Harley Davidson 2008 Touring Models. Service Manual

AUXILIARY LAMP BRACKET

Removal

Proceed as follows:

FLHR/C:

Remove headlamp assembly. See

. Disconnect

auxiliary lamps connector [73], white 2-place Multilock.
Disconnect front turn signal lamps connector [31], 6-
place Multilock, anchored in hole of fork stem nut
lockplate (left side). See

Figure 8-26

FLHT/C/U: Remove outer fairing. See

2.35 UPPER

FAIRING AND WINDSHIELD: FLHX, FLHT/C/U

Disconnect the 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 sides). See

Figure 8-27

Proceed as follows:

FLHR/C: Remove acorn nuts from fork bracket studs.

FLHT/C/U: Loosen screws in upper and lower fork
brackets.

Remove auxiliary lamp bracket from motorcycle.

Installation

Install auxiliary lamp bracket on motorcycle. Proceed as
follows:

FLHR/C: Slide slots of auxiliary lamp bracket onto
upper and lower fork bracket studs. Install acorn nuts
on studs. Alternately tighten acorn nuts to 72-108 in-
lbs (8.1-12.2 Nm) using a crosswise pattern.

FLHT/C/U: Slide slots of auxiliary lamp bracket onto
screws in upper and lower fork brackets. Alternately
tighten screws to 15-20 ft-lbs (20-27 Nm) using a
crosswise pattern.

Proceed as follows:

FLHR/C: Connect auxiliary lamps connector [73],
white 2-place Multilock. Connect front turn signal
lamps connector [31], 6-place Multilock. Install anchor
on connector into hole of fork stem nut lockplate (left
side). Install headlamp assembly. See

8.9 HEAD-

LAMP: ALL EXCEPT FLTR

FLHT/C/U: Connect the left and right front turn
signal/auxiliary lamp connectors [31L/R], 4-place
Multilocks. Install connectors on T-studs at top of left
and right fairing support braces (outboard sides).
Verify that conduit is routed inboard using reliefs in
upper outboard corners of chrome skirt. Install outer
fairing. See

2.35 UPPER FAIRING AND WIND-

SHIELD: FLHX, FLHT/C/U

ADJUSTMENT

Headlamp High Beam

Adjust the headlamp high beam for proper height and lat-
eral alignment. See

1.21 HEADLAMP ALIGNMENT

With a rider seated on the motorcycle and the front wheel
pointed straight ahead, turn on the headlamp high beam.

Mark the center of the headlamp high beam by making a
vertical line through the horizontal line already drawn on
the wall. Properly adjusted, the beam should project an
equal area of light to the left and right of the vertical
centerline. See item 1 in

Figure 8-30

Auxiliary Lamps

Turn the headlamp off and move to the front of the
motorcycle.

Measure the distance from the headlamp horizontal
centerline down to the horizontal centerline of the left side
auxiliary lamp. Now measure the distance from the head-
lamp vertical centerline out to the vertical centerline of the
same lamp.

Repeat measurements performed in previous step on right
side auxiliary lamp.

From the headlamp high beam centerlines, perform the
measurements taken in steps 5-6 to locate the left and
right side auxiliary lamp centerlines on the wall. See items
2 and 3 in

Figure 8-30

Turn on the headlamp high beam again, and with a rider
seated on the motorcycle, verify that it is still aligned with
the horizontal and vertical centerlines.

Turn on the headlamp low beam and then cover both the
headlamp and the right side auxiliary lamp. Adjust the left
side auxiliary lamp as necessary so that the entire high
intensity zone is both below and to the right of the left side
auxiliary lamp centerlines. See item 4 in

Figure 8-30

Leaving the headlamp covered, remove cover from right
side auxiliary lamp and place over left side auxiliary lamp.
Adjust the right side auxiliary lamp as necessary so that
the entire high intensity zone is both below and to the right
of the right side auxiliary lamp centerlines. See item 5 in

Figure 8-30

Verify that auxiliary lamps are properly tightened. Proceed
as follows:

Remove two screws to release turn signal lamp from
mounting bracket.

Insert flare nut socket (Snap-on® FRX181) at bottom
of turn signal mounting bracket and tighten locknut
to 18 ft-lbs (24.4 Nm).

Start two screws to secure turn signal lamp to
mounting bracket. Verify that conduit fits in slot at
back of bracket and is not pinched. Alternately tighten
screws to 36-60 in-lbs (4.1-6.8 Nm).

2008 Touring Service: Electrical 8-25

8.12

TAIL LAMP

TAIL LAMP/TAIL LAMP BULB

Removal

Remove two screws from lens to release tail lamp
assembly from chrome base. See left side of

Figure 8-31

Disconnect tail lamp connector [93], 4-place Multilock. See
right side of

Figure 8-31

Rotate bulb socket 1/4 turn in a counterclockwise direction
and remove from tail lamp assembly. Gently pull bulb from
socket.

Installation

Gently push new bulb into socket. Insert socket into tail
lamp assembly and rotate 1/4 turn in a clockwise direction.

Connect tail lamp connector [93], 4-place Multilock. See
right side of

Figure 8-31

Place tail lamp into position against chrome base.

Install two screws and alternately tighten to 20-24 in-
lbs (2.3-2.7 Nm).

NOTE

Over tightening screws can crack the lens or result in scratching
of the fender paint.

Turn the Ignition/Light Key Switch to IGNITION and test
lamp for proper operation.

68140-98

sm03623

Tail lamp assembly

Chrome base

Tail lamp connector [93]

Figure 8-31. Remove Tail Lamp and Depress Button to Release Socket Housing

CIRCUIT BOARD/CHROME BASE

Removal

Remove two screws to release tail lamp assembly from
chrome base. See left side of

Figure 8-31

Disconnect tail lamp connector [93], 4-place Multilock. See
right side of

Figure 8-31

Disconnect remaining connectors. See

Figure 8-32

. To

release socket housings of left and right turn signal lamps,
use a pick or small screwdriver to depress button as shown
in

Figure 8-33

NOTE

The rear fender tip lamp is present on FLHR and FLHT/C/U
models only. As the lamp is absent on FLHX models, the circuit

board location is used for power to the license plate lamps, a
feature unique to that model. On FLHRC and FLTR models,
the location is unused.

Remove screw (with captive washer) at center of chrome
base. Use both thumbs to push chrome base upward until
it becomes free of fender and then pull out of fender hole.

Feed socket housings through openings to inboard side
of chrome base. See

Figure 8-32

. For best results, free

the smaller socket housings first.

2008 Touring Service: Electrical 8-27

sm03624

Left turn signal lamp [18]

Right turn signal lamp [19]

Rear fender tip lamp [45]

Tail lamp [93]

Rear fender lights harness [94]

Opening

Figure 8-32. Rear Fender Lights Assembly

sm03625

Figure 8-33. Use Pick Tool to Release Left Turn Signal

Lamp Socket

Remove pin housing/circuit board from chrome base. For
best results, push index pins on pin housing from holes in
chrome base.

Installation

Feed socket housings through openings to outboard side
of chrome base. See

Figure 8-32

. For best results, feed

the larger socket housings first.

Fit bottom of chrome base into fender hole and then push
down to align center hole with clip nut on fender flange.

Place pin housing over circuit board, if removed. See

Figure 8-34

Insert index pins at back of pin housing into holes in
chrome base.

Install screw (with captive washer) to secure pin
housing/circuit board and chrome base to clip nut on
fender flange. Tighten screw to 40-48 in-lbs (4.5-5.4 Nm).

NOTE

Over tightening screw can crack the chrome base or result in
scratching of the fender paint.

Install socket housings into pin housing/circuit board. Install
rear fender tip lamp and both left and right turn signal lamp
sockets so that the release buttons are at the top. Install
the rear fender lights harness socket with the button on
the outboard side and the tail lamp socket with the button
at the bottom.

To avoid stressing wires, verify that tail lamp conduit is
positioned on the outboard side of the rear fender tip lamp
and left turn signal lamp conduit as shown in

Figure 8-31

Place tail lamp into position against chrome base.

Install two screws and alternately tighten to 20-24 in-
lbs (2.3-2.7 Nm).

NOTE

Over tightening screws can crack the lens or result in scratching
of the fender paint.

10. Turn the Ignition/Light Key Switch to IGNITION and test

lamp for proper operation.

H-D

USA

68830-98

sm03626

Figure 8-34. Place Pin Housing Over Circuit Board

REAR FENDER LIGHTS HARNESS

Removal

Remove rear fender. See

2.47 REAR FENDER

See

Figure 8-31

. Remove two screws to release tail lamp

assembly from chrome base.

8-28 2008 Touring Service: Electrical

Disconnect tail lamp connector [93], 4-place Multilock. Set
tail lamp assembly aside.

See

Figure 8-32

. Disconnect rear fender lights connector

[94], 6-place Multilock. Feed socket housing through
opening to inboard side of fender.

Release left and right rear turn signal lamp conduit from
respective cable clip anchored on T-stud. On FLHX
models, also release license plate lamps conduit from left
side cable clip. On FLHR and FLHT/C/U models, release
rear fender tip lamp conduit from both left side cable clip
and stamped fender clip.

Release rear fender lights harness from channel in stud
plate. Loosen two flange nuts, if necessary.

Draw socket housing of rear fender lights connector [7],
8-place Multilock, through hole to inboard side of fender.

Remove wire harness and adhesive conduit from fender
well.

Installation

Proceed as follows:

Thoroughly clean fender well with soap and water.
Do not use solvents or harsh chemicals or damage
to painted surfaces may occur.

Remove remnants of old conduit, as well as all
residual adhesive. For good results, use 3M general
Purpose adhesive remover (Part No. 051135).

See

Figure 8-35

. Using a soapy Scotch Brite® pad,

thoroughly clean fender well in area of adhesive
conduit.

Rinse with clear water and thoroughly dry with a clean
white cloth. Repeat step until clean cloth shows no
evidence of dirt.

Swab area with isopropyl alcohol and allow to dry.

Obtain new harness with adhesive conduit. Remove
paper backing to expose adhesive and lightly press
into place in the right side fender well.

NOTE

See

Figure 8-35

. Adhesive conduit should be approxim-

ately 0.88 in (22.4 mm) from the chrome base hole and

1.43 in (36.3 mm) from the fender seat screw centerline.

Using a wallpaper seam roller (available at most home
improvement stores), work roller over adhesive con-
duit to purge air from between fender and adhesive.
Be aware that most other installation methods will
produce unsatisfactory results.

Allow the adhesive 72 hours to fully cure. Installation
of the fender may proceed, but exercise caution to
avoid pulling or repositioning adhesive conduit.

Feed socket housing of rear fender lights connector [7],
8-place Multilock, through hole to outboard side of fender.

sm03627

Adhesive conduit

Stud plate

T-stud cable clips (2)

Stamped fender clip

Cable strap

0.88 in. (22.4 mm) between conduit and chrome
base hole

1.43 in. (36.3 mm) between conduit and fender
seat screw centerline

Figure 8-35. Rear Fender Well

Capture rear fender lights harness in channel of stud plate.
If loosened, tighten two flange nuts to 60-96 in-lbs (6.8-
10.9 Nm).

See

Figure 8-32

. Feed socket housing of rear fender lights

connector [94] through opening to outboard side of fender.
Connect socket housing to pin housing/circuit board.

Capture left and right rear turn signal lamp conduit in
respective cable clip anchored on T-stud. On FLHX
models, also capture license plate lamps conduit in left
side cable clip. On FLHR and FLHT/C/U models, capture

2008 Touring Service: Electrical 8-29

8.13

FENDER TIP LAMPS

FRONT FENDER TIP LAMP

Removal

Insert blade of small screwdriver into slot at top of fender
tip lamp lens. Rotate end of screwdriver to unsnap lens
from lamp bracket.

Holding Keps nuts at inboard side of rear fender, remove
two screws to release fender tip lamp bracket.

Disconnect front fender tip lamp connector [143], 2-place
Multilock. See

Figure 8-38

Installation

Connect front fender tip lamp connector [143], 2-place
Multilock. See

Figure 8-38

With wires routed along bottom left side, place fender tip
lamp bracket into position aligning holes in bracket with
those in fender.

Slide screws through bracket and fender holes and install
Keps nuts. Holding nuts at inboard side of fender, tighten
screws to 20-25 in-lbs (2.3-2.8 Nm).

NOTE

Over tightening screws can crack the bracket or result in
scratching of the fender paint.

Insert tab at bottom of lens into slot of fender tip lamp
bracket. Apply thumb pressure at top of lens until it snaps
into place.

Turn the Ignition/Light Key Switch to IGNITION and test
lamp for proper operation.

FRONT FENDER TIP LAMP JUMPER
HARNESS

Removal

FLHR: Remove headlamp assembly. See

8.9 HEADLAMP:

ALL EXCEPT FLTR

. Disconnect the front fender tip lamp

jumper harness connector [32], 2-place Multilock. See

Figure 8-36

FLHT/C/U: Reaching in below the fairing cap on the left
side of the steering head, disconnect the front fender tip
lamp jumper harness connector [32], 2-place Multilock.
See

Figure 8-37

. Remove outer fairing only if necessary.

See

2.35 UPPER FAIRING AND WINDSHIELD: FLHX,

FLHT/C/U

Draw socket housing down to fender area.

Carefully cut cable strap to release front fender tip lamp
wires from brake caliper hose.

Remove terminals from socket housing.

NOTE

For instructions on removing terminals, see

A.2 AMP MULTI-

LOCK CONNECTORS

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

sm05089

Figure 8-36. Front Fender Tip Lamp Jumper Harness

Connector (FLHR)

sm03628

Figure 8-37. Front Fender Tip Lamp Jumper Harness

Connector (FLHX, FLHT/C/U)

Remove front wheel. See

2.3 FRONT WHEEL

From inboard side of front fender, remove two nuts to
release trim strip from left side of fender. See

Figure 8-39

Pull wires and socket terminals through grommet to
inboard side of fender. See

Figure 8-40

. Reaching under

left side of fender, draw wires forward out from beneath
fender bracket.

10. Feed wires through oblong hole to outboard side of fender.

2008 Touring Service: Electrical 8-31

sm03629

Front fender tip lamp bracket

Front fender tip lamp connector [143]

Figure 8-38. Front Fender Tip Lamp Assembly

11. Insert blade of small screwdriver into slot at top of fender

tip lamp lens. Rotate end of screwdriver to unsnap lens
from lamp bracket.

12. Holding Keps nuts at inboard side of front fender, remove

two screws to release fender tip lamp bracket.

13. Disconnect front fender tip lamp connector [143], 2-place

Multilock, to release fender tip lamp assembly from jumper
harness. See

Figure 8-38

Installation

Connect front fender tip lamp connector [143], 2-place
Multilock, to attach fender tip lamp assembly to jumper
harness. See

Figure 8-38

Pull jumper harness conduit as close to fender tip lamp
connector [143] as possible, for the conduit is not easily
routed beneath the fender bracket.

With conduit routed along bottom left side, place fender
tip lamp bracket into position aligning holes in bracket with
those in fender.

Slide screws through bracket and fender holes and install
Keps nuts. Holding nuts at inboard side of fender, tighten
screws to 20-25 in-lbs (2.3-2.8 Nm).

NOTE

Over tightening screws can crack the bracket or result in
scratching of the fender paint.

Insert tab at bottom of lens into slot of fender tip lamp
bracket. Apply thumb pressure at top of lens until it snaps
into place.

Route wire conduit inside trim strip and slide front tee bolt
over conduit. See

Figure 8-39

. Verify that second tee bolt

is in position at rear of trim strip.

sm03630

Fender tip lamp bracket

Tee bolt

Wire conduit

Trim strip

Oblong hole

Figure 8-39. Install Conduit in Trim Strip

sm03631

Grommet

Socket terminals

Figure 8-40. Pull Fender Tip Lamp Wires and Terminals

Through Fender Grommet

Feed socket terminals and wires through oblong hole to
inboard side of fender.

NOTE

Use the rearmost oblong hole as the front may be used for
installation of certain P&A accessories.

While removing slack from wires on outboard side of
fender, align tee bolts with fender holes. With trim strip
positioned against left side of fender, reach under fender
and install nuts on tee bolts. Alternately tighten nuts to
10-15 in-lbs (1.1-1.7 Nm).

8-32 2008 Touring Service: Electrical

Reaching under left side of fender, route wires of the
jumper harness rearward between tee bolt nut and fender
bracket and then beneath fender bracket to grommet. See

Figure 8-41

10. Feed socket terminals and wires through grommet to out-

board side of fender. See

Figure 8-40

NOTE

If any portion of the jumper harness is above the height of the
fender bracket, contact with the tire can cause chafing or other
damage. Damage to the wiring can lead to loss of lighting.

11. Remove slack from wires on inboard side of fender. Verify

that no portion of the jumper harness is above the height
of the fender bracket.

12. Install terminals into socket housing.

NOTE

For instructions on installing terminals, see

A.2 AMP MULTI-

LOCK CONNECTORS

13. Route socket housing upward behind chrome skirt

(FLHT/C/U) or through bottom of headlamp nacelle (FLHR)
to area beneath upper fork bracket. Connect front fender
tip lamp jumper harness connector [32].

NOTE

To connect jumper harness connector with the outer fairing
installed (FLHT/C/U models), reach in below the fairing cap on
the left side of the steering head.

14. Install front wheel. See

2.3 FRONT WHEEL

15. Install new cable strap to secure front fender tip lamp wires

to brake caliper hose. See

Figure 8-42

16. FLHR: Install headlamp assembly. See

8.9 HEADLAMP:

ALL EXCEPT FLTR

17. FLHT/C/U:

Install outer fairing, if removed. See

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

sm03632

Oblong hole

Jumper harness

T-bolt nut

Fender bracket

Grommet

Figure 8-41. Left Side Front Fender Well

sm03520

Figure 8-42. Capture Brake Hose and Front Fender Tip

Lamp Wires

18. Turn Ignition/Light Key Switch to IGNITION and test lamp

for proper operation.

REAR FENDER TIP LAMP

Removal

Remove two screws to release tail lamp assembly from
chrome base.

Disconnect tail lamp connector [93], 4-place Multilock. Set
tail lamp assembly aside. See

Figure 8-43

Disconnect rear fender tip lamp connector [45], 3-place
Multilock.

Feed socket housing through opening in chrome base to
inboard side of rear fender.

Reaching under left side of rear fender, release conduit
from cable clip anchored on T-stud. Release conduit from
stamped fender clip.

Insert blade of small screwdriver into slot at top of fender
tip lamp lens. Rotate end of screwdriver to unsnap lens
from lamp bracket. See upper frame of

Figure 8-44

Holding nuts at inboard side of rear fender, remove two
screws to release fender tip lamp bracket. See lower frame
of

Figure 8-44

Draw conduit and socket housing out through bottom
fender hole. See

Figure 8-45

Remove terminals from socket housing.

NOTE

For instructions on removing terminals, see

A.2 AMP MULTI-

LOCK CONNECTORS

2008 Touring Service: Electrical 8-33

sm03633

Tail lamp [93]

Rear fender tip lamp [45]

Opening

Figure 8-43. Depress Button to Release Socket from Pin

Housing

Installation

Place new fender tip lamp assembly next to discarded
unit and cut wires to proper length.

Crimp new socket terminals onto fender tip lamp wires.

NOTE

For instructions on crimping terminals, see

A.2 AMP MULTI-

LOCK CONNECTORS

Install terminals into socket housing.

Table 8-7. Rear Fender Tip Lamps [45]

CHAMBER NUMBER

WIRE COLOR

Black

Not Used

Black

NOTE

For instructions on installing terminals, see

A.2 AMP MULTI-

LOCK CONNECTORS

Feed socket housing and conduit through bottom fender
hole. See

Figure 8-45

Place fender tip lamp bracket into position aligning holes
in bracket with those in fender. Slide screws through
bracket and fender holes and install nuts. See lower frame
of

Figure 8-44

Insert tab at bottom of lens into slot of fender tip lamp
bracket. Apply thumb pressure at top of lens until it snaps
into place.

Reaching under left side of rear fender, capture conduit
in cable clip anchored on T-stud. Capture conduit in
stamped fender clip next to fender hole.

Feed socket housing through opening on left side of
chrome base to outboard side of rear fender. Oriented
with the release button at the top, insert socket housing
into pin housing/circuit board.

To install tail lamp assembly, orient 4-place Multilock
socket so that the release button is at the bottom and insert
into pin housing until it clicks. To avoid stressing wires,
verify that tail lamp conduit is positioned on the outboard
side of the rear fender tip lamp and left turn signal lamp
conduit as shown in

Figure 8-43

10. Place tail lamp into position against chrome base.

11. Install two screws and alternately tighten to 20-24 in-

lbs (2.3-2.7 Nm).

NOTE

Over tightening screws can crack the lens or result in scratching
of the fender paint.

sm03634

Screwdriver

Lens

Screws

Rear fender tip lamp bracket

Figure 8-44. Remove Rear Fender Tip Lamp Lens and

Bracket

8-34 2008 Touring Service: Electrical

8.14

TURN SIGNAL LAMPS

BULB REPLACEMENT

Removal

Proceed as follows:

FLHR/C, FLHT/C/U: Remove two screws to release
lens from lamp. See

Figure 8-46

FLHX, FLTR: Insert blade of small screwdriver into
slot at bottom of lens. Gently rotate end of screwdriver
to unsnap lens from lamp.

Push in bulb and rotate in a counterclockwise direction to
remove.

Inspect condition of electrical contacts in socket. If
necessary, clean with a small wire brush and electrical
contact cleaner.

sm03644

Turn signal lamp

Phillips screw (2)

Lens

Allen head screw (2)

Mounting bracket

Figure 8-46. Front Turn Signal Lamp (FLHR/C, FLHT/C/U)

Installation

Liberally apply dielectric grease to contacts in socket and
at bottom of new bulb. For correct bulb type, see

1.4 BULB

REQUIREMENTS

Push in bulb and rotate in a clockwise direction to install.

Proceed as follows:

FLHR/C, FLHT/C/U: Seat lens in lamp and install two
screws.

FLHX, FLTR: Seat lens in lamp and gently apply
thumb pressure until it snaps into place. Rotate lens
to position slot at bottom of lamp.

FRONT TURN SIGNAL LAMP

Removal: FLHR/C, FLHT/C/U

FLHR/C: Remove headlamp assembly. See

8.9 HEAD-

LAMP: ALL EXCEPT FLTR

. See

Figure 8-47

. Disconnect

front turn signal lamps connector [31], 6-place Multilock,
anchored in hole of fork stem nut lockplate (left side).

FLHT/C/U: Remove outer fairing. See

2.35 UPPER

FAIRING AND WINDSHIELD: FLHX, FLHT/C/U

. See

Figure 8-48

. Disconnect the left or right front turn

signal/auxiliary lamp connector [31L/R], 4-place Multilock,
on T-stud at top of left or right fairing support brace (out-
board side).

Remove appropriate terminal(s) from socket housing as
follows:

Table 8-8. FLHR/C Front Turn Signal Lamps [31]

RIGHT SIDE

LEFT SIDE

CHAMBER

WIRE COLOR

CHAMBER

WIRE COLOR

Black

Blue (DOM)

Brown

Violet

Blue (DOM)

Black

Table 8-9. FLHT/C/U Front Turn Signal Lamps [31L/R]

RIGHT SIDE [31R]

LEFT SIDE [31L]

CHAMBER

WIRE COLOR

CHAMBER

WIRE COLOR

Blue

Brown

Violet

Black

Note: Terminal 4 is reserved for the auxiliary lamp.

NOTE

For instructions on removing terminals, see

. Remove two screws to release turn signal

lamp from mounting bracket.

Obtain three equal lengths of strong flexible wire for use
as mechanics wire. Feed wire through opening in socket
terminal and then loop back twisting end until tightly coiled
around longer strand as shown in

Figure 8-49

. Repeat

step with remaining socket terminals.

8-36 2008 Touring Service: Electrical

sm03646

Front turn signal lamps [31]

Figure 8-47. Headlamp Nacelle (FLHR/C)

sm05085

Right front turn signal/auxiliary lamp [31R]

Left front turn signal/auxiliary lamp [31L]

Figure 8-48. Inner Fairing (FLHT/C/U)

NOTE

Be sure that mechanics wire is of sufficient strength to pull
terminals through conduit without breaking. Wire lengths must
also be long enough so that free ends are not lost in conduit
when pulled.

Carefully pull wires to draw socket terminals through both
sections of conduit. For best results, pull one wire at a
time.

Unravel mechanics wire to release socket terminals.

Installation: FLHR/C, FLHT/C/U

Lay old turn signal lamp next to new turn signal lamp and
cut wires to length.

Strip 3/16 in. (4.8 mm) of insulation off lamp wires and
crimp on new socket terminals.

NOTE

For instructions on crimping terminals, see

A.2 AMP MULTI-

LOCK CONNECTORS

Reattach mechanics wire to socket terminals and carefully
pull ends of mechanics wire to draw socket terminals back
through conduit.

Carefully remove mechanics wire to avoid damage to ter-
minals.

Install terminals into socket housing. For correct terminal
locations refer to

Table 8-8

Table 8-9

NOTE

For instructions on installing terminals, see

A.2 AMP MULTI-

LOCK CONNECTORS

See

Figure 8-46

. Start two screws to secure turn signal

lamp to mounting bracket. Verify that conduit fits in slot at
back of bracket and is not pinched. Alternately tighten
screws to 30-60 in-lbs (4.1-6.8 Nm).

Connect front turn signal/auxiliary lamp connector.

FLHR/C: Install anchor on connector into hole of fork stem
nut lockplate (left side). See

Figure 8-47

. Install headlamp

assembly. See

8.9 HEADLAMP: ALL EXCEPT FLTR

FLHT/C/U: Install connector on T-stud at top of left or right
fairing support brace (outboard side). Verify that conduit
is routed inboard using relief in upper outboard corner of
chrome skirt. Install outer fairing. See

2.35 UPPER

FAIRING AND WINDSHIELD: FLHX, FLHT/C/U

sm03621

Figure 8-49. Fix Mechanics Wire to Socket Terminal

Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

2008 Touring Service: Electrical 8-37

10. Turn Ignition/Light Key Switch to IGNITION and test for

proper operation.

Removal: FLXH

Remove outer fairing. See

2.35 UPPER FAIRING AND

WINDSHIELD: FLHX, FLHT/C/U

See

Figure 8-48

. Disconnect the left or right front turn

signal lamp connector [31L/R], 4-place Multilock. Con-
nector is attached to T-stud at top of left or right fairing
support brace (outboard side).

See

Figure 8-50

. Remove two screws to release turn signal

lamp mounting bracket from upper and lower fork brackets.

To remove socket/isolator assembly, proceed as follows:

Remove terminals from socket housing.

NOTE

For instructions on removing terminals, see

A.2 AMP

MULTILOCK CONNECTORS

Pull mounting bracket from conduit.

Insert blade of small screwdriver into slot at bottom
of lens. Gently rotate end of screwdriver to unsnap
lens from lamp.

Push in bulb and rotate counterclockwise to remove.

Inserting blade of small screwdriver between outer
edge of rubber isolator and inside of lamp housing,
gently pry up socket assembly until free.

Pull socket assembly to draw conduit and terminals
into lamp and then out through lens opening.

Remove rubber isolator from lamp if still installed.

sm03650

Figure 8-50. Front Turn Signal Lamp (FLHX)

sm03651

Figure 8-51. Route Conduit Through Mounting Bracket

and Chrome Skirt Reliefs (FLHX)

Installation: FLHX

NOTE

If turn signal lamp is already assembled, begin procedure at
step 2.

To install socket/isolator assembly, proceed as follows:

Seat socket assembly in rubber isolator aligning tab
on socket with slot in isolator.

Feed terminals and conduit into lamp through lens
opening and then out through unthreaded hole.

Install socket assembly aligning tab on socket with
slot inside lamp.

Using thumbs of both hands, apply even pressure
around outer edge of socket assembly until fully
seated.

Liberally apply dielectric grease to contacts in socket
and at bottom of bulb. Push in bulb and rotate clock-
wise to install.

Install lens in lamp and gently apply thumb pressure
until it snaps into place. Rotate lens to position slot
at bottom of lamp.

Feed terminals and conduit through triangular shaped
hole in mounting bracket.

Align thru hole in mounting bracket with threaded hole
in lamp and start hex screw. Tighten hex screw to 15-
20 ft-lbs (20-27 Nm).

NOTE

For instructions on installing terminals, see

A.2 AMP

MULTILOCK CONNECTORS

Install terminals into socket housing as follows:

8-38 2008 Touring Service: Electrical

Table 8-10. FLHX, FLTR Front Turn Signal Lamps [31L/R]

RIGHT SIDE [31R]

LEFT SIDE [31L]

CHAMBER

WIRE COLOR

CHAMBER

WIRE COLOR

Blue

Brown

Violet

Black

Empty

Start two screws to fasten turn signal lamp mounting
bracket to upper and lower fork brackets.

To avoid pinching wires, verify that conduit is routed for-
ward through relief at front of mounting bracket, and then
inboard using relief in upper outboard corner of chrome
skirt. See

Figure 8-51

Alternately tighten screws to 15-20 ft-lbs (20-27 Nm).

See

Figure 8-48

. Connect front turn signal lamp connector.

Install connector on T-stud at top of left or right fairing
support brace (outboard side).

Install outer fairing. See

2.35 UPPER FAIRING AND

WINDSHIELD: FLHX, FLHT/C/U

Removal: FLTR

See

Figure 8-52

. Remove outer fairing and front turn signal

lamp. See

2.39 UPPER FAIRING AND WINDSHIELD:

FLTR

To remove socket/isolator assembly, proceed as follows:

Remove terminals from socket housing.

NOTE

For instructions on removing terminals, see

A.2 AMP

MULTILOCK CONNECTORS

Pull lamp from mounting bracket.

Insert blade of small screwdriver into slot at bottom
of lens. Gently rotate end of screwdriver to unsnap
lens from lamp.

Push in bulb and rotate counterclockwise to remove.

Inserting blade of small screwdriver between outer
edge of rubber isolator and inside of lamp housing,
gently pry up socket assembly until free.

Pull socket assembly to draw conduit and terminals
into lamp and then out through lens opening.

Remove rubber isolator from lamp if still installed.

Installation: FLTR

NOTE

If turn signal lamp is already assembled, begin procedure at
step 2.

Assemble front turn signal lamp as follows:

Seat socket assembly in rubber isolator aligning tab
on socket with slot in isolator.

Feed terminals and conduit into lamp through lens
opening and then out through unthreaded hole.

Install socket assembly aligning tab on socket with
slot inside lamp.

Using thumbs of both hands, apply even pressure
around outer edge of socket assembly until fully
seated.

Liberally apply dielectric grease to contacts in socket
and at bottom of bulb. Push in bulb and rotate clock-
wise to install.

Install lens in lamp and gently apply thumb pressure
until it snaps into place. Rotate lens to position slot
at bottom of lamp.

Install lamp onto mounting bracket. See

Figure 8-52

NOTE

For instructions on installing terminals, see

A.2 AMP

MULTILOCK CONNECTORS

Install terminals into socket housing. For correct ter-
minal locations refer to

Table 8-10

Install outer fairing and front turn signal lamp. See

2.39 UPPER FAIRING AND WINDSHIELD: FLTR

Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

Turn Ignition/Light Key Switch to IGNITION and test for
proper operation.

sm03652

Figure 8-52. Front Turn Signal Lamp (FLTR)

REAR TURN SIGNAL LAMP

Removal: FLHR/C, FLHT/C/U

Remove saddlebag on same side of motorcycle. See

2.27 SADDLEBAGS

2008 Touring Service: Electrical 8-39

Remove two screws to release tail lamp assembly from
chrome base.

sm03653

Left turn signal lamp [18]

Right turn signal lamp [19]

Tail lamp [93]

Figure 8-53. Release Tail Lamp Socket

sm03655

Opening

Fender hole

Figure 8-54. Use Pick Tool to Release Left Turn Signal

Lamp Socket

Disconnect tail lamp connector [93], 4-place Multilock. Set
tail lamp assembly aside. See

Figure 8-53

Disconnect turn signal lamp assembly, 2-place Multilock.
For best results, use a pick or small screwdriver to depress
release button as shown in

Figure 8-54

Feed socket housing through opening in chrome base to
inboard side of rear fender.

Reaching under rear fender, release conduit from cable
clip anchored on T-stud.

Draw conduit and socket housing out through fender hole
just below chrome base. See

Figure 8-54

Draw socket housing through channel on inboard side of
rear turn signal lamp bracket, so that length of conduit
hangs below turn signal lamp.

Inserting a long shank ball end socket (Snap-on® FABL5)
through channel in bracket, remove two screws to release
turn signal lamp assembly.

10. Remove terminals from socket housing.

NOTE

For instructions on removing terminals, see

A.2 AMP MULTI-

LOCK CONNECTORS

Installation: FLHR/C, FLHT/C/U

Place new turn signal lamp assembly next to discarded
unit and cut wires to proper length.

Crimp new socket terminals onto turn signal lamp wires.

NOTE

For instructions on crimping terminals, see

A.2 AMP MULTI-

LOCK CONNECTORS

Install terminals into socket housing.

Table 8-11. Rear Turn Signal Lamps [18/19]

CHAMBER NUMBER

WIRE COLOR

Violet/Brown

Black

NOTE

For instructions on installing terminals, see

A.2 AMP MULTI-

LOCK CONNECTORS

Align holes in turn signal lamp assembly with those in rear
turn signal lamp bracket and start two screws. For best
results, insert a long shank ball end socket (Snap-on®
FABL5) through channel on inboard side of bracket.
Alternately tighten screws to 30-50 in-lbs (3.4-5.6 Nm).

Route socket housing through channel in bracket, and
then feed through fender hole just below chrome base.
See

Figure 8-54

Reaching under rear fender, capture conduit in cable clip
anchored on T-stud.

Feed socket housing through opening in chrome base to
outboard side of rear fender.

Orient socket housing so that the release button is at the
top and insert into pin housing/circuit board.

To install tail lamp assembly, orient 4-place Multilock
socket so that the release button is at the bottom and insert

8-40 2008 Touring Service: Electrical

Harley Davidson 2008 Touring Models. Service Manual - page 27