires and radio
antenna cable from shoulder of upper frame tube (just in
front of air valve mounting bracket).

Disconnect rear facia lamp connector [12], 3-place Multi-
lock, inboard of upper frame tube.

NOTE

Connector [12] serves as the Tour-Pak lights connector on
FLHTC/U models.

2-136 2008 Touring Service: Chassis

Installation

Route rear facia lamp wires forward through cable clip at
top of radio antenna bracket and then upward in front of
saddlebag rear mounting bracket to inboard side of upper
frame tube.

On inboard side of upper frame tube, mate pin and socket
housings of rear facia lamp connector [12], 3-place Multi-
lock.

Using slotted hole, install new cable strap to secure rear
facia lamp wires and radio antenna cable to rear fender
support. See

Figure 2-173

Install new cable strap to secure rear facia lamp wires and
radio antenna cable to shoulder of upper frame tube (just
in front of air valve mounting bracket).

Install chrome frame tube cover on frame tube. Install
Phillips screw and tighten to 25-40 in-lbs (2.8-4.5 Nm).

Insert bolt (with flat washer) through passenger seat strap
and slotted hole of saddlebag front mounting bracket.
Insert bolt into forward hole in chrome frame tube cover.
Snug saddlebag front mounting bracket bolt, but do not
tighten.

sm02924

Figure 2-173. Capture Rear Facia Lamp Wires

Install rear facia. See

2.48 REAR FACIA: FLHX

Using an open end/box wrench, tighten saddlebag front
mounting bracket bolt to 60-96 in-lbs (6.8-10.8 Nm).

2008 Touring Service: Chassis 2-137

2.49

FOOTBOARDS AND FOOTRESTS

RIDER FOOTBOARDS

Removal

Remove right side footboard and bracket assembly as
follows: Remove two allen head socket screws (with lock
washers and flat washers) to release footboard brackets
from frame weldment. See

Figure 2-174

Figure 2-175

For best results, approach from left side of motorcycle
using a 3/8 inch ball allen with extension.

Remove left side footboard and bracket assembly as fol-
lows:

Raise motorcycle on center stand so that weight is
not resting on jiffy stand.

Remove socket screw (with lockwasher and flat
washer) to release footboard forward bracket from
frame weldment. See

Figure 2-174

Figure 2-175

For best results, approach from opposite side of
motorcycle using a 3/8 inch ball allen with extension.

Remove two hex screws (with lockwashers) to free
jiffy stand bracket and footboard rear bracket from
frame weldment.

Installation

Install right side footboard and bracket assembly as fol-
lows:

Insert two allen head socket screws (with lockwashers
and flat washers) through frame weldment into foot-
board brackets. See

Figure 2-174

Figure 2-175

For best results, approach from left side of motorcycle
using a 3/8 inch ball allen with extension.

Alternately tighten socket screws to 30-35 ft-lbs (41-
48 Nm).

sm03587

Left front bracket

Rubber pad (2)

Footboard (2)

Socket screw (3)

10.

Lockwasher (3)

Pivot screw (4)

11.

Pivot screw nut (4)

Flat washer (3)

12.

Right front bracket

Left rear bracket

13.

Hex screw (2)

Right rear bracket

Lockwasher (2)

Figure 2-174. Rider Footboards (All Models Except FLHX)

2-138 2008 Touring Service: Chassis

sm03588

Left front bracket

Rubber pad (2)

Footboard (2)

Socket screw (3)

10.

Lockwasher (3)

Pivot screws (4)

11.

Pivot screw nut (4)

Flat washer (3)

12.

Right front bracket

Left rear bracket

13.

Hex screw (2)

Right rear bracket

Lockwasher (2)

Figure 2-175. Rider Footboards (FLHX)

PASSENGER FOOTBOARD

Removal

Remove socket screw with lockwasher to remove footboard
bracket from rear swingarm bracket.

Installation

Insert pin on footboard bracket into hole in rear swingarm
bracket.

NOTE

Passenger footboards can be adjusted to one of three positions.
To move footboards to a new position, remove plastic plugs
from holes in rear swingarm bracket as necessary.

Install socket screw with lockwasher. Tighten socket screw
to 30-35 ft-lbs (40.7-47.5 Nm).

Disassembly

NOTE

If only replacing the rubber pad, refer to step 1 below and then
see steps 4-5 under ASSEMBLY.

Tilt footboard upward. From bottom of footboard, use a
small flat blade screwdriver to push rubber beads on pad

up through holes in footboard. Remove pad. See

Figure 2-176

Using a brass drift and rubber mallet, tap two pivot pins
toward center of footboard and remove.

Remove footboard from footboard bracket.

Remove steel ball and spring from hole in footboard
bracket.

Remove footboard bracket from rear swingarm bracket.
See REMOVAL.

Assembly

Install footboard bracket. See INSTALLATION.

Place spring into hole in footboard bracket. Place ball on
top of spring. See

Figure 2-176

Place footboard into position on bracket and install pivot
pins from the outboard side. Using a brass drift and rubber
mallet, tap pins until centered in lugs of bracket.

2-140 2008 Touring Service: Chassis

sm02925

Rubber pad

Footboard

Pivot pin (2)

Footboard bracket

Steel ball

Spring

Socket screw

Lockwasher

Figure 2-176. Passenger Footboard (All Models Except

FLHX)

Moisten rubber beads on new pad with soapy water. Place
pad into position on footboard. From bottom of footboard,
use needle nose pliers to pull rubber beads down through
holes in footboard.

Engage nubs on inboard corners of pad with holes in
footboard.

PASSENGER FOOTREST (FLHX)

Removal

Remove socket screw with lockwasher to remove footrest
bracket from rear swingarm bracket.

Installation

Insert pin on footrest bracket into hole in rear swingarm
bracket.

NOTE

Passenger footrests can be adjusted to one of three positions.
To move footrests to a new position, remove plastic plugs from
holes in rear swingarm bracket as necessary.

Install socket screw with lockwasher. Tighten socket screw
to 30-35 ft-lbs (40.7-47.5 Nm).

Disassembly

NOTE

If only replacing the rubber pad, refer to step 1 below and then
see steps 7-9 under ASSEMBLY.

Remove socket screw from end of footrest. Remove rubber
pad from footrest. See

Figure 2-177

Remove footrest from footrest mount.

Remove retaining ring from groove at end of pivot pin.
Remove pivot pin.

Remove footrest mount and wave spring from footrest
bracket.

Remove footrest bracket from rear swingarm bracket. See
REMOVAL.

Assembly

Install footrest bracket. See INSTALLATION.

Align hole in wave spring with bottom hole in footrest
bracket. See

Figure 2-177

. Be sure that the concave side

is down and the flat edge is against the inboard side of
the footrest bracket.

Holding wave spring in place, install footrest mount
between arms of bracket with the rounded side of the pivot
pin end up.

Install pivot pin into top hole in footrest bracket. Top hole
is countersunk so that head of pivot pin is flush after
installation.

NOTE

Verify operation of footrest mount before installing retaining
ring. The ease with which the footrest mount pivots is based
on the curvature of the wave spring. Flattening the wave spring
allows the footrest mount to move more easily, while increasing
the curvature makes movement more difficult.

Install new retaining ring in groove at end of pivot pin.

Slide footrest onto footrest mount.

Place rubber pad into footrest.

Apply a small dab of Loctite Medium Strength Threadlocker
243 (blue) to threads of socket screw.

Start socket screw into end of footrest. Rotate footrest so
that the rubber pad is topside and tighten socket screw to
15-20 ft-lbs (20-27 Nm).

2008 Touring Service: Chassis 2-141

sm02926

Socket screw

Rubber pad

Footrest

Retaining ring

Pivot pin

Footrest mount

Wave spring

Footrest bracket

Socket screw

10. Lockwasher

Figure 2-177. Passenger Footrest (FLHX)

2-142 2008 Touring Service: Chassis

2.50

JIFFY STAND

GENERAL

The jiffy stand locks when placed in the full forward (down)
position with vehicle weight on it. If the jiffy stand is not
in the full forward (down) position with vehicle weight on
it, the vehicle can fall over which could result in death or
serious injury. (00006a)

Always park motorcycle on a level, firm surface. An
unbalanced motorcycle can fall over, which could result
in death or serious injury. (00039a)

REMOVAL

Block vehicle under frame such that vehicle will not fall
when jiffy stand is removed. Failure to properly block
vehicle could result in death or serious injury. (00462b)

Block motorcycle under frame, so that motorcycle is
securely upright and level. Jiffy stand should be able to
move through its full range of travel without the weight of
the motorcycle resting on it.

Move jiffy stand to the full forward (down) position. Remove
hex screw, lockwasher, flat washer and leg stop from
threaded end of jiffy stand. See

Figure 2-178

Swing jiffy stand forward beyond the normal down position
and remove end of spring from hole in jiffy stand weldment.
Remove jiffy stand from bracket. Remove other end of
spring from hole in frame weldment.

Inspect jiffy stand assembly for worn or damaged parts.
Replace parts as necessary.

INSTALLATION

Lubricate jiffy stand with Loctite Aerosol Anti-Seize Lub-
ricant. Restrict application to area of jiffy stand that rotates
within the bracket.

Install end of spring into hole in frame weldment. Insert
threaded end of jiffy stand up through bottom of bracket.
Swing jiffy stand forward beyond the normal down position
and install other end of spring into hole in jiffy stand
weldment.

NOTE

Verify that end of spring enters hole at front of jiffy stand
weldment. See

Figure 2-179

. If end of spring enters hole at

rear of weldment, spring coil will rub on jiffy stand when exer-
cised.

Holding jiffy stand at the full forward (down) position, install
leg stop over threaded end with the stamped side down.
Install flat washer, lockwasher and hex screw. Tighten hex
screw to 15-20 ft-lbs (20.3-27.1 Nm).

sm04760

Leg stop (longer side faces rear)

Hex screw, lockwasher and flat washer

Bracket

Figure 2-178. Leg Stop Orientation in Full Forward (Down)

Position

sm04761

Figure 2-179. Rubber Stop and Spring Orientation

If leg stop is incorrectly installed, excessive wear can allow
vehicle to fall when rested on jiffy stand, which could result
in death or serious injury. (00479b)

2008 Touring Service: Chassis 2-143

Verify that the longer side of the leg stop faces the rear of
the motorcycle. See

Figure 2-178

Extend and retract jiffy stand several times to verify proper
operation. Jiffy stand should swing freely to the fully
extended and fully retracted positions.

Move jiffy stand to the full forward (down) position. Care-
fully remove support blocking from beneath motorcycle
frame and rest motorcycle on jiffy stand.

NOTE

Verify that rubber stop is installed in hole of jiffy stand weld-
ment. Without the rubber stop, the jiffy stand will make hard
contact with the lower frame tube when retracted, possibly
resulting in chipping or nicking of the powder coat. Install new
rubber stop if damaged or missing. See

Figure 2-179

JIFFY STAND BRACKET

Removal

Remove jiffy stand.

Remove two short hex screws (with lockwashers) to
release front of jiffy stand bracket from frame weldment.
See

Figure 2-180

sm04763

Short hex screw (3)

Lockwasher (5)

Flat washer

Leg stop

Spring

Frame hole

Jiffy stand

Rubber stop

Long hex screw (2)

10. Bracket

Figure 2-180. Jiffy Stand Assembly

Remove two long hex screws (with lockwashers) to free
rear of jiffy stand bracket and rider footboard rear bracket
from frame weldment.

Installation

Start two short hex screws (with lockwashers) to fasten
front of jiffy stand bracket to frame weldment.

Start two long hex screws (with lockwashers) to fasten
rear of jiffy stand bracket and rider footboard rear bracket
to frame weldment.

Alternately tighten four hex screws to 15-20 ft-lbs (20.3-
27.1 Nm) using a crosswise pattern.

NOTE

The threaded inserts for the three jiffy stand bracket screws
are not replaceable. Drive the insert from the frame weldment
if it should become stripped, cross-threaded or loose. Replace
with a 5/16 inch Grade 5 screw of suitable length with lock
washer, flat washer and locknut. Be sure flat washer is posi-
tioned against inboard side of frame weldment and screw is
tightened to 15-20 ft-lbs (20.3-27.1 Nm).

Install jiffy stand.

JIFFY STAND INTERLOCK SENSOR

Removal

Push anchor on jiffy stand interlock sensor connector [133],
3-place Molex, from hole in front electrical caddy. Discon-
nect connector.

Cut anchored cable strap at top of frame weldment to
release cable.

Move jiffy stand to full forward (down) position.

Remove socket head screw and pull sensor from bore of
jiffy stand bracket. See

Figure 2-181

sm04951

Figure 2-181. Jiffy Stand Interlock Sensor

Installation

Move jiffy stand to full forward (down) position.

Install sensor into bore of jiffy stand bracket.

2-144 2008 Touring Service: Chassis

Install socket head screw and tighten to 96-120 in-
lbs (10.8-13.6 Nm). If reusing screw, apply a small dab
Use Loctite Medium Strength Threadlocker 243 (blue) to
threads before installation.

Route connector and cable over top of frame weldment
staying rear of front engine stabilizer link, and then down
to front electrical caddy.

Connect jiffy stand interlock sensor connector [133] and
push anchor into hole in front electrical caddy. See

Figure 2-182

Install new anchored cable strap into hole at top of frame
weldment and capture cable. Cut any excess cable strap
material.

sm04388

CKP sensor connector [79]

Jiffy stand interlock sensor connector [133]

Figure 2-182. Front Caddy

2008 Touring Service: Chassis 2-145

Harley Davidson 2008 Touring Models. Service Manual - page 18