2008 FLT Police Models Service Manual Supplement

Transcription

2008 FLT Police Models
Service Manual Supplement
©2007 H-D.
ALL RIGHTS RESERVED
99483-08SP
Printed in the U.S.A.
VISIT THE HARLEY-DAVIDSON WEB SITE
http://www.harley-davidson.com
ABOUT THIS MANUAL
GENERAL
PREPARATION FOR SERVICE
This Service Manual Supplement has been designed to be
used with the current Service Manual and has been prepared
with two purposes in mind. First, it will acquaint the user with
the construction of the Harley-Davidson product and assist in
the performance of basic maintenance and repair. Secondly,
it will introduce to the professional Harley-Davidson Technician
the latest field-tested and factory-approved major repair
methods. We sincerely believe that this Service Manual Supplement will make your association with Harley-Davidson
products more pleasant and profitable.
Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)
This Service Manual Supplement provides information unique
to this model motorcycle. Any information not presented in this
supplement can be found in the appropriate Service Manual
or Electrical Diagnostic Manual.
HOW TO USE YOUR SERVICE MANUAL
SUPPLEMENT
Use the TABLE OF CONTENTS (which follows this FOREWORD) and the INDEX (at the back of this manual) to quickly
locate subjects. Sections and topics in this manual are
sequentially numbered for easy navigation.
NO.
CHAPTER
1
Maintenance
2
Chassis
3
Engine
4
Fuel System
5
Electric Starter
6
Drive
7
Transmission
8
Electrical
A
Appendix A Wiring
B
Appendix B Glossary
For example, a cross-reference shown as 2.1 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFICATIONS.
If the subject you seek is not in this supplement, refer to the
corresponding section in the appropriate Service Manual.
Check the title page located in the front of each section to find
the subject.
For quick and easy reference, all pages contain a section
number followed by a page number. For example, page 3-5
refers to page 5 in section 3.
In figure legends, the number following the name of a part
indicates the quantity necessary for one complete assembly.
NOTES
•
To avoid unnecessary disassembly, carefully read all relative service information before repair work is started.
•
In figure legends, the number which follows the name of
a part indicates the quantity necessary for one complete
assembly.
•
When servicing a vehicle equipped with the HarleyDavidson Smart Security System (H-DSSS), you must
first disarm the security system. Either keep the fob in
close proximity to the vehicle, or use Digital Technician to
disable the security system while the vehicle is being serviced and re-enable the system after service is completed.
SERVICE BULLETINS
In addition to the information presented in this Service Manual
Supplement and the appropriate Service Manual, HarleyDavidson Motor Company will periodically issue Service Bulletins to Harley-Davidson dealers. Service Bulletins cover
interim engineering changes and supplementary information.
Consult the Service Bulletins to keep your product knowledge
current and complete.
USE GENUINE REPLACEMENT PARTS
Do not use aftermarket parts and custom made front forks
which can adversely affect performance and handling.
Removing or altering factory installed parts can adversely
affect performance and could result in death or serious
injury. (00001a)
To ensure satisfactory and lasting repairs, carefully follow the
Service Manual instructions and use only genuine HarleyDavidson replacement parts. Behind the emblem bearing the
words GENUINE HARLEY-DAVIDSON stand more than 100
years of design, research, manufacturing, testing and inspecting
experience.This is your assurance that the parts you are using
will fit right, operate properly and last longer.
WARNINGS AND CAUTIONS
Statements in this service manual preceded by the following
words are of special significance.
I
FOREWORD
NOTE
Good preparation is very important for efficient service work.
A clean work area at the start of each job will allow you to
perform the repair as easily and quickly as possible, and will
reduce the incidence of misplaced tools and parts. A motorcycle
that is excessively dirty should be cleaned before work starts.
Cleaning will occasionally uncover sources of trouble. Tools,
instruments and any parts needed for the job should be
gathered before work is started. Interrupting a job to locate
tools or parts is a distraction and causes needless delay.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury. (00119a)
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury. (00139a)
CAUTION used without the safety alert symbol indicates
a potentially hazardous situation which, if not avoided,
may result in property damage. (00140a)
NOTE
Refers to important information, and is placed in italic type. It
is recommended that you take special notice of these items.
Proper service and repair is important for the safe, reliable
operation of all mechanical products. The service procedures
recommended and described in this service manual are
effective methods for performing service operations.
Always wear proper eye protection when using hammers,
arbor or hydraulic presses, gear pullers, spring compressors, slide hammers and similar tools. Flying parts
could result in death or serious injury. (00496b)
Some of these service operations require the use of tools
specially designed for the purpose. These special tools should
be used when and as recommended. It is important to note
that some warnings against the use of specific service methods,
which could damage the motorcycle or render it unsafe, are
stated in this service manual. However, please remember that
these warnings are not all-inclusive. Inadequate safety precautions could result in death or serious injury.
Since Harley-Davidson could not possibly know, evaluate or
advise the service trade of all possible ways in which service
might be performed, or of the possible hazardous consequences of each method, we have not undertaken any such
broad evaluation. Accordingly, anyone who uses a service
procedure or tool which is not recommended by HarleyDavidson must first thoroughly satisfy himself that neither his
nor the operator's safety will be jeopardized as a result. Failure
to do so could result in death or serious injury.
PRODUCT REFERENCES
Read and follow warnings and directions on all products.
Failure to follow warnings and directions can result in
death or serious injury. (00470b)
II FOREWORD
When reference is made in this manual to a specific brand
name product, tool or instrument, an equivalent product, tool
or instrument may be substituted.
Kent-Moore Products
All tools mentioned in this manual with an "HD", "J" or "B"
preface must be ordered through SPX Kent-Moore. For ordering
information or product returns, warranty or otherwise, visit
www.spx.com.
Loctite Sealing and Threadlocking Products
Some procedures in this manual call for the use of Loctite
products. If you have any questions regarding Loctite product
usage or retailer/wholesaler locations, please contact Loctite
Corp. at www.loctite.com.
PRODUCT REGISTERED MARKS
Allen, Amp Multilock, Bluetooth, Brembo, Delphi, Deutsch,
Dunlop, Dynojet, Fluke, G.E. Versilube, Gunk, Hydroseal,
Hylomar, Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Magnaflux, Marson Thread-Setter Tool Kit, MAXI fuse, Molex, MPZ,
Mulitilock, Novus, Packard, Pirelli, Permatex, Philips, PJ1,
Pozidriv, Robinair, S100, Sems, Snap-on, Teflon, Threadlocker,
Torca, Torco, TORX, Tufoil, Tyco, Ultratorch, Velcro, X-Acto,
and XM Satellite Radio are among the trademarks of their
respective owners.
H-D MICHIGAN, INC. TRADEMARK
INFORMATION
Harley, Harley-Davidson, H-D, Bar & Shield, Digital Tech,
Digital Technician, Destroyer, Deuce, Dyna, Electra Glide,
Evolution, Fat Boy, Glaze, Gloss, H-D, H-Dnet.com, HD, Harley,
Heritage Softail, Heritage Springer, Low Rider, Night Rod, Night
Train, Profile, Revolution, Road Glide, Road King, Rocker,
Softail, Sportster, Sun Ray, Sunwash, Tech Link, Twin Cam
88, Twin Cam 88B, Twin Cam 96, Twin Cam 96B, Twin Cam
103, Twin Cam 103B, Twin Cam 110, Twin Cam 110B, TourPak, Screamin' Eagle, Softail, Super Guide, Super Premium,
SYN3, Ultra Glide, V-Rod, VRSC, Wide Glide, and HarleyDavidson Genuine Motor Parts and Genuine Motor Accessories
are among the trademarks of H-D Michigan, Inc.
CONTENTS
All photographs, illustrations and procedures may not necessarily depict the most current model or component, but are
based on the latest production information available at the time
of publication.
Since product improvement is our continual goal, HarleyDavidson reserves the right to change specifications, equipment
or designs at any time without notice and without incurring
obligation.
1.1 SCHEDULED MAINTENANCE
General...............................................................................1-1
CHASSIS
2.1 SPECIFICATIONS: CHASSIS
General...............................................................................2-1
2.2 VEHICLE IDENTIFICATION NUMBER
(V.I.N.)
General...............................................................................2-2
2.3 TIRES
General...............................................................................2-3
2.4 SEAT
General...............................................................................2-4
Seat Removal.....................................................................2-6
Seat Installation..................................................................2-6
Air Spring Replacement.....................................................2-6
Removal......................................................................2-6
Installation...................................................................2-6
Seat Bracket Mount Replacement......................................2-7
Removal......................................................................2-7
Installation...................................................................2-7
2.5 AIR SEAT RESERVOIR
Removal.............................................................................2-8
Installation..........................................................................2-9
2.6 SADDLEBAGS
Lockset.............................................................................2-11
Removal....................................................................2-11
Installation.................................................................2-11
Lockset Catch...................................................................2-11
Removal....................................................................2-11
Installation.................................................................2-11
Hinges..............................................................................2-11
Removal....................................................................2-11
Installation.................................................................2-12
Tether................................................................................2-12
Removal....................................................................2-12
Installation.................................................................2-12
Tether Brackets.................................................................2-12
Removal....................................................................2-12
Installation.................................................................2-12
Knob and Spring Latch.....................................................2-12
Removal....................................................................2-12
Installation.................................................................2-13
Spring Latch Bracket........................................................2-13
Removal....................................................................2-13
Installation.................................................................2-13
Manufacturing Tolerances...................................................3-1
3.2 SERVICE WEAR LIMITS
General...............................................................................3-2
3.3 OIL COOLER
Operation............................................................................3-3
Removal.............................................................................3-3
Cleaning and Inspection.....................................................3-4
Installation..........................................................................3-4
Oil Cooler Adapter and Thermostat Replacement..............3-4
Removal......................................................................3-4
Installation...................................................................3-4
FUEL SYSTEM
4.1 FUEL SYSTEM
No Unique Content.............................................................4-1
ELECTRIC STARTER
5.1 ELECTRIC STARTER
DRIVE
6.1 DRIVE
TRANSMISSION
7.1 TRANSMISSION
ELECTRICAL
8.1 BULB CHART
General...............................................................................8-1
8.2 SYSTEM FUSES AND RELAYS
System Fuses.....................................................................8-3
Removal......................................................................8-3
Installation...................................................................8-4
8.3 REAR MARKER LIGHTS
Marker Lights Replacement................................................8-5
Removal.............................................................................8-5
Installation..........................................................................8-5
8.4 HANDLEBAR SWITCHES
ENGINE
Horn and Siren Yelp Switch................................................8-6
Removal......................................................................8-6
Installation...................................................................8-6
Clutch Interlock Switch.......................................................8-7
Removal......................................................................8-7
Installation...................................................................8-7
Pursuit and Auxiliary Switch...............................................8-8
Removal......................................................................8-8
Installation...................................................................8-8
3.1 SPECIFICATIONS: ENGINE
8.5 AUTOMATIC COMPRESSION RELEASE
General...............................................................................3-1
General.............................................................................8-10
Removal...........................................................................8-10
2.7 TACHOMETER BRACKET: FLHP/E
Removal...........................................................................2-14
Installation........................................................................2-15
III
TABLE OF CONTENTS
MAINTENANCE
TABLE OF CONTENTS
Installation........................................................................8-10
Compression Test.............................................................8-11
Diagnostics.......................................................................8-12
Diagnostic Tips..........................................................8-12
Diagnostic Notes.......................................................8-12
Wiring Diagrams.................................................................A-8
APPENDIX A WIRING
Acronyms and Abbreviations..............................................B-1
A.1 CONNECTORS
Connectors.........................................................................A-1
A.2 INDEX TO WIRING DIAGRAMS
Wiring Diagram Information...............................................A-7
Wire Color Codes........................................................A-7
Wiring Diagram Symbols............................................A-7
IV TABLE OF CONTENTS
APPENDIX B GLOSSARY
B.1 GLOSSARY
REFERENCE MATERIAL
TOOLS...........................................................I
TORQUE VALUES.......................................III
INDEX...........................................................V
MAINTENANCE
SUBJECT............................................................................................................................PAGE NO.
1.1 SCHEDULED MAINTENANCE.................................................................................................1-1
NOTES
SCHEDULED MAINTENANCE
1.1
specifications. If more detailed information is needed, turn to
the Touring Models Service Manual for step-by-step instructions.
GENERAL
The table below lists the maintenance requirements for police
motorcycles. If you are familiar with the procedures, refer to
the table for the recommended service interval. If necessary,
refer to the quick reference table (Table 1-2) for the required
Various lubricants, sealants and greases are recommended
in certain service operations. Refer to Table 1-3 for the appropriate part numbers for these items.
Table 1-1. Regular Service Intervals: 2008 Touring Models
ITEM SERVICED
PROCEDURE
1000 MI.
1600 KM
5000 MI.
8000 KM
10,000 MI.
16,000 KM
15,000 MI.
24,000 KM
20,000 MI.
32,000 KM
25,000 MI.
40,000 KM
Engine oil and filter
Oil lines and brake system
Replace
X
X
X
X
X
X
Inspect for leaks
X
X
X
X
X
X
Air cleaner
Inspect, service as required
X
X
X
X
X
X
Tires
Check pressure, inspect
tread
X
X
X
X
X
X
Wheel spokes
Check tightness
X
X
X
1
1
Primary chaincase lubricant Replace
X
Transmission lubricant
Replace
X
Clutch
Check adjustment
X
X
X
X
X
X
1
X
X
X
X
X
X
1
Drive belt and compensator Inspect, adjust belt
sprocket
X
NOTES
X
X
Compensator sprocket isol- Inspect for wear
ators
5
Brake and clutch controls
Check, adjust and lubricate
X
X
X
X
X
X
1
Jiffy stand
Inspect and lubricate
X
X
X
X
X
X
1
Fuel lines and fittings
Inspect for leaks
X
X
X
X
X
X
1
Fuel tank filter
Replace
X
1
Brake fluid
Check levels and condition
X
X
X
X
X
X
4
Brake pads and discs
Inspect for wear
X
X
X
X
X
X
Spark plugs
Inspect
X
X
X
X
Replace
Electrical equipment and
switches
Check operation
Front fork oil
Replace
Steering head bearings
Lubricate
X
X
X
X
X
X
X
1, 2
X
X
X
Adjust
Air suspension
Check pressure, operation
and leakage
Windshield bushings (if
applicable)
Inspect
X
X
X
X
X
X
X
X
X
2
X
1
X
1
X
X
X
1
Fuel door, Tour-Pak, saddle- Lubricate hinges and latches
bags
X
X
Critical fasteners
Check tightness
X
Engine mounts and
stablizers
Inspect, check tightness
Battery
Check battery and clean
connections
Exhaust system
Inspect for leaks, cracks, and
loose or missing fasteners or
heat shields
X
X
X
X
X
X
Road test
Verify component and
system functions
X
X
X
X
X
X
NOTES:
1. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically
qualified.
2. Disassemble, lubricate and inspect every 50,000 miles (80,000 kilometers).
3. Perform annually.
4. Change D.O.T. 4 and flush brake system every two years.
5. Perform at each rear tire change.
X
X
1
X
X
1
3
3
2008 FLT Police Service: Maintenance 1-1
Table 1-2. Quick Reference Maintenance Chart: 2008 Police Models
ITEM SERVICED
SPECIFICATION
DATA
Engine oil and filter
Drain plug torque
14-21 ft-lbs (19.0-28.5 Nm)
Oil capacity
4 qt. (3.8 L)
Filter
Hand tighten 1/2-3/4 turn after gasket contact
Chrome filter part number
63798-99A
Black filter part number
63731-99A
Primary chain lubricant Lubricant type and capacity
Clutch adjustment
Transmission lubricant
FORMULA+ TRANSMISSION AND PRIMARY
CHAIN LUBRICATION (Part No. 99851-05)
Wet: 38 oz. (1124 ml)
Dry: 45 oz. (1331 ml)
Primary chaincase drain plug torque
14-21 ft-lbs (19.0-28.5 Nm)
Adjuster screw free play
1/2-1 turn
Adjuster screw locknut torque
72-120 in-lbs (8.1-13.6 Nm)
Free play at hand lever
1/16-1/8 in. (1.6-3.2 mm)
Clutch inspection cover torque
84-108 in-lbs (9.5-12.2 Nm)
Lubricant level
Dipstick at FULL with motorcycle on jiffy stand and
filler plug resting on threads.
Lubricant type and capacity
FORMULA+ TRANSMISSION AND PRIMARY
CHAIN LUBRICATION (Part No. 99851-05)
32 oz (0.95 liters)
Transmission drain plug torque
14-21 ft-lbs (19.0-28.5 Nm)
Transmission filler plug/dipstick torque
25-75 in-lbs (2.8-8.5 Nm)
Tire pressure and wear Pressure: solo rider
Front: 36 psi (248 kPA)
Rear: 36-40 psi (248-276 kPA)
Wear
Replace if less than 1/32 in. (0.8 mm) of tread
pattern
Wheel spokes
Spoke nipple torque
55 in-lbs (6.2 Nm) minimum
Brake fluid level
D.O.T. 4 hydraulic brake fluid part number
99953-99A (12 oz.)
Fluid level (from top of master cylinder reservoir)
Front: 0.20 in. (5.0 mm)
Rear: 0.26 in. (6.5 mm)
Master cylinder reservoir cover screw torque
Front: 7-10 in-lbs (0.8-1.1 Nm)
Rear: 12-15 in-lbs (1.4-1.7 Nm)
Minimum brake pad thickness
0.016 in. (0.4 mm)
Brake caliper pad pin torque
75-102 in-lbs (8.5.-11.5 Nm)
Minimum brake disc thickness
Front: 0.18 in. (4.5 mm)
Rear: 0.25 in. (6.3 mm)
Maximum brake disc lateral runout (warpage)
0.008 in. (0.2 mm)
Upward force applied at midpoint of bottom belt
strand
10 lb. (4.5 kg)
FLHTP
3/8-7/16 in. (9.5-11.1 mm)
FLHP/FLHPE
1/4-5/16 in. (6.4-7.9 mm)
Air cleaner cover bracket screw torque
40-60 in-lbs (4.5-6.8 Nm)
Air cleaner cover screw torque
36-60 in-lbs (4.1-6.8 Nm)
Air cleaner cover screw Threadlocker
LOCTITE MEDIUM STRENGTH THREADLOCKER
243 (BLUE)
Part No. 99642-97 (6 ml)
Lubricant part number
LUBIT-8 SUPER OIL, Part No. 94968-85TV (1/4
fl. oz.)
Handlebar switch housing screw torque
35-45 in-lbs (4.0-5.1 Nm)
Brake pads and discs
Drive belt deflection
Air cleaner
Clutch cable
1-2 2008 FLT Police Service: Maintenance
Table 1-2. Quick Reference Maintenance Chart: 2008 Police Models
ITEM SERVICED
SPECIFICATION
DATA
Spark plugs
Type
HD-6R12
Gap
0.038-0.043 in. (0.97-1.09 mm)
Torque
12-18 ft-lbs (16.3-24.4 Nm)
Amount
See FRONT FORK in the Touring Service Manual.
Type and part number
HYDRAULIC FORK OIL (TYPE E)
Part No. 99884-80 (16 oz.)
Terminal bolt torque
60-96 in-lbs (6.8-10.9 Nm)
Top caddy clamp screw torque
15-20 ft-lbs (20-27 Nm)
Front fork oil
Battery
Table 1-3. Lubricants, Greases, Sealants
ITEM
PART NUMBER
PACKAGE
Anti-Seize Lubricant
98960-97
1 oz squeeze tube
CCI #20 Brake Grease
42830-05 (included in master cylinder
rebuild kit)
squeeze packet
D.O.T. 4 Brake Fluid
99953-99A
12 oz. bottle
Electrical Contact Lubricant
99861-02
1 oz squeeze tube
Genuine Harley-Davidson Formula+
Transmission and Primary Chaincase
Lubricant
99851-05
1 qt bottle
G40M Brake Grease
42820-04
squeeze packet
Gray High Performance Sealant
99650-02
1.9 oz squeeze tube
HYLOMAR Gasket and Thread Sealant
99653-85
3.5 oz tube
Loctite Pipe Sealant With Teflon 565
99818-97
6 ml squeeze tube
Loctite Threadlocker 243 (blue)
99642-97
6 ml squeeze tube
Loctite Threadlocker 262 (red)
94759-99
6 ml squeeze tube
Loctite Threadlocker 272
98618-03
10 ml bottle
Special Purpose Grease
99857-97
14 oz. cartridge
Super Oil
94968-85TV
1/4 fl. oz
Type "E" Hydraulic Fork Oil
99884-80
16 oz bottle
Loctite Prism Primer (770)
Loctite Prism Superbonder (411)
Loctite Superbonder 420 Adhesive
2008 FLT Police Service: Maintenance 1-3
NOTES
1-4 2008 FLT Police Service: Maintenance
CHASSIS
SUBJECT............................................................................................................................PAGE NO.
2.1 SPECIFICATIONS: CHASSIS...................................................................................................2-1
2.2 VEHICLE IDENTIFICATION NUMBER (V.I.N.)..........................................................................2-2
2.3 TIRES........................................................................................................................................2-3
2.4 SEAT..........................................................................................................................................2-4
2.5 AIR SEAT RESERVOIR.............................................................................................................2-8
2.6 SADDLEBAGS........................................................................................................................2-11
2.7 TACHOMETER BRACKET: FLHP/E........................................................................................2-14
NOTES
SPECIFICATIONS: CHASSIS
2.1
GENERAL
Table 2-3. Weights: 2008 Police Models
ITEM
Table 2-1. Capacities: 2008 Police Models
ITEM
U.S.
LITERS
Fuel tank (total)
6.0 gal
22.7
Low fuel warning lamp on
1.0 gal
3.8
Oil tank with filter
4.0 U.S. qt.
3.8
Transmission
(approximate)
32.0 fl. oz.
0.95
Primary chaincase
(drained)
38.0 fl. oz.
1.12
Primary chaincase
(cover removed)
45.0 fl. oz.
1.33
FLHTP
LB.
KG.
LB.
KG.
Weight as shipped
from factory
764
347
739
335
GVWR
1200
544
1200
544
GAWR front
500
227
500
227
GAWR rear
827
375
827
375
NOTE
Gross vehicle weight rating (GVWR) (maximum allowable
loaded vehicle weight) and corresponding gross axle weight
rating (GAWR) are printed on a label fixed to the bottom of the
right front frame downtube.
Table 2-2. Dimensions: 2008 Police Models
ITEM
FLHTP
NOTE
FLHP
IN.
MM
IN.
MM
Wheel base
63.5
1612.9
63.5
1612.9
Overall length
93.7
2380
93.7
2380
Overall width
39.0
990.6
34.5
876.3
Road clearance
5.1
129.5
5.1
129.5
Overall height
61.0
1549.4
55.1
1399.5
Saddle height*
27.3
693.4
27.3
693.4
*With 180 lb. ( 81.7 kg) rider on seat.
FLHP
See 2.3 TIRES for important information regarding tire data
and tire inflation.
Table 2-4. Rear Air Suspension Pressures
SHOCK LOADING
RECOMMENDED
PRESSURES
PSI 0-35
kPa 0-241
0
0
Solo rider 150-200 lbs. (68-91 kg)
0-10
0-69
5-15
35-103
At maximum GVWR
20-35
138-241
Solo rider up to 150 lbs. (68 kg)
NOTE
Initial suspension fill pressure for a normally equipped police
motorcycle is 25 psi (172.4 kPa).
2008 FLT Police Service: Chassis 2-1
VEHICLE IDENTIFICATION NUMBER (V.I.N.)
2.2
Sample V.I.N. as it appears on the steering head 1HD1FHM137Y110000
GENERAL
See Figure 2-1. The full 17-digit serial number, or Vehicle
Identification Number (V.I.N.), is stamped on the right side of
the frame backbone at the rear of the steering head (and under
the main harness conduit). A label bearing the V.I.N. code is
also affixed to the left side of the steering head. An abbreviated
V.I.N. is stamped between the front and rear cylinders on the
left side of the crankcase.
Sample abbreviated V.I.N. as it appears on the crankcase FHM7110000
NOTE
Always give the complete V.I.N. when ordering parts or making
an inquiry about your motorcycle.
om01103
1
2
3
4
5
6
7
8
9
10
1HD 1 FM M 1 3 8 Y 111000
Figure 2-1. Typical Harley-Davidson V.I.N.: 2008 Police Models
Table 2-5. Harley-Davidson V.I.N. Breakdown: 2008 Police Models
POSITION
DESCRIPTION
POSSIBLE VALUES
1
Market designation
1=Originally manufactured for sale within the United States
5=Originally manufactured for sale outside of the United States
2
Manufacturer
HD=Harley-Davidson
3
Motorcycle type
1=Heavyweight motorcycle (901cc or larger)
4
Model
See V.I.N. model table
5
Engine type
M=Twin Cam 103™ 1690cc air-cooled, fuel injected
6
Introduction date
1=Regular
2=Mid-year
3=California/regular
4=Cosmetic changes and/or special introductory date
5=California/cosmetic changes and/or special introductory date
6=California/mid-year
7
V.I.N. check digit
Can be 0-9 or X
8
Model year
8=2008
9
Assembly plant
Y=York, PA U.S.A.
10
Sequential number
Varies
Table 2-6. V.I.N. Model Codes: 2008 Police Models
CODE
MODEL
FM
FLHTP
FH
FLHP
FT
FLHPE
2-2 2008 FLT Police Service: Chassis
TIRES
2.3
GENERAL
NOTE
The rear tire on FL police model motorcycles is fit for solo riding
only. If converted to a two-up bike, that is, configured for passenger use (with luggage), then the rear tire needs to be
changed to one with a higher weight rating. Since it has long
been Harley-Davidson policy not to mix different types of tires
on the same vehicle, we strongly recommend that both front
and rear tires be replaced. In order to alert the customer to this
safety issue, the following warning appears on a label fitted to
the rear fender approximately 1/4 inch (6.4 mm) behind the
domestic seat mounting hole.
Use the tires recommended for civilian/pleasure vehicles of
the same year and model family.
Harley-Davidson front and rear tires are not the same.
Interchanging front and rear tires can cause tire failure,
which could result in death or serious injury. (00026a)
Tire size, manufacturer's description and inflation pressure are
listed below.
NOTE
This vehicle has tires with weight ratings for one person
operation. If this vehicle is modified to carry two people,
the tires must be changed. See a Harley-Davidson dealer
for proper replacement tires. Using improper tires can
cause tire failure which could result in death or serious
injury. (00096a)
ABS motorcycles must always use tires and wheels that are
the same as the original equipment. The ABS monitors the
rotational speed of the wheels through individual wheel speed
sensors. Changing to different diameter wheels or different
size tires can alter the rotational speed. This can upset the
calibration of the ABS and have an adverse effect on its ability
to detect and prevent lockups. Tire inflation pressure that is
significantly low also can have an adverse effect.
Table 2-7. Tire Data
TIRE LOCATION
SIZE
MANUFACTURER'S DESIGNATION
TIRE PRESSURE
(COLD)
Front
MT90B 16 72H
Dunlop D402F PT
36 psi (248 kPa)
Rear
MT90B 16 72H
Dunlop D402 PT
36-40 psi (248-276 kPa)
All 2008 vehicles use only Dunlop Harley-Davidson tires.
SEAT
2.4
GENERAL
om00451
Maximum air pressure for the seat is 100 psi (689 kPa).
Normal air pressure is 30-45 psi (207-310 kPa). Do not
operate with air pressure so low that system bottoms out
on bumpy roads. (00167a)
3
1
NOTES
•
Initially pressurize the seat air suspension system to 40
psi (275.8 kPa), then add or remove pressure to the rider's
comfort. DO NOT operate motorcycle with system underinflated.
•
To check minimum air pressure, have rider sit on seat and
bounce to simulate riding conditions. Visually check for
any contact between air spring and frame components.
Add air as necessary.
•
See Figure 2-2. Removal and installation of retaining pin
(1) requires that the air pressure be removed from the seat
air suspension system. The seat will no longer pivot up
because the front of the seat will hit the fuel tank. Retaining
pin (1) should not be removed unless the seat is to be
removed.
•
The seat does not adjust forward or rearward.
2
1. Retaining pin
2. Rear seat bracket
3. Support post
Figure 2-2. Seat Latch: Police Models
sm04695
9
10
8
5
3
13
4
11
7
14
12
6
2
1
15
16
17
23
18
22
19
21
20
1.
2.
3.
4.
5.
6.
7.
8.
Cap
Air fitting
Fastener (2)
Air reservoir
Fastener (2)
Flat Washer
Flange nut (2)
Rubber bumper (2)
9.
10.
11.
12.
13.
14.
15.
16.
Seat
Seat bracket
Flange nut (2)
Fastener (2)
Acorn Nut
Seat bracket mount
Hex scrwe
Pivot bolt
17.
18.
19.
20.
21.
22.
23.
Seat fairing
Retaining pin
Air spring
Nut (2)
Set screw
Top plate
Fastener
Figure 2-3. Air Seat Assembly
SEAT REMOVAL
1.
Remove air pressure from air spring and reservoir.
2.
See Figure 2-2. Standing on left side of motorcycle, press
down on rear of seat and pull pin (1) from post (3) on top
plate.
Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)
3.
See Figure 2-3. Remove front pivot bolt (16) and nut (13).
2.
Disconnect battery, negative (-) cable first.
4.
Lift seat and bracket assembly from motorcycle.
3.
Remove battery from battery box.
5.
Remove two flange nuts (11) and hex screw (15) to release
seat from seat bracket (10).
4.
Remove air pressure from air spring and reservoir.
5.
6.
Inspect two rubber bumpers (8) on seat bracket for cuts,
tears or general deterioration. If damaged, deteriorated or
missing, replace as follows:
Depress collar on compression fitting and remove air tube
from air reservoir.
6.
See Figure 2-3. Holding air spring to prevent twisting,
remove two fasteners (23) to release top plate (22) from
air spring (19).
7.
Remove two flange nuts (20) under frame weldment (at
rear of battery box). Remove air spring from motorcycle.
7.
a.
Remove old rubber bumper and discard.
b.
Moisten bead on new rubber bumper with soapy
water. Place rubber bumper into position at bottom
of seat bracket. Feed tail on bead up through hole in
seat bracket. Using a needle nose pliers, grasp tail
as close to bead as possible, and then pull bead up
through hole in seat bracket.
sm04699
If necessary, remove two flange nuts (7) and washers (6)
and remove seat fairing (17) under seat.
SEAT INSTALLATION
1.
See Figure 2-3. If removed, install seat fairing (17) under
seat. Tighten flange nuts (7) to 60-120 in-lbs (6.8-13.6
Nm).
2.
Install seat onto seat bracket and start two flange nuts
(11). Align threaded hole in seat with hole in front of seat
bracket and start hex screw (15).
Figure 2-4. Air Spring Assembly
3.
Tighten flange nuts to 96-144 in-lbs (10.9-16.3 Nm).
Installation
4.
Tighten hex screw to 60-120 in-lbs (6.8-13.6 Nm).
1.
5.
Place seat and bracket assembly on motorcycle and install
front pivot bolt (16). Tighten nut (13) to 48-84 in-lbs (5.49.5 Nm).
Feed air tube through large center hole in frame weldment
(at rear of battery box) and then route rearward following
inboard side of right upper frame tube to air reservoir.
2.
See Figure 2-2. Align post (3) on top plate with hole in rear
seat bracket. While pressing down on rear of seat, insert
pin (1) into post on top plate.
Depress collar on compression fitting of air seat reservoir,
and insert air tube until it bottoms. Gently tug on tube to
verify that it is locked in place.
3.
Connect air tube to compression fitting at bottom of air
spring, if removed.
4.
See Figure 2-3. Place air spring on frame weldment while
engaging the two set screws.
5.
Install two flange nuts (20) onto set screws (21). Tighten
flange nuts to 50-70 in-lbs (5.7-7.9 Nm).
6.
Position top plate (22) onto air spring and start two
fasteners (23). Holding air spring to prevent twisting,
tighten screws to 36-60 in-lbs (4.1-6.8 Nm).
7.
Place battery into battery box, terminal side forward.
6.
7.
Fill air reservoir to 40 psi (275.8 kPa), then add or remove
pressure to the rider's comfort. Install protective cap on
air fitting.
AIR SPRING REPLACEMENT
Removal
1.
Remove seat and seat fairing. See 2.4 SEAT, Seat
Removal.
Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)
8.
Connect battery cables, positive (+) cable first. Tighten to
60-96 in-lbs (6.8-10.9 Nm).
9.
Apply a light coat of petroleum jelly or ELECTRICAL
CONTACT LUBRICANT, Part No. 99861-02 (1 oz. tube),
to both battery terminals.
10. Install hold-down clamp so that the lip (with rubber pad)
rests on the edge of the battery. Tighten T40 TORX screw
to 15-20 ft-lbs (20-27 Nm).
11. Install seat fairing. Tighten fasteners to 60-120 in-lbs (6.813.6 Nm).
12. Install seat and insert pin into post on top plate or air
spring. See 2.4 SEAT, Seat Installation.
13. Fill air reservoir to 40 psi (275.8 kPa), then add or remove
air valve.
SEAT BRACKET MOUNT REPLACEMENT
Removal
1.
Remove seat. See 2.4 SEAT, Seat Removal.
2.
See Figure 2-3. Remove two fasteners (12) to release
seat bracket mount from frame backbone.
Installation
1.
Install seat bracket mount using two fasteners (12).Tighten
fasteners to 15-20 ft-lbs (20.3-27.1 Nm).
2.
Install seat and insert pin into post on top plate of air
spring. See 2.4 SEAT, Seat Installation.
AIR SEAT RESERVOIR
2.5
REMOVAL
om00282
1.
Remove both saddlebags.
2.
On the right side of the motorcycle, locate the air seat
reservoir air valve under the luggage rack, and on the left
side, the rear shock air valve just below the chrome frame
cover. See Figure 2-5 and Figure 2-6.
Use caution when bleeding air from the suspension.
Moisture combined with lubricant may leak onto the rear
wheel, tire and/or brake components and adversely affect
traction, which could result in death or serious injury.
(00084a)
om00465
1
2
Figure 2-6. Rear Air Suspension Air Valve
3
sm04700
1. Air reservoir
2. Air pressure gauge
3. Seat air valve
Figure 2-5. Seat Air Valve: Police Models
Figure 2-7. Raise Luggage Rack
3.
Remove protective cap from each air valve and depress
pin to bleed air from both reservoir and shocks. To purge
rear air suspension lines of any oil, add 3-5 psi (20.7-34.5
kPa) before releasing air. Depress collar on each compression fitting and pull out air tube.
4.
Remove bolt (with flat washer) to remove saddlebag front
mounting bracket from chrome frame tube cover. Remove
Phillips screw and chrome frame tube cover. Repeat step
on opposite side of motorcycle.
5.
At inboard side of rear marker lights bracket, carefully pull
left and right rear marker lights connectors.
6.
Remove two hex bolts to free license plate bracket from
bottom support tube.
7.
Remove T40 TORX screws (with spacers) on each side
of motorcycle to release ends of luggage rack from frame
tube weldments.
8.
9.
Raise luggage rack high enough to access air reservoir.
See Figure 2-7.
Remove two Phillips screws (with external tooth lockwashers) from mounting plate (pole lamp) at top of luggage
rack to release air reservoir bracket.
10. Remove two Phillips screws from license plate bracket to
free rear of air reservoir bracket. Be sure to hold reservoir
as the last screw is removed or damage to fender paint
can occur if assembly is dropped. See Figure 2-8.
11. Remove fittings and/or air pressure gauge from reservoir,
if necessary.
bracket. Alternately tighten screws to 20-30 in-lbs (2.33.4 Nm).
5.
Place luggage rack into position inboard of frame tubes.
6.
Install T40 TORX screws (with spacers) on each side of
motorcycle to secure ends of luggage rack to frame tube
weldments. Alternately tighten screws to 15-20 ft-lbs (20.327.1 Nm).
7.
Install two hex bolts to fasten license plate bracket to
bottom support tube. Alternately tighten screws to 15-20
ft-lbs (20.3-27.1 Nm).
8.
At inboard side of rear marker lights bracket, connect left
and right rear marker lights connectors.
9.
Install chrome frame tube cover on frame tube. Install
Phillips screw and tighten to 25-40 in-lbs (2.8-4.5 Nm).
Repeat step on opposite side of motorcycle.
10. Install bolt (with flat washer) to install saddlebag front
mounting bracket, but do not tighten. Repeat step on
opposite side of motorcycle.
11. Depress collar on compression fitting of air seat reservoir,
and insert air tube until it bottoms. Gently tug on tube to
verify that it is locked in place.
sm04701
12. Fill air reservoir to 40 psi (275.8 kPa), then add or remove
air valve. See Figure 2-5.
NOTE
To set minimum air pressure, have rider sit on seat and bounce
to simulate riding conditions. Visually check for any contact
between air spring and frame components. Add air as necessary.
Figure 2-8. Air Seat Reservoir Assembly
INSTALLATION
PART NUMBER
HD-34633
1.
TOOL NAME
AIR SUSPENSION PUMP AND
GAUGE
Reassemble fittings and/or air pressure gauge onto air
reservoir, if removed. Orient parts as shown in Figure 2-8.
Apply PIPE SEALANT WITH TEFLON to threads before
assembly.
2.
Position air reservoir beneath luggage rack exercising
caution to avoid scratching fender paint.
3.
Slide two Phillips screws through holes in license plate
bracket engaging weld nuts at rear of air reservoir bracket.
Alternately tighten screws to 20-30 in-lbs (2.3-3.4 Nm).
4.
Slide two Phillips screws (with external tooth lockwashers)
through holes in mounting plate (pole lamp) at top of luggage rack engaging weld nuts at top of air reservoir
13. Observe air pressure gauge. If leakage occurs, then
remove tube and inspect end for burrs or damage. If either
condition is found, snip off end of tube and insert back into
fitting.
14. Depress collar on compression fitting of each shock and
insert air tube until it bottoms. Gently tug on tube to verify
that it is locked in place.
Do not exceed maximum air pressure for rear suspension.
Air components fill rapidly. Therefore, use low air line
pressure. Failure to do so may result in possible damage
to components. (00165a)
NOTE
Initial suspension fill pressure for a normally equipped police
motorcycle is 25 psi (172.4 kPa).
15. Fill shocks to 25 psi (172.4 kPa), then add or remove
pressure to the rider's comfort. Refer to Table 2-8.
NOTE
Table 2-8. Rear Air Suspension Pressures
SHOCK LOADING
RECOMMENDED
PRESSURES
PSI 0-35
kPa 0-241
0
0
0-10
0-69
5-15
35-103
Maximum GVWR (see 2.1 SPECIFICATIONS: CHASSIS)
20-35
138-241
Solo rider up to 150 lbs. (68 kg)
Do not exceed the motorcycle's Gross Vehicle Weight
Rating (GVWR) or Gross Axle Weight Rating (GAWR).
Exceeding these weight ratings can affect stability and
handling, which could result in death or serious injury.
(00016e)
An AIR SUSPENSION PUMP AND GAUGE (Part No. HD34633) is available at your Harley-Davidson dealer.
16. Observe air pressure gauge while filling. If leakage occurs,
remove tubes and inspect ends for burrs or damage. If
either condition is found, snip off end of tube and insert
back into fitting.
17. When air pressure remains constant, install protective cap
on air valve.
18. Install saddlebags. Tighten saddlebag front mounting
bracket bolts to 60-96 in-lbs (6.8-10.8 Nm).
SADDLEBAGS
2.6
LOCKSET
sm04804
Removal
1.
At inside of saddlebag lid, remove hex nut, internal tooth
lockwasher, cam hook and cam washer. Remove jam nut
and lock guide. See Figure 2-9.
2.
At outside of saddlebag lid, remove lockset. See
Figure 2-10.
1
2
5
3
Installation
1.
With cam stop facing outboard side of saddlebag lid, install
lockset into hole. See Figure 2-10.
2.
Install lock guide over threaded body of lockset oriented
with finger on inboard side of saddlebag lid and pointing
toward bottom. See Figure 2-9.
3.
Install jam nut and tighten to 30-45 in-lbs (3.4-5.1 Nm).
4.
Verify that groove in threaded stud of lockset is facing
inboard side of saddlebag lid. Use key to rotate threaded
stud, if necessary.
5.
6.
Align cam hook and cam washer as shown in Figure 2-10.
With the cam hook toward the outboard side of saddlebag
lid and cam washer on the inboard side, slide assembly
down threaded stud.
Install internal tooth lockwasher and hex nut onto threaded
stud. Tighten hex nut to 25-35 in-lbs (2.8-4.0 Nm).
4
1.
2.
3.
4.
5.
6.
Lockset
Thin washer
Cam stop
Threaded stud
Cam washer
Cam hook
Figure 2-10. Lockset Mechanism
LOCKSET CATCH
Removal
1.
Drill out two rivets using a 5/32 inch drill bit.
2.
Remove backplate, lockset catch and flat washers.
Installation
sm03550
1
4
1.
Slide two new rivets through holes in backplate,
saddlebag, lockset catch and flat washers.
2.
Compress rivets using a suitable rivet tool.
HINGES
PART NUMBER
2
5
3
7
6
1.
2.
3.
4.
5.
6.
7.
Lock guide
Jam nut
Lockset
Cam washer
Cam hook
Lockwasher
Hex nut
HD-39787A
TOOL NAME
RIVET TOOL
Removal
1.
Remove tether. See 2.6 SADDLEBAGS, Tether.
2.
Drill off peened end of hinge pin rivet using a 3/8 inch drill
bit. Use a punch to tap rivet shaft out of hinge.
3.
Drill out eight rivets using a 3/16 inch drill bit.
4.
Remove hinge and backplates.
Figure 2-9. Lockset Assembly
3.
sm03552
Repeat previous steps to remove opposite end of tether
from second tether bracket.
Installation
1
2
1.
With the concave side toward the tether bracket, install
wave spring onto threaded boss.
2.
Install tether eyelet onto threaded boss.
3.
Apply a small dab of LOCTITE HIGH STRENGTH
THREADLOCKER 262 (red) to threads of T15 TORX
screw.
4.
Install screw into threaded boss and tighten to 20-25 inlbs (2.3-2.8 Nm). See Figure 2-12.
5.
Repeat this procedure to fasten opposite end of tether to
second tether bracket.
sm04702
1. Adjuster thumbscrew
2. Drive head
4
3
Figure 2-11. Rivet Tool (HD-39787A)
Installation
5
1.
Slide new rivet through holes in hinge, saddlebag and
backplate.
2.
Obtain RIVET TOOL (Part No. HD-39787A). See
Figure 2-11.
3.
4.
2
Orient tool so that head of rivet is seated in depression of
drive head. Turn adjuster thumbscrew in or out of handle
until both ends of rivet are captured.
1.
2.
3.
4.
5.
Slowly squeeze handle of tool to compress rivet. Turn
adjuster thumbscrew slightly in a clockwise direction and
then squeeze handle again to further compress rivet.
Repeat step as necessary until rivet is fully installed.
NOTE
Compress rivet in small increments only. This method provides
for best retention and alignment of parts and avoids possible
damage to tool and painted surfaces of saddlebag.
1
Tether bracket
Rivet (4)
T15 TORX screw
Tether eyelet
Wave spring
Figure 2-12. Tether and Tether Bracket
TETHER BRACKETS
Removal
5.
Repeat previous steps to install remaining rivets.
1.
Remove tether. See 2.6 SADDLEBAGS, Tether
6.
Install lid onto saddlebag engaging upper and lower
hinges.
2.
Drill out four rivets using a 3/16 inch drill bit.
7.
Compress new hinge pin rivet using a suitable rivet tool.
3.
Remove tether bracket and backplate.
8.
Install tether. See 2.6 SADDLEBAGS, Tether.
Installation
1.
Slide new rivets through holes in backplate,
saddlebag/saddlebag lid and tether bracket (with the
threaded boss on the outboard side).
NOTE
2.
Install rivets. See 2.6 SADDLEBAGS, Hinges.
When the tether is removed, use caution to keep lid from
opening beyond its normal travel or damage to painted surfaces
or hinges can occur.
3.
Install tether. See 2.6 SADDLEBAGS, Tether.
1.
Remove T15 TORX screw from threaded boss on tether
bracket. See Figure 2-12.
Removal
2.
Remove tether eyelet and wave spring from threaded
boss.
TETHER
Removal
KNOB AND SPRING LATCH
1.
Place multiple strips of masking tape on each side of knob
to protect finished surfaces from scratches and other
damage. Using a large flat blade screwdriver, alternately
pry up each side of knob until free of post. See upper
frame of Figure 2-13.
2.
Remove knob seal and masking tape. Remove any
residual adhesive with 3M general Purpose adhesive
remover (Part No. 051135). See lower frame of
Figure 2-13.
3.
Drill out two rivets using a 13/64 inch drill bit. Remove
spring latch. See Figure 2-14.
sm04704
Installation
1.
Hold spring latch at bottom of saddlebag lid with the flat
side facing opposite the hinges. See Figure 2-14.
2.
Slide two new rivets through holes in saddlebag lid and
spring latch.
3.
Compress rivets using a suitable rivet tool.
4.
Peel paper backing off adhesive side of knob seal. Place
knob seal over post, so that the adhesive side contacts
the saddlebag lid. Press knob seal firmly into place.
5.
Install knob onto post and alternately work each side down
until it bottoms.
sm04703
Figure 2-14. Spring Latch
SPRING LATCH BRACKET
Removal
1.
From outside saddlebag, loosen two Phillips screws.
2.
Inside saddlebag, remove two Keps nuts and spring latch
bracket. Remove Phillips screws. See Figure 2-15.
Installation
1.
From outside saddlebag, slide two Phillips screws through
holes in saddlebag.
2.
Inside saddlebag, install spring latch bracket and two Keps
nuts. See Figure 2-15.
3.
Alternately tighten Phillips screws until snug.
sm04705
1
2
3
1. Spring latch bracket
2. Keps nut (2)
3. Phillips screw (2)
Figure 2-15. Spring Latch Bracket
Figure 2-13. Saddlebag Knob and Seal
TACHOMETER BRACKET: FLHP/E
2.7
REMOVAL
sm04707
NOTE
The two rear holes in the handlebar clamp shroud allow the
rider to adjust the handlebars without having to remove the
shroud. To keep out moisture and debris, be sure to install
plastic plugs back into holes after handlebar adjustment. See
Figure 2-18.
1.
Remove windshield. See WINDSHIELD: FLHR/C in the
Touring Models Service Manual.
2.
Remove Phillips screw at bottom of headlamp door
(chrome ring). Remove headlamp door.
3.
Remove seven Phillips screws to free headlamp housing
from headlamp nacelle.
4.
Remove headlamp connector at back of headlamp bulb.
Remove headlamp housing assembly from motorcycle.
5.
From inside the headlamp nacelle:
a.
Disconnect tachometer harness connector [20], 6place Deutsch. See Figure 2-16.
b.
Remove flange nut from weld stud to release chrome
strip at top of nacelle.
c.
Catch Keps nut and flat washer while removing Phillips screw from tab at front of handlebar clamp shroud.
6.
Carefully pry off the fork lock plate at the rear of the
handlebar clamp shroud. Remove two Phillips screws
beneath the lock plate.
7.
Remove the handlebar clamp shroud from the motorcycle,
while gently pulling the tachometer harness conduit and
connector out of the headlamp nacelle.
8.
Remove two acorn nuts (with flat washers) to release
tachometer bracket from studs at top of handlebar clamp
shroud.
NOTE
Do not operate ABS equipped motorcycles with the tachometer
removed. While the ABS remains operational, the rider will
receive no warning if a malfunction occurs.The means to report
DTC's also will be eliminated.
Figure 2-16. Disconnect Tachometer Connector
sm04708
7
sm04709
8
1
9
4
6
2
10
3
11
5
1.
2.
3.
4.
4
Tachometer bracket
Handlebar clamp shroud
Fork lock plate
Handlebar adjustment access hole plug
Figure 2-18. Install Handlebar Clamp Shroud
3
INSTALLATION
1.
2
1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Headlamp nacelle
Keps nut
Flat washer
Flange nut
Chrome strip
Phillips screw (2)
Tachometer bracket
Acorn nut (2)
Fork lock plate
Handlebar clamp shroud
Stud plate
Place tachometer bracket over studs at top of handlebar
clamp shroud. Install two acorn nuts (with flat washers)
onto studs and alternately tighten to 72-108 in-lbs (8.112.2 Nm). See Figure 2-18.
NOTE
A peel and stick foam tape on the stud plate holds it in place
on the inboard side of the handlebar clamp shroud.
2.
Feed tachometer harness connector and conduit through
opening at top of headlamp nacelle. Install handlebar
clamp shroud over mating flange while routing tachometer
harness conduit through opening for left side handlebar.
3.
From inside the headlamp nacelle:
a.
Start flat washer and Keps nut onto Phillips screw
installed in tab at front of handlebar clamp shroud.
Tighten Phillips screw to 10-20 in-lbs (1.1-2.3 Nm).
See Figure 2-17.
b.
Install flange nut onto weld stud of chrome strip
installed into hole at the top of headlamp nacelle.
Tighten flange nut to 15-20 in-lbs (1.7-2.3 Nm).
c.
Connect tachometer harness connector [20], 6-place
Deutsch. See Figure 2-16.
Figure 2-17. Headlamp Nacelle Assembly
4.
Install two Phillips screws to fasten handlebar clamp
shroud to the fork lock mechanism. Install fork lock plate.
5.
Install headlamp connector at back of headlamp bulb.
6.
Align holes in headlamp housing with those in headlamp
nacelle (headlamp door bracket at bottom). Install seven
Phillips screws and alternately tighten to 9-18 in-lbs (1.02.0 Nm).
7.
Fit the square-shaped portion of the headlamp door spring
into slot at top of headlamp housing and then snap the
headlamp door (chrome ring) into place. Install Phillips
screw at bottom of headlamp door and tighten to 9-18 inlbs (1.0-2.0 Nm).
8.
Install windshield. See WINDSHIELD: FLHR/C in the
Touring Models Service Manual.
ENGINE
SUBJECT............................................................................................................................PAGE NO.
3.1 SPECIFICATIONS: ENGINE.....................................................................................................3-1
3.2 SERVICE WEAR LIMITS...........................................................................................................3-2
3.3 OIL COOLER.............................................................................................................................3-3
NOTES
SPECIFICATIONS: ENGINE
GENERAL
3.1
MANUFACTURING TOLERANCES
Table 3-1. Engine: 2008 Police Models
ITEM
Table 3-3. Valves
SPECIFICATION
Number of cylinders
Type
2
4-cycle, 45 degree
V-Type, air cooled
Compression ratio
9.6-1
Bore
3.875 in.
98 mm
Stroke
4.375 in.
111 mm
Displacement
Torque
103 cu. in.
1690 cc
102 ft-lbs @
2500 RPM
138 Nm @
2500 RPM
Table 3-2. Oiling System
ITEM
ITEM
IN.
MM
Fit in guide (exhaust)
0.0015-0.0033
0.038-0.084
Fit in guide (intake)
0.0008-0.0026
0.020-0.066
1.990-2.024
50.55-51.41
Stem protrusion from
cylinder head boss
Table 3-4. Valve Spring Assembly
ITEM
PRESSURE
DIMENSION
Closed
165 lbs (75 kg)
1.820 in. (46.2 mm)
Open
416 lbs (189 kg)
1.290 in. (32.7 mm)
n/a
2.210 in. (56.1 mm)
Free length
SPECIFICATION
Pump
Twin gerotor, dual scavenge, crank
mounted and driven, internal oil pump,
dry sump
Pressure
30-38 psi (207-262 kN/m2) at 2000 RPM
and normal operating temperature of
230° F (110° C)
Filtration
10 micron media, filtered between pump
and engine
Cooling
Thermostat controlled oil cooler
Table 3-5. Connecting Rods
ITEM
INCHES
MM
Piston pin fit (loose)
0.0003-0.0007
0.008-0.018
Table 3-6. Crankshaft/Sprocket Shaft Bearing
ITEM
Bearing inner race on
crankshaft (tight)
INCHES
MM
0.0001-0.0010
0.0025-0.0254
2008 FLT Police Service: Engine 3-1
SERVICE WEAR LIMITS
3.2
GENERAL
Table 3-8. Cylinder Bore
Wear limits can be used as a guide when deciding whether to
reuse engine parts. Replace used parts whenever the following
wear limits are exceeded.
Table 3-7. Cam Support Plate
ITEM
Cam chain tensioner
shoe
Warpage
Crankshaft bushing fit
REPLACE IF WEAR EXCEEDS
INCHES
MM
0.080-0.090
2.03-2.29
0.010
0.25
0.0008-0.001
0.0203-0.0254
ITEM
INCHES
MM
Standard
3.877
98.48
0.005 in. oversize
3.882
98.60
0.010 in. oversize
3.887
98.73
Table 3-9. Connecting Rods
ITEM
Piston pin fit (loose)
INCHES
MM
0.001
0.025
Table 3-10. Crankshaft/Sprocket Shaft Bearing
ITEM
Crankshaft runout
Bearing fit in crankcase
(tight)
Bearing inner race on
crankshaft (tight)
INCHES
MM
Greater than
0.003
Greater than
0.076
0.0038-0.0054
0.097-0.137
Less than 0.0001 Less than 0.0254
Table 3-11. Valve Stem to Guide Clearance
ITEM
3-2 2008 FLT Police Service: Engine
INCHES
MM
Intake
0.0035
0.089
Exhaust
0.0040
0.102
OIL COOLER
3.3
OPERATION
sm04712
Pressurized oil flows through a hole in the oil filter mount into
a passage in the oil cooler adapter. The oil cooler adapter is
mounted between the oil filter mount and the oil filter.
8
7
6
A thermostat inside the oil cooler adapter controls the flow of
oil to the oil cooler. The thermostat consists of a temperature
sensitive element compressed between a spring and threaded
plug. See Figure 3-1.
10
While the engine oil temperature is below 200° F (93° C), the
thermostat is open allowing most of the engine oil to pass from
the supply port directly to the return port en route to the oil
filter.
When the engine oil temperature reaches 200° F (93° C), the
thermostat closes and the entire flow is directed to the oil cooler
through the supply hose.
9
5
4
The fins on the tubes of the oil cooler dissipate heat before the
flow returns to the oil cooler adapter through the return hose.
The engine oil then passes through the oil filter before returning
to the crankcase.
3
NOTE
For a complete description of the engine oil flow, see GENERAL INFORMATION in the Touring Models Service Manual.
2
sm04710
1
1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
2
Flange nut (3)
Flat washer (3)
Mounting bracket
Oil cooler
Supply hose
Return hose
Hose clamp (4)
Oil cooler adapter
Oil filter adapter
Adhesive gasket
Figure 3-2. Oil Cooler Assembly
REMOVAL
3
1. Return fitting
2. Supply fitting
3. Thermostat
Figure 3-1. Oil Cooler Adapter
1.
Place a suitable drain pan beneath the oil cooler.
2.
See Figure 3-2. Remove three flange nuts with flat
washers. Raise oil cooler to free threaded studs from holes
in mounting bracket.
3.
Using a side cutters, cut and remove clamps on oil cooler
adapter side of supply and return hoses. Pull hoses from
fittings.
4.
Remove oil cooler from motorcycle.
5.
side of supply and return hoses. Pull hoses from fittings.
6.
Remove mounting bracket as follows:
a.
b.
Remove voltage regulator and front electrical caddy.
See VOLTAGE REGULATOR in the Touring Models
Service Manual.
Lift mounting bracket off studs on lower frame crossmember.
6.
Slide new clamp onto free end of supply hose (stamped
COOLER TOP). Install hose on lower fitting of oil cooler
adapter. Crimp clamp.
7.
Check engine oil level. See ENGINE OIL AND FILTER in
the Touring Models Service Manual.
CLEANING AND INSPECTION
OIL COOLER ADAPTER AND THERMOSTAT
REPLACEMENT
1.
Using a clean shop cloth or soft bristle brush, gently clean
oil cooler fins of dirt and debris.
PART NUMBER
2.
If engine failure and/or oil contamination requires inspection and cleaning of oil passageways, then remove oil
cooler adapter and proceed as follows:
HD-97087-65B
TOOL NAME
HOSE CLAMP PLIERS
Removal
NOTE
a.
See Figure 3-3. Remove two socket screws (3) to
release inspection cover (4) and gasket (2).
A faulty thermostat requires replacement of the oil cooler
adapter.
b.
Thoroughly flush oil passageways with solvent and
blow out with compressed air.
1.
Place a suitable drain pan beneath the oil cooler and oil
filter.
c.
Install inspection cover with new gasket.
2.
d.
Apply a small dab of Loctite Medium Strength
Threadlocker 243 (blue) to threads of socket screws.
Install screws and alternately tighten to 90-120 inlbs (10.2-13.6 Nm).
adapter side of supply and return hoses. Pull hoses from
fittings.
3.
Remove the engine oil filter. See ENGINE OIL AND
FILTER in the Touring Models Service Manual.
4.
Using internal hex, remove the oil filter adapter. Remove
the oil cooler adapter and gasket. See Figure 3-2.
INSTALLATION
PART NUMBER
HD-97087-65B
TOOL NAME
HOSE CLAMP PLIERS
Installation
NOTE
NOTE
If mounting bracket is already installed, proceed to next step.
1.
Skip first step if hose fittings are already installed.
1.
Install mounting bracket as follows:
a.
b.
With the "TOP" stamp facing upward, install mounting
bracket onto studs on lower frame crossmember.
Install front electrical caddy and voltage regulator.
See VOLTAGE REGULATOR in the Touring Models
Service Manual.
Install hose fittings as follows:
a.
Install hose fittings until finger tight.
b.
Using wrench on flats, rotate hose fittings an additional 2-3 turns.
2.
Position oil cooler adapter flange against oil filter mount.
Index tabs on flange engage a recess on each side of the
oil filter mount oil outlet hole. See Figure 3-3.
3.
Slide new clamp onto oil cooler side of supply hose, which
can be identified by the paint stamp reading COOLER
TOP. With the script facing upward, install hose onto top
fitting of oil cooler. Crimp clamp.
Apply Loctite High Temperature/Medium Strength
Threadlocker 246 to threads of oil filter adapter. With the
internal hex on the outboard side, thread oil filter adapter
into oil filter mount. Holding the oil cooler adapter to prevent rotation, tighten oil filter adapter to 18-22 ft-lbs (24.429.8 Nm).
4.
NOTE
If the paint stamps are not present, the long hose is the return
and the short hose is the supply. Install both hoses, so that the
90° bend goes to the oil cooler adapter.
Slide new clamp onto free end of return hose (stamped
COOLER BOTTOM). Install hose on upper fitting of oil
cooler adapter. Crimp clamp using HOSE CLAMP
PLIERS (Part No. HD-97087-65B).
5.
Slide new clamp onto free end of supply hose (stamped
COOLER TOP). Install hose on lower fitting of oil cooler
adapter. Crimp clamp.
6.
Install new oil filter and check engine oil level. See
ENGINE OIL AND FILTER in the Touring Models Service
Manual.
7.
Start engine and inspect oil cooler/adapter fittings and
hoses for leaks.
2.
3.
4.
5.
Slide new clamp onto oil cooler side of return hose, which
can be identified by the paint stamp reading COOLER
BOTTOM. With the script facing upward, install hose onto
bottom fitting of oil cooler. Crimp clamp using HOSE
CLAMP PLIERS (Part No. HD-97087-65B).
Slide threaded studs at bottom of oil cooler through holes
in mounting bracket. Install flat washers and flange nuts
on studs. Alternately tighten flange nuts to 70-100 inlbs (7.9-11.3 Nm).
Slide new clamp onto free end of return hose (stamped
COOLER BOTTOM). Install hose on upper fitting of oil
cooler adapter. Crimp clamp using HOSE CLAMP
PLIERS (Part No. HD-97087-65B).
sm04713
1
3
4
2
1.
2.
3.
4.
Index tabs
Adhesive gasket
Socket screw (2)
Inspection cover
Figure 3-3. Oil Cooler Adapter
NOTES
FUEL SYSTEM
SUBJECT............................................................................................................................PAGE NO.
4.1 FUEL SYSTEM..........................................................................................................................4-1
NOTES
FUEL SYSTEM
4.1
NO UNIQUE CONTENT
Any information not presented in this supplement can be found
in the Touring Models Service Manual.
2008 FLT Police Service: Fuel System 4-1
NOTES
4-2 2008 FLT Police Service: Fuel System
ELECTRIC STARTER
SUBJECT............................................................................................................................PAGE NO.
5.1 ELECTRIC STARTER................................................................................................................5-1
NOTES
ELECTRIC STARTER
5.1
NO UNIQUE CONTENT
2008 FLT Police Service: Electric Starter 5-1
NOTES
5-2 2008 FLT Police Service: Electric Starter
DRIVE
SUBJECT............................................................................................................................PAGE NO.
6.1 DRIVE........................................................................................................................................6-1
NOTES
DRIVE
6.1
NO UNIQUE CONTENT
2008 FLT Police Service: Drive 6-1
NOTES
6-2 2008 FLT Police Service: Drive
TRANSMISSION
SUBJECT............................................................................................................................PAGE NO.
7.1 TRANSMISSION.......................................................................................................................7-1
NOTES
TRANSMISSION
7.1
NO UNIQUE CONTENT
2008 FLT Police Service: Transmission 7-1
NOTES
7-2 2008 FLT Police Service: Transmission
ELECTRICAL
SUBJECT............................................................................................................................PAGE NO.
8.1 BULB CHART............................................................................................................................8-1
8.2 SYSTEM FUSES AND RELAYS...............................................................................................8-3
8.3 REAR MARKER LIGHTS..........................................................................................................8-5
8.4 HANDLEBAR SWITCHES.........................................................................................................8-6
8.5 AUTOMATIC COMPRESSION RELEASE...............................................................................8-10
NOTES
BULB CHART
8.1
GENERAL
The table below gives the bulb requirements for FLHTP and
FLHP/E police model motorcycles.
The rear strobe is a source of high voltage and must be
off at least 10 minutes before servicing. Inadequate safety
precautions may result in death or serious injury. (00097a)
Table 8-1. Bulb Chart FLHTP, FLHP/E
LAMP DESCRIPTION
(ALL LAMPS 12V)
NUMBER OF BULBS
(REQUIRED)
CURRENT DRAW
(AMPERAGE)
WATTAGE
HARLEY-DAVIDSON
PART NUMBER
1
4.58
55
68329-03
5.00
60
0.59
6
2.10
24
Head Lamp
Low Beam
HIgh Beam
Tail/Stop Lamp
Tail Lamp
1
Stop Lamp
68167-88
Turn Signal Lamp
Front / Running
2
2.25 / 0.59
27/7
68168-89
Rear
2
2.25
27
68572-64B
2
0.33
3.7
53439-79
1
2.5
30
68727-64A
Rear Fender Tip Lamp
Rear Fender Tip Bulb
Pursuit Lamp
Left (Red)
Right (Blue)
68728-64
Rear Strobe, if provided
N/A
20
67598-88
Instrument Panel Lamps-FLHTP Indicator Module (with LEDs)
High Beam Indicator**
N/A
0.05
N/A
68859-07
N/A
N/A
N/A
N/A
1
0.24
3.4
67445-00
N/A
N/A
N/A
N/A
1
0.08
1.1
68642-96
N/A
68113-99B
Oil Pressure Indicator**
Neutral Indicator**
Turn Signal Indicator**
Gauge Lamps-FLHTP
Speedometer**
Tachometer**
Voltmeter
Fuel Gauge
Engine**
Pursuit (fairing)
Instrument/Gauge Lamps-FLHP/E Indicator Module (with LEDs)
High Beam Indicator**
N/A
0.05
Oil Pressure Indicator**
Neutral Indicator**
Turn Signal Indicator**
2008 FLT Police Service: Electrical 8-1
Table 8-1. Bulb Chart FLHTP, FLHP/E
LAMP DESCRIPTION
(ALL LAMPS 12V)
Fuel Gauge**
NUMBER OF BULBS
(REQUIRED)
CURRENT DRAW
(AMPERAGE)
WATTAGE
HARLEY-DAVIDSON
PART NUMBER
N/A
N/A
N/A
N/A
Speedometer**
Odometer**
Engine**
Pursuit**
** LED illuminated. LEDs are not repairable. Assembly must be replaced if LED fails.
8-2 2008 FLT Police Service: Electrical
SYSTEM FUSES AND RELAYS
8.2
SYSTEM FUSES
Removal
1.
Verify that the Ignition/Light Key Switch is turned to the
OFF position.
2.
Remove left side saddlebag.
3.
See Figure 8-1. Remove wing nut style bolt to release
bottom of siren amplifier mounting bracket from clamp on
saddlebag guard. Rotate bracket upward to gain complete
access to side cover area. Loosen top bolt, if necessary.
4.
Gently pull side cover from frame downtubes (no tools
required). Exercise caution to avoid scratching side cover
on amplifier mounting bracket.
5.
Raise the fuse block cover.
Always use replacement fuses that are of the correct type
and amperage rating. Use of incorrect fuses can result in
damage to electrical systems. (00222a)
ed01646
NOTE
The fuse block cover has a fuse puller attachment that may be
used to remove fuses.
6.
Remove fuse from fuse block and inspect the element.
7.
See Figure 8-2 to identify fuse location. Replace fuse if
element is burned or broken. Automotive type ATO fuses
are used.
Figure 8-1. Siren Amplifier Mounting Bracket
ed01653
1
2
3
5
6
7
9
4
10
8
11
15
19
12
13
16
17
14
18
20
21
1.
2.
3.
4.
5.
Brakes/Pursuit (15A)
Accessory (15A)
P&A (15A)
Radio/Siren (15A)
Radio memory (if equipped)
(15A)
6. Battery (15A)
7. ECM power (15A)
8.
9.
10.
11.
Fuel pump (15A)
EFI system relay
Starter relay
P&A ignition (if equipped) (2A
max)
12. Instruments (15A)
13. Ignition (15A)
14. Engine control (15A)
15.
16.
17.
18.
19.
20.
21.
Brake light relay
Headlamp (15A)
Lighting (15A)
Spare (15A)
ABS (if equipped) (30A)
Spare (30A)
MAXIFUSE (40A)
Figure 8-2. Left Side Electrical Caddy
Installation
1.
2.
Install fuse in fuse block. For correct type and amperage
rating, refer to Figure 8-2.
3.
Align barbed studs in side cover with grommets in frame
downtubes and push firmly into place (no tools required).
4.
Rotate siren amplifier mounting bracket downward. Install
wing nut style bolt to secure bracket to clamp on saddlebag
guard. Tighten top bolt, if loosened.
5.
Install left side saddlebag.
Install cover on fuse block.
REAR MARKER LIGHTS
8.3
MARKER LIGHTS REPLACEMENT
4.
Remove rear marker lights assembly from motorcycle.
1.
On inboard side of rear marker lights bracket, gently pull
electrical connector from prongs on marker light.
INSTALLATION
2.
Rotate marker light in a counterclockwise direction and
remove from hole in rear marker lights bracket.
3.
Place new marker light into hole in rear marker lights
bracket and rotate in a clockwise direction to install.
4.
On inboard side of rear marker lights bracket, gently push
electrical connector onto prongs on marker light.
1.
Gently pull both electrical connectors from prongs to
detach rear marker lights harness.
2.
On inboard side of left upper frame tube, mate pin and
socket housings of rear marker lights harness connector
[12], 3-place Multilock.
3.
Route free end of rear marker lights conduit rearward following inboard side of bottom support tube. When conduit
reaches air reservoir, loop left side rear marker light conduit to outboard side, while routing right side rear marker
light conduit between top of bottom support tube and
bottom of air reservoir bracket to right side of motorcycle.
REMOVAL
1.
Disconnect rear marker lights harness connector [12], 3place Multilock, inboard of left upper frame tube.
2.
Carefully cut cable strap to release rear marker lights (and
pole lamp) conduit from left side of bottom support tube.
4.
Engage catches on each side of rear marker lights bracket
into oblong holes in license plate bracket.
3.
On inboard side of license plate bracket, note that catches
on rear marker lights bracket engage oblong holes in
license plate bracket. Using tip of flat blade screwdriver,
gently push top catch down and then bottom catch up to
release from oblong hole. Repeat step to release other
side of rear marker lights bracket.
5.
On inboard side of rear marker lights bracket, gently push
electrical connectors onto prongs on marker lights.
6.
Install new cable strap to secure rear marker lights (and
pole lamp) conduit to left side of bottom support tube. Cut
any excess cable strap material.
ed01647
1
4
2
3
1.
2.
3.
4.
5.
5
Rear marker light (2)
Rear marker lights bracket
Rear marker lights harness
License plate bracket
Bottom support tube
Figure 8-3. Rear Marker Lights Assembly
HANDLEBAR SWITCHES
8.4
HORN AND SIREN YELP SWITCH
ed01654
NOTE
Install new cable strap to secure rear marker lights (and pole
lamp) conduit to left side of bottom support tube. Cut any
excess cable strap material.
2
1
Removal
1.
Gain access to the inside of the switch housing. See
HANDLEBAR SWITCH ASSEMBLIES in the Touring
Models Service Manual.
2.
From inside the switch housing, carefully cut cable strap
to free conduit from the turn signal switch bracket.
3.
Remove the Phillips screw (with lockwasher) to release
the turn signal switch bracket. Remove the switch
assembly from the housing.
4.
Remove the two T8 TORX screws and the Phillips screw
(with lockwasher) to release the lower bracket. Carefully
lift out the bracket so as not to disturb the spring-loaded
ramp on the inboard side of the housing.
5.
Carefully remove the keycap disengaging slot from hook
on ramp.
6.
While holding down the ramp, pull both switches from the
housing.
7.
Cut the wires from the old switches as follows:
a.
Yellow/Black wire: 1-1/4 in. (32 mm)
b.
Orange/White wires: 1-7/8 in. (48 mm)
c.
Brown/Black wire: 1-1/2 in. (38 mm)
3
5
4
1.
2.
3.
4.
Engine start switch
Front stoplight switch
Engine stop switch: Off/Run
Pole and pursuit lamp switch: Off/Auxiliary/Pursuit
5. Turn-right signal switch
Figure 8-4. Right Handlebar Switch Housing
ed01655
1
2
3
NOTE
Replacement Horn/Siren Yelp Switch wires are cut to length
and partially stripped (Yellow/Black wire: 3-3/4 in. (95 mm);
Orange/White wires: 3-1/2 in. (89 mm); Brown/Black wire: 33/8 in. (86 mm).
8.
4
Connect wires of new switch. See HANDLEBAR SWITCH
ASSEMBLIES in the Touring Models Service Manual.
5
NOTE
1.
2.
3.
4.
5.
If the ramp and spring mechanism becomes loose, install as
follows:
•
Using the blade of a small screwdriver, compress spring
and place in wider portion of channel at bottom of ramp.
•
Verify that spring is evenly compressed and is not cocked
or skewed. Push spring so that it bottoms in channel.
•
With tab side of ramp facing inboard and hook end on
switch side of casting, install ramp so that narrow channels
engage pins cast into housing.
Clutch/starter interlock switch
Siren switch: On/Off
Light switch: high and low beams
Turn-left signal switch
Horn/siren yelp switch
Figure 8-5. Left Handlebar Switch Housing
Installation
1.
Install the switches in the housing with contacts facing
tabs on ramp. For best results, install one switch at a time.
Ribs cast in lower housing hold switches in position.
The Horn switch with the Yellow/Black lead (pivot point
towards rider) is installed at the bottom, while the Siren
Yelp switch with the Brown/Black lead (pivot point towards
the front) is at the top. Route switch wires in channel on
the outboard side of the ribbed area.
2.
Install the keycap engaging slot with hook on ramp.
2.
3.
Install lower bracket sliding pin through keycap and
engaging hole in lower casting.
3.
4.
Remove the clutch interlock switch from the housing.
5.
Cut wires 1/4 in. (6 mm) from old switch. Discard switch
assembly.
4.
Slide T8 TORX screws through holes in lower bracket and
switches and thread into lower casting until snug.
5.
Install Phillips screw (with lockwasher), to secure lower
bracket to threaded boss in housing. Verify operation of
Horn and Siren Yelp switches to ensure that both are
spring returned.
6.
Install clutch interlock switch in bore of lower switch
housing, if loose.
7.
Insert tapered end of new 7-inch cable strap into round
hole in turn signal switch bracket and then feed back
through using the adjacent hole. Reserve the oblong hole
for the bracket screw.
NOTE
Replacement clutch interlock switch wires are cut to length.
Looking at rear side, left side switch wire is 2-1/4 in. (57 mm),
and right side is 2-3/4 in. (70 mm) and partially stripped.
6.
Installation
NOTE
Be sure that all splices are positioned above the turn signal
switch bracket.
1.
Install clutch interlock switch in bore of lower switch
housing.
8.
Place the turn signal switch assembly into the housing
aligning the oblong hole in the bracket with the lower
bracket weld nut. Be sure that bracket is fully seated. Tabs
on each side are captured in slots cast into switch housing.
2.
Insert tapered end of new 7-inch cable strap into round
hole in turn signal switch bracket and then feed back
through using the adjacent hole. Reserve the oblong hole
for the bracket screw.
9.
Install Phillips screw (with lockwasher) to secure bracket
inside housing.
NOTE
switch bracket.
3.
4.
Install Phillips screw (with lockwasher) to secure bracket
inside housing. If routed incorrectly, wires may be pinched
by casting or handlebar resulting in switch failure.
If routed incorrectly, wires can be pinched by casting or
handlebar resulting in switch failure. (00542b)
10. Loop switch wires so that spliced lengths are positioned
directly over bracket screw.
11. Capturing conduit about 1/4 inch (6 mm) from end,
securely tighten cable strap to draw conduit to bracket.
Remove any excess cable strap material.
12. On opposite side, install second 7-inch cable strap capturing conduit and wire splices. Securely tighten cable
strap to draw splices to conduit. Remove any excess cable
strap material.
13. Route wire bundle to upper switch housing below and then
forward of the main wire harness positioning conduit in
channel next to angular arm of bracket. Secure bundle to
arm placing new cable strap 1/4 inch (6 mm) from end of
conduit. Cut any excess cable strap material. If necessary,
bend angular arm of bracket downward to firmly secure
clutch interlock switch in installed position.
14. See HANDLEBAR SWITCHES in the Touring Models
Service Manual.
5.
Loop switch wires so that spliced lengths are positioned
6.
Capturing conduit about 1/4 in. (6 mm) from end, securely
tighten cable strap to draw conduit to bracket. Remove
7.
On opposite side, install second 7-inch cable strap capturing conduit and wire splices. Securely tighten cable
strap material.
8.
Route wire bundle to upper switch housing below and then
forward of the main wire harness positioning conduit in
channel next to angular arm of bracket. Secure bundle to
arm placing new cable strap 1/4 in. (6 mm) from end of
conduit. Cut any excess cable strap material. If necessary,
bend angular arm of bracket downward to firmly secure
clutch interlock switch in installed position.
9.
See HANDLEBAR SWITCH ASSEMBLIES in the Touring
CLUTCH INTERLOCK SWITCH
NOTE
All Police models have a clutch interlock switch that prevents
the motorcycle from starting (even in NEUTRAL) if the clutch
lever is not pulled in.
Removal
1.
The Auxiliary switch with the Gray/Black lead is installed
at the bottom, while the Pursuit switch with the Green/Red
lead is at the top. Route switch wires into corner space
outside of the ribbed area.
ed01649
NOTE
If the keycap and ramp mechanism requires replacement,
install as follows:
•
Slide ramp upward to remove from keycap shaft.
•
Remove keycap from switch housing.
•
Install spring into hole on inboard side of new keycap.
Position ball on end of spring. Use a small amount of
grease to hold ball in place.
•
Install keycap so that ball engages detent in switch
housing.
•
Slide ramp over keycap shaft so that tongues on ramp
engage grooves in keycap shaft.
Installation
1.
Install lower bracket with the weld nut side down.
2.
Slide the T8 TORX screws through holes in lower bracket
and switches and thread into lower casting until snug.
3.
Install Phillips screw (with lockwasher), to secure lower
bracket to threaded boss in housing. Work Auxiliary and
Pursuit switches to ensure smooth operation.
4.
See Figure 8-7. Insert tapered end of new 7-inch cable
strap into round hole in turn signal switch bracket and then
feed back through using the adjacent hole. Reserve the
oblong hole for the bracket screw.
Figure 8-6. Lower Switch Housing
PURSUIT AND AUXILIARY SWITCH
NOTE
Pursuit lamps are operational on domestic motorcycles only.
Removal
1.
2.
3.
4.
Remove the two T8 TORX screws and the Phillips screw
(with lockwasher) to release the lower bracket. Remove
the bracket from the housing.
5.
Pull both switches from the housing.
6.
Cut the wires from the old switches as follows:
a.
Gray/Black wire: 1-1/2 in. (38 mm)
b.
Orange/Violet wires: 1-7/8 in. (48 mm)
c.
Green/Red wire: 1-1/4 in. (32 mm)
NOTE
switch bracket.
5.
6.
Install Phillips screw (with lockwasher) to secure turn signal
switch bracket inside housing.
7.
Loop switch wires so that spliced lengths are positioned
8.
Capturing conduit about 1/4 in. (6 mm) from end, securely
tighten cable strap to draw conduit to bracket. Remove
9.
On opposite side, install second 7-inch cable strap capturing conduit and wire splices. Securely tighten cable
strap material.
NOTE
Replacement pursuit/auxiliary switch wires are cut to length
and partially stripped (Gray/Black wire: 2 in. (51 mm);
Orange/Violet wires: 1-7/8 in. (48 mm); Green/Red wire: 13/4 in. (45 mm).
7.
8.
Move keycap to the OFF position. Install the switches in
the housing with contacts facing the recessed area on the
ramp. Ribs cast in lower housing hold switches in position.
10. Route wire bundle to upper switch housing in channel next
to angular arm of bracket. Secure bundle to arm placing
new cable strap 1/4 in. (6 mm) from end of conduit. Cut
any excess cable strap material. If necessary, bend
angular arm of bracket downward to firmly secure Front
Stoplight Switch in installed position.
ed01650
1
11. See HANDLEBAR SWITCH ASSEMBLIES in the Touring
2
3
1. 7" cable strap
2. Bracket
3. Right turn signal switch
Figure 8-7. Hole Location Cable Strap Switch Bracket
AUTOMATIC COMPRESSION RELEASE
8.5
GENERAL
ed01625
See Figure 8-8. The Automatic Compression Release (ACR)
is opened and closed by the ECM to assist starting.
See Figure 8-9. When open, compressed gases are released
through the exhaust port.
REMOVAL
PART NUMBER
HD-48498
TOOL NAME
ACR SOLENOID SOCKET
1.
While preparing motorcycle for service, separate the ACR
rear [203R] and front [203F] connectors from the main
wiring harness.
2.
Remove the rocker cover and the rocker box. See
STRIPPING MOTORCYCLE FOR SERVICE and TOP
END OVERHAUL in the Service Manual for procedures.
3.
See Figure 8-13. Use ACR SOLENOID SOCKET (Part
No. HD-48498) to remove the ACR from the cylinder head.
Figure 8-10. ACR in Head
INSTALLATION
PART NUMBER
TOOL NAME
ed01623
HD-48498
1.
Verify that the copper seal washer is in place on the ACR.
2.
See Figure 8-11. Identify a location around the threads of
the ACR approximately 1/3 of the way up from the end.
3.
See Figure 8-12. Apply three equally spaced dots of
LOCTITE
246
THREADLOCKER
MEDIUM
STRENGTH/HIGH TEMPERATURE (blue) on threads.
4.
To prevent cross threading, install and finger tighten.
5.
See Figure 8-13. Using ACR SOLENOID SOCKET (Part
No. HD-48498), tighten to 11-15 ft-lbs (14.9-20.3 Nm).
6.
Before installing the rocker box on each cylinder head,
route the wire harness toward the inside of the cylinder V.
7.
With rocker boxes installed and the engine in the chassis,
mate the ACR connectors [203R] and [203F] to the corresponding socket housings on the main wiring harness.
Figure 8-8. ACR Valve in Combustion Chamber
ed01624
Figure 8-9. ACR Exhaust Port Release
ACR SOLENOID SOCKET
ed01628
ed01626
Figure 8-13. ACR Solenoid Socket (HD-48498) and ACR
COMPRESSION TEST
PART NUMBER
HD-33223-1
TOOL NAME
CYLINDER COMPRESSION GAUGE
A compression test can determine the source of cylinder
leakage. Use CYLINDER COMPRESSION GAUGE (Part
No. HD-33223-1) with a screw-in type adapter.
NOTE
The Twin Cam 103 Engine uses a 12 mm adapter with the
compression gauge.
Figure 8-11. Bottom Third
1.
Operate engine to normal operating temperature.
2.
Disconnect spark plug wires.
3.
Clean around plug base and remove front cylinder spark
plug.
4.
Install compression tester to front cylinder per gauge
instructions.
ed01627
NOTE
The test results will vary depending on whether the ACR is
connected or not. Refer to Table 8-2 for specifications.
Figure 8-12. Three Dots of Loctite 246 Medium
Strength/High Temperature
5.
Shift transmission to neutral. Crank engine continuously
through 5 to 7 compression strokes.
6.
Record gauge readings at the end of the first and last
compression strokes (highest readings).
7.
Replace front spark plug and repeat test on rear cylinder.
8.
Refer to Table 8-2. Readings should be within specified
range. If readings are higher than normal, suspect a
compression release that is not functioning correctly. If
readings are low, inject approximately 1/2 oz. (15 ml)
engine oil into each cylinder and repeat the compression
tests on both cylinders.
NOTE
Readings that are considerably higher after injecting the oil
indicate worn piston rings.
3.
Table 8-2. Compression Specifications
PSI
kN/m2
Connected
130-170
896-1,173
Disconnected
200-220
1,379-1,517
ACR STATUS
If V/GY wire is shorted to ground, the ACRs will remain
on for a time that exceeds the design parameters and the
ACR solenoids will fail.
em00235
DIAGNOSTICS
[119B]
PART NUMBER
[78A] [78B]
TOOL NAME
HD-41404-B
TEST CONNECTOR KIT
HD-48637
BREAK-OUT BOX
Y/GN
ACR 19
19
V/GY
K
T
E
S
U
87
87A
30
85
86
Diagnostic Tips
Refer to flow charts that follow for troubleshooting.
Diagnostic Notes
2.
Connect BREAK-OUT BOX (Part No. HD-48637) to ECM.
Y/GN
[203FB]
V/GY
Use TEST CONNECTOR KIT (Part No. HD-41404-B) with
gray terminal probes and patch cords.
Y/GN
1.
V/GY
NOTE
The step numbers below correlate with the circled numbers in
the flow chart.
1 2
1
2
[203RB]
Figure 8-14. ACR Circuit
Table 8-3. Connectors/Fuse in ACR Circuit
NUMBER
DESCRIPTION
TYPE
LOCATION
[78]
ECM
73-place Delphi
Under seat
[203F]
ACR
2-place Amp (Tyco)
Between cylinders
[203R]
ACR
2-place Amp (Tyco)
Between cylinders
[119]
System relay
Lugs
ESPFI fuse block
5
4
3
2
1
ACR Diagnostics (Part 1 of 2)
Is battery voltage 12.6
VDC or higher?
YES
NO
Perform starter current draw test while cranking
engine at room temperature. Remove system
relay and repeat starter current draw test.
Is current draw 20-40 Amps greater with
system relay removed?
Charge battery.
YES
NO
Review symptoms.
Issue is not ACR related.
1
2
During the first 2 seconds after turning the
key on (while relay is energized) or while
cranking, measure voltage at terminal “1” on
connector [203FB] (front) or [203RB] (rear).
Is battery voltage present?
YES
NO
Measure continuity between
terminal “2” on connector [203FB]
(front) or [203RB] (rear) and
breakout box terminal “19”.
Is continuity present?
Locate and repair open on Y/GN
wire between terminal “1” on
connector [203FB] (front) or
[203RB] (rear) and system relay.
7077
3
YES
NO
Disconnect breakout box from ECM
leaving harness connected to breakout
box. Measure continuity between terminal
“19” on breakout box and ground.
Locate and repair open on V/GY wire
between terminal “2” on connector
[203FB] (front) or [203RB] (rear) and
ECM connector [78B] terminal “19”.
7076
YES
NO
Disconnect connector [203FB] (front)
and [203RB] (rear) one at a time.
Is continuity to ground still resent?
STOP
Go to
ACR Diagnostics
(Part 2 of 2).
YES
NO
Locate and repair short to ground on
V/GY wire between terminal “2” on
connector [203FB] (front) or [203RB]
(rear) and ECM connector [78B}
terminal “19” and replace both ACRs.
Replace grounded
ACR.
7077
fc01777_en
7078
ACR Diagnostics (Part 2 of 2)
Continued from ACR Diagnostics
(Part 1 of 2).
Measure voltage at breakout box terminal “19”
with breakout box disconnected from ECM.
Is voltage present?
YES
NO
Locate and repair short to voltage
on V/GY wire between terminal
“2” on connector [203FB] (front)
or [203RB] (rear) and ECM
connector [78B] terminal “19”.
Measure resistance between
terminal “1” and “2” on connector
[203FA] (front) or [203RA].
7079
YES
NO
Reconnect breakout box and ECM; and
ACRs to the engine wiring harness. Measure
voltage at terminal “19” during cranking.
Replace defective
ACR solenoid.
7077
Is voltage 0.1-8.0 VDC and fluctuating while
engine cranks?
YES
NO
Perform compression test (only one spark plug can
be removed at a time or ACR will be disabled).
Refer to COMPRESSION TEST.
Is compression 130 - 170 PSI (896- 1,173 kN/m2 0
with ACR connected and 200-220 PSI (1379-1517
kN/m2) with ACR disconnected?
Replace ECM
7080
YES
NO
Review symptoms. Issue
is not ACR related.
Replace ACR on cylinder
that is non-functional.
7077
fc01778_en
APPENDIX A WIRING
SUBJECT............................................................................................................................PAGE NO.
A.1 CONNECTORS........................................................................................................................A-1
A.2 INDEX TO WIRING DIAGRAMS...............................................................................................A-7
NOTES
CONNECTORS
A.1
CONNECTORS
ed01651
[108]
[2]
[39]
[21]
[69]
[1]
[24]
[70]
[31R]
[176]
[31L]
[33]
[15]
[32]
[207]
[22]
[167]
Figure A-1. Inner Fairing
Table A-1. FLHTP Wire Harness Connectors
NO.
DESCRIPTION
TYPE
LOCATION
[1]
Main to interconnect harness
16-place Molex (black)
Inner fairing - right storage box support
bracket
[2]
12-place Molex (gray)
Inner fairing - right fairing support brace
[4]
Accessory
4-place Deutsch
Upper frame cross member (under seat)
2008 FLT Police Service: Appendix A Wiring A-1
NO.
DESCRIPTION
TYPE
LOCATION
[5]
MAXIFUSE
2-place Packard
Under left side cover
[7]
Rear fender lights harness
8-place Multilock
Top of rear fender (under seat)
[12]
3-place Multilock
Inboard of left upper frame tube
[13]
Fuel tank harness
4-place Multilock
Behind fuel tank (under seat)
[15]
4-place Packard
Inner fairing - front of right fairing bracket
[18]
Left rear turn signal
2-place Multilock
Circuit board under tail lamp assembly
[19]
Right rear turn signal
2-place Multilock
[21]
Indicator lights
10-place Multilock
Inner fairing - above storage box
[22]
Interconnect to right handlebar switches
Inner fairing - fork stem nut lock plate (left
side)
[24]
Interconnect to left handlebar switches
12-place Molex (gray)
Inner fairing - left fairing support brace
[30]
TSM/HFSM
12-place Deutsch
Cavity in crossmember at rear of battery
box (under seat)
[31L]
Left front turn signal/pursuit lamp
4-place Multilock
Inner fairing - outboard of left fairing
bracket
[31R]
Right front turn signal/pursuit lamp
4-place Multilock
[32]
Front fender tip lamp jumper harness
2-place Multilock (black)
Inner fairing - below upper fork bracket
(left side)
[33]
Ignition/light key switch
3-place Packard
Inner fairing - under storage box (front of
ignition switch housing)
[38]
Headlamp
Headlamp Connector
Inner fairing (back of headlamp)
[39]
Speedometer
12-place Packard (black)
Inner fairing (back of speedometer)
[45]
Rear fender tip lamp
3-place Multilock
[46]
Stator
3-place Lyall
Bottom of voltage regulator (left side)
[57]
Siren/PA speaker
2-place Deutsch
Top rail of engine guard (right side)
[59]
Rear pole lamp
2-place Deutsch
Under luggage rack (left side)
[64]
Fuse block
Packard
[65]
VSS
3-place Delphi
Top of transmission case (under Starter)
[69]
Pursuit flasher (domestic only)
Relay connector
Inner fairing - front of speedometer
[70]
Siren amplifier harness
12-place Deutsch (black)
Inner fairing - left fairing support brace
[72]
Siren amplifier
18-place Packard
Top rail of saddlebag guard (left side)
[77]
Voltage regulator
2-place Lyall
Bottom of voltage regulator (right side)
[78]
ECM
73-place Packard
Under right side cover
[79]
CKP sensor
2-place Deutsch
Electrical caddy at bottom of lower frame
crossmember
[80]
MAP sensor
3-place Packard
Top of induction module
[83]
Ignition coil
4-place Delphi
Below fuel tank (left side)
[84]
Front injector
2-place Delphi
[85]
Rear injector
2-place Delphi
[87]
IAC
4-place Delphi
Below fuel tank (right side)
[88]
TP sensor
3-place Delphi
[89]
IAT sensor
2-place Delphi
[90]
ET sensor
2-place Delphi
Back of front cylinder (left side)
[91]
Data link
4-place Deutsch
[93]
Tail lamp
4-place Multilock
[94]
Rear fender lights harness to circuit board 6-place Multilock
A-2 2008 FLT Police Service: Appendix A Wiring
NO.
DESCRIPTION
TYPE
LOCATION
[105]
Fairing cap switches
12-place Multilock
Inner fairing - above upper fork bracket
(right side)
[108]
Tachometer
12-place Packard (gray)
Inner fairing (back of tachometer)
[110]
Voltmeter lamp
Spade connector
Inner fairing (back of voltmeter)
[111]
Voltmeter
Spade connector
Inner fairing (back of voltmeter)
[116]
Fuel gauge lamp
Spade connector
Inner fairing (back of fuel gauge)
[117]
Fuel gauge
Spade connector
Inner fairing (back of fuel gauge)
[119]
EFI fuses
Fuse terminals
Fuse block (under right side cover)
[121]
Rear brake light switch
Spade terminals
Bottom of rear frame downtube (right side)
[122]
Horn
Spade terminals
Between cylinders (left side)
[123]
Starter relay
Relay connector
Fuse block (under left side cover)
[124]
Brake light relay
Relay connector
Fuse block (under left side cover)
[126]
Ignition keyswitch relay
Relay connector
box (under seat)
[128]
Starter solenoid
Spade terminals
Top of starter
[129]
Harness grounds
Ring terminals
[131]
Neutral switch
Post terminals
Top of transmission (right side)
[132]
Cigarette lighter
Spade terminals
Inner fairing (left side)
[133]
Jiffy Stand Sensor
HDI: Electrical caddie at bottom of lower
frame crossmember. (Not used on
Domestic)
[135]
EFI system relay
Relay connector
[137]
O2 sensor rear exhaust header
2-place Amp (Tyco)
Under chrome starter cover
[138]
O2 sensor front exhaust header
2-place Amp (Tyco)
Back of cross brace between front frame
downtubes (left side)
[139]
Oil pressure sender
4-place Delphi
Front right crankcase
[141]
Fuel level sender and fuel pump
4-place Packard
Top of canopy (under console)
[156]
6-place Deutsch
[160]
B+
1-place Packard
[166]
ABS module
20-place Molex
[167]
Front wheel speed sensor
2-place Amp (Tyco)
Inner fairing - below upper fork bracket
(left side)
[168]
Rear wheel speed sensor
2-place Amp (Tyco)
[176]
6-place Deutsch
Inner fairing - outboard of right fairing
bracket
[178]
Active intake solenoid
2-place Amp (Tyco)
Back of air cleaner backplate
[179]
Active exhaust actuator
5-place Amp (Tyco)
Domestic (not used): under right side
cover
HDI: under right side cover (behind electrical bracket)
[201]
ABS diode pack
4-place Deutsch
[203F]
ACR solenoid
2-place Amp (Tyco)
Between cylinders
[203R]
ACR solenoid
2-place Amp (Tyco)
Between cylinders
[204]
Twist Grip sensor
6-place Molex
Inner fairing, right support bracket
[207]
Stealth (disable lighting circuit)
Inner fairing - front of right fairing bracket
[211]
Throttle Control Actuator
6-place Molex
Throttle body
ed01652
[67]
[22]
[24]
[31]
[20]
[73]
[207]
[177]
[167]
[32]
Figure A-2. Headlamp Nacelle (FLHP/E)
Table A-2. FLHP/E Wire Harness Connectors
NO.
DESCRIPTION
TYPE
LOCATION
[4]
Accessory
4-place Deutsch
[5]
MAXIFUSE
2-place Packard
[7]
Rear fender lights harness
8-place Multilock
Top of rear Fender (under seat)
[18]
Left rear turn signal
2-place Multilock
[19]
Right rear turn signal
2-place Multilock
[20]
Tachometer harness
6-place Deutsch
Inside headlamp nacelle
[21]
Indicator lamps
8-place Deutsch
Under console
[22]
Right handlebar switches
12-place Molex
Inside headlamp nacelle - fork stem nut
lock plate (right side)
[24]
Left handlebar switches
12-place Molex
lock plate (left side)
[30]
TSM/HFSM
12-place Deutsch
box (under seat)
[31]
Front turn signals
6-place Multilock
lock plate (left side)
[32]
Front fender tip lamp jumper harness
[33]
Ignition/light key switch
3-place Packard
Under console
[38]
Headlamp
Headlamp connector
[39]
Speedometer
12-place Packard
Back of speedometer (under console)
NO.
DESCRIPTION
TYPE
LOCATION
[45]
Rear fender tip lamp
3-place Multilock
[46]
Stator
3-place Lyall
Bottom of voltage regulator (left side)
[57]
Siren/PA speaker
2-place Deutsch
Top rail of engine guard (right side)
[59]
Rear pole lamp
2-place Deutsch
Under luggage rack (left side)
[64]
Fuse block
Packard
[65]
VSS
3-place Delphi
Top of transmission case (under Starter)
[67]
Accessory switch
4-place Amp
[69]
Pursuit flasher (domestic only)
Relay connector
[72]
Siren amplifier
18-place Packard
Top rail of saddlebag guard (left side)
[73]
Pursuit lamps
2-place Multilock (white)
[77]
Voltage regulator
2-place Lyall
Bottom of voltage regulator (right side)
[78]
ECM
73-place Packard
[79]
CKP sensor
2-place Deutsch
Electrical caddy at bottom of lower frame
crossmember
[80]
MAP sensor
3-place Packard
Top of induction module
[83]
Ignition coil
4-place Delphi
[84]
Front injector
2-place Delphi
[85]
Rear injector
2-place Delphi
[87]
IAC
4-place Delphi
[88]
TP sensor
3-place Delphi
[89]
IAT sensor
2-place Delphi
[90]
ET sensor
2-place Delphi
Back of Front Cylinder (left side)
[91]
Data link
4-place Deutsch
[93]
Tail lamp
4-place Multilock
[94]
Rear fender lights harness to circuit board 6-place Multilock
[108]
Tachometer
12-place Packard (gray)
Back of tachometer
[117]
Fuel gauge
4-place Multilock
[119]
EFI fuses
Fuse terminals
[120]
Oil pressure switch
Post terminal
Front Right Crankcase
[121]
Rear brake light switch
Spade terminals
Bottom of rear frame downtube (right side)
[122]
Horn
Spade terminals
Between cylinders (left side)
[123]
Starter relay
Relay connector
Fuse Block (under left side cover)
[124]
Brake light relay
Relay connector
Fuse Block (under left side cover)
[126]
Ignition keyswitch relay
Relay connector
box (under seat)
[128]
Starter solenoid
Spade terminals
Top of starter
[129]
Harness grounds
Ring terminals
[131]
Neutral switch
Post terminals
Top of transmission (right side)
[133]
Jiffy Stand Sensor
HDI: Electrical caddie at bottom of lower
frame crossmember. (Not used on
Domestic)
[135]
EFI system relay
Relay connector
[137]
O2 sensor rear exhaust header
2-place Amp (Tyco)
Under chrome starter cover
[138]
O2 sensor front exhaust header
2-place Amp (Tyco)
Back of cross brace between front frame
downtubes (left side)
[141]
Fuel level sender and fuel pump
4-place Packard
Top of canopy (under console)
NO.
DESCRIPTION
[143]
Front fender tip lamp (DOM)
Under front fender tip lamp bracket
[160]
B+
1-place Packard
[166]
ABS module
20-place Molex
[167]
Front wheel speed sensor
2-place Amp (Tyco)
Inside headlamp nacelle (left side)
[168]
Rear wheel speed sensor
2-place Amp (Tyco)
[173]
3-place Multilock
Inboard of left upper frame tube
[176]
Main to main harness
4-place Deutsch
Under left side cover (beneath harness)
[178]
Active intake solenoid
2-place Amp (Tyco)
Back of air cleaner backplate
[179]
Active exhaust actuator
5-place Amp (Tyco)
Domestic (not used): under right side
cover
HDI: under right side cover (behind electrical bracket)
[177]
Main to main harness
2-place Deutsch
Inside headlamp nacelle (left side)
[201]
ABS diode pack
4-place Deutsch
[203F]
ACR solenoid
2-place Amp (Tyco)
Between cylinders
[203R]
ACR solenoid
2-place Amp (Tyco)
Between cylinders
[204]
Twist Grip sensor
6-place Molex
Inside Headlamp Nacelle
[207]
Stealth (disable lighting circuit)
3-place Molex
[211]
6-place Molex
Throttle body
[222]
Ignition switch interconnect
4-place Packard
Under the seat
TYPE
LOCATION
INDEX TO WIRING DIAGRAMS
A.2
WIRING DIAGRAM INFORMATION
ed01269
Wire Color Codes
Wire traces on wiring diagrams are labeled with alpha codes.
Refer to Table A-3.
3
4
For Solid Color Wires: See Figure A-3. The alpha code
identifies wire color (3).
5
W
GN/Y
TN
1
2
4
[21B]
1
2
4
TN
See Figure A-3. On wiring diagrams and in service/repair
instructions, connectors are identified by a number in brackets
(1). The letter (2) inside the brackets identifies whether the
housing is a socket or pin housing.
[21A]
W
Wiring Diagram Symbols
2
GN/Y
1
For Striped Wires: The code is written with a slash (/) between
the solid color code and the stripe code (4). For example, a
trace labeled GN / Y is a green wire with a yellow stripe.
1
A=Pin: The letter A after a connector number and the pin
symbol (6) identifies a pin housing.
2
10
6
7
8
9
B=Socket: The letter B after a connector number and the
socket symbol (5) identifies a socket housing.
Other symbols found on the wiring diagrams include the symbol
for a diode (7), a symbol for a wire-to-wire connection (8), a
symbol that verifies that no connection (9) between two wire
traces exists and a symbol identifying two wires that are twisted
together (10).
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Connector number
Terminal code (A=pin, B=socket)
Solid wire color
Striped wire color
Socket symbol
Pin symbol
Diode
Connection
No connection
Twisted pair
Figure A-3. Connector/Wiring Diagram Symbols (typical)
Table A-3. Wire Color Codes
ALPHA CODE
WIRE COLOR
BE
Blue
BK
Black
BN
Brown
GN
Green
GY
Grey
LGN
Light Green
O
Orange
PK
Pink
R
Red
TN
Tan
V
Violet
W
White
Y
Yellow
WIRING DIAGRAMS
Wiring Diagram List
DIAGRAM
LOCATION
2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Main Harness without ABS (1 of 2)
Figure A-4
2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Main Harness with ABS (1 of 2)
Figure A-5
2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Main Harness (2 of 2)
Figure A-6
2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Interconnect Harness
Figure A-7
2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Pursuit Lamps, Directional Lamps, Tail Lamp and
Fender Tip Lamps
Figure A-8
2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Starting and Charging
Figure A-9
2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Handlebar Switches, Indicator Lamps, Fairing
Cap Switches and HFSM Antenna
Figure A-10
2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Anti-Lock Brake System (ABS) Siren Amplifier
and Strobe Harness
Figure A-11
2008 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models, Main Harness without ABS (1 of 2)
Figure A-12
2008 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models, Main Harness with ABS (1 of 2)
Figure A-13
2008 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models, Main Harness (2 of 2)
Figure A-14
2008 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models, Starting and Charging
Figure A-15
2008 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models, Handlebar Switches, Indicator Lamps,
Tail Lamp, Pursuit Lamps, Directional Lamps, Accessory/Spot Switch, Speedometer, Tachometer and HFSM
Antenna
Figure A-16
2008 FLHTP, FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models, Optional Strobe System
Figure A-17
1 2 3
[77B]
R
BK
1 2 3
[160B]
1B Cruise/Brake - 15A 1A
O/V
1 2 3 4
O/W
Accessory - 15A
1C
R/GY
1F
P & A - 15A
1H
Radio Power/
Siren - 15A
1E
O/R
R/GY
1G
Police Stealth
O/BE
R/GY
LGN/V
GY
Y/GN
BE/GY
W/BK
BK
LGN/R
GN
BK/R
TN/GN
To
Fairing
Harness
[15A]
3
5
1
2
Amber cap removed
when stealth switch
option is used
Start
Relay
2B Radio Memory - 15A 2A
[GND1]
4B Fuel Pump - 15A
4A
Y/GN
Y/GN
BE/GY
W/BK
GN/O
Rear GND
Stud
(Clean)
3D
4C
4D
3C
30
87
86
85
3
5
1
2
System
Relay
[GND2]
BK/GN
O
1B
P & A - 15A
1A
1D
INSTRS - 15A
1C
1F
Ignition - 15A
1E
R/BK
O
GY
1H Engine CNTRL - 15A 1G
LGN/R
2D
Headlamp - 15A
B
A
BE
R/O
[126B]
2C
[126A]
R/BK
BE
BK
[207B]
R/BK
R
BE/GY
BE/GY
O/GY
BK
O
2F ECM Power - 15A 2E
BK/GN
BK/R
TN
GN/Y
BN/GN
O
Y/BK
Y/W
BN/GY
BE
BK/R
R/BE
D
[207A]
R
BK
R/BK
12
11
10
9
8
7
6
5
4
3
2
1
3
R
[GND1A]
W/V
W/BN
O/BE
BN
V
W/BK
O/W
O/R
GY
O/V
O
1
2C
R/BK
11
10
9
8
7
6
5
4
3
2
1
3
87(5)
87A(4)
30(3)
85(2)
86(1)
LGN/V
Battery - 15A
BN/GY
BK
1
R
2D
[1B]
[2B]
To
Fairing
Harness
[2A]
(GY)
30
87
86
85
R/O
13
To
Fairing
Harness
[1A]
(BK)
3H
4G
4H
3G
R/BK
1 2 3 4
BK/GN
Front GND
Stud
(Dirty)
[33B]
[142B]
O/GY
Y/W
BK/GN
BK
[13A]
[5B]
2
1 2 3
1D
GN/O
1
BK
R
Power
Signal
Ground
[BATT]
B
R/BK
[13B]
[141B]
[128B]
Ignition
Switch
[33A]
B+
Connector
R/GY
R
R/BK
Fuel Pump
Assembly Intank
A
[142A]
Voltage
Regulator
BN/GY
LGN/BN
BK/GN
Y/W
O/GY
BK/GN
BK
A B CD
R/BE
2F
Lights - 15A
2E
3H
Spare - 15A
3G
Lighting
Relay
BE
BK
[15B]
4B
R/Y
2
[4A]
B
A
BN/GN
GN/Y
[122]
[139B]
1
Neutral
Switch
[131]
Rear
Stop Light
Switch
[121]
1 2 3 4
Accessory
Connector
[12B]
4A
R/BE
2A 85 2
(BK)
[7A]
4H
BK
3 2 1
Tour-Pak
[12A]
1 2 3
Brake
Relay
1
A
15A
2
15A
3
4
1
BK
R/Y
BE
1
BN
O/W
V
A
BK
R/Y
BE
Oil
Pressure
Sender
[139A]
B
BK
O/R
R/Y
O
BK
2
BK
2B 30 3
3A 87 5
3B 86 1
O/V
R/BE
O/W
TN
BK
Horn
Spare - 30A
(ABS Only)
BK
Y/BK
BK
To Main Harness Page 2
Main Power
40 Amp
at Starter MAXIFUSE
A B CD
Fuel
Pump
Turn Signal/ [30A] [30B]
Turn Signal Security
(GY)
Module
Start
Solenoid
R
[141A]
GN
1 BN/GY
2
GY
LGN/V
3
4
TN
5
V
6
BN
7 W/BN
8 W/V
9 TN/GN
10 BK/R
11 LGN/BN
12 BK/GN
O/GY
Y/W
BK/GN
BK
Battery 1
Ignition 2
Serial Data 3
Neutral Switch 4
Left Turn Feed 5
Right Turn Feed 6
Right Turn SW Input 7
Left Turn SW Input 8
Start Relay Control 9
Clutch Switch 10
Alarm Signal 11
Ground 12
Optional
Security
Siren
R
et00067
5 6 7
To Rear Lighting
Figure A-4. 2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Main Harness without ABS (1 of 2)
Spare - 30A
4G
15A
B
A
15A
2 85 30
31579-04
12VOC
3 87
86
4
30A
B
C
15A
E
15A
15A
15A
85 30
31579-04
12VOC
87 86
D
F
C
15A
E
15A
15A
15A
G
15A
85 30
31579-04
12VOC
87 86
H
G
15A
15A
D
F
J
30A
H
J
Figure A-4.
2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Main
Harness without ABS (1 of 2)
Figure A-4.
Harness without ABS (1 of 2)
et00068
1
[5B]
2
1 2 3
[77B] [160B]
1 2 3
1 2 3
[142B]
BN/GY
LGN/BN
BK/GN
R
O/V
1 2 3 4
O/W
[13A]
GN/O
O/GY
Y/W
BK/GN
BK
1D
R/BE
Accessory - 15A
1C
R/GY
1F
P & A - 15A
1H
Radio Power/
Siren - 15A
1E
O/R
BK/GN
R/GY
1G
O/BE
R/GY
LGN/V
GY
Y/GN
BE/GY
W/BK
BK
LGN/R
GN
BK/R
TN/GN
To
Fairing
Harness
[15A]
3
5
1
2
Start
Relay
2B Radio Memory - 15A 2A
[GND1]
4B Fuel Pump - 15A
B
A
BE
R/O
O
4A
[207B]
Y/GN
Y/GN
BE/GY
W/BK
GN/O
Rear GND
Stud
(Clean)
3D
4C
4D
3C
30
87
86
85
3
5
1
2
System
Relay
[GND2]
BK/GN
O
1B
P & A - 15A
1A
1D
INSTRS - 15A
1C
1F
Ignition - 15A
1E
R/BK
O
GY
LGN/R
2D
Headlamp - 15A
[126B]
2C
R/BK
BE
BK
3
R/BK
R
BE/GY
BE/GY
O/GY
BK
BK/GN
BK/R
TN
GN/Y
BN/GN
O
Y/BK
Y/W
BN/GY
BE
BK/R
R/BN
D
1
[207A]
R
BK
R/BK
12
11
10
9
8
7
6
5
4
3
2
1
R
[GND1A]
W/V
W/BN
O/BE
BN
V
W/BK
O/W
O/R
GY
O/V
O
2C
R/BK
11
10
9
8
7
6
5
4
3
2
1
3
87(5)
87A(4)
30(3)
85(2)
86(1)
LGN/V
Battery - 15A
BN/GY
BK
1
R
2D
[1B]
[2B]
To
Fairing
Harness
[2A]
(GY)
30
87
86
85
R/O
13
To
Fairing
Harness
[1A]
(BK)
3H
4G
4H
3G
Police Stealth
Amber cap removed
when stealth switch
option is used
R/BK
1 2 3 4
R/BK
[13B]
Front
GND
Stud
(Dirty)
[33B]
R/GY
R
R/BK
B
B+
Ignition Switch
Connector
[33A]
R
[BATT]
R
[128B]
R
Ground
A
[142A]
GN
Y/W
O/GY
BK/GN
BK
[141B]
Fuel Pump
Assembly Intank
Signal
A B CD
Voltage
Regulator
BK
40 Amp
MAXIFUSE
BK
Main Power
at Starter
A B CD
Fuel
Pump
Turn Signal/ [30A] [30B]
Module
2F
Lights - 15A
2E
3H
Spare 15A
3G
Lighting
Relay
BE
BK
[15B]
4B
ABS - 30 A
4A
R/V
2
B
A
BN/GN
GN/Y
[122]
[139B]
1
[4A]
(BK)
Neutral
Switch
[131]
BK
R/BE
2A 85 2
Rear
Stop Light
Switch
[121]
1 2 3 4
3 2 1
1 2 3
5 6 7
Accessory
Connector
Tour-Pak
[12A]
[12B]
Brake
Relay
1
A
15A
2
15A
3
4
15A
B
A
BK
R/Y
BE
1
BN
O/W
V
A
BK
R/Y
BE
B
R
2B 30 3
3A 87 5
3B 86 1
O/V
O/R
R/Y
O
BK
TN
BK
2
Y/BK
Horn
Oil
Pressure
Sender
[139A]
PK/BN
O/W
R/Y
BK
Start
Solenoid
R
[141A]
To ABS
Power
BN/GY
GY
LGN/V
TN
V
BN
W/BN
W/V
TN/GN
BK/R
LGN/BN
BK/GN
O/GY
Y/W
BK/GN
BK
1
2
3
4
5
6
7
8
9
10
11
12
BK
R/BN
PK/BN
R/BE
R/V
LGN/V
GY
Battery 1
Ignition 2
Serial Data 3
Neutral Switch 4
Left Turn Feed 5
Right Turn Feed 6
Clutch Switch 10
Alarm Signal 11
Ground 12
Optional
Security
Siren
[7A]
4H
BK
To Rear Lighting
Figure A-5. 2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Main Harness with ABS (1 of 2)
Spare 30A
4G
1
2 85 30
31579-04
12VOC
3 87
86
4
30A
B
C
15A
E
15A
15A
15A
85 30
31579-04
12VOC
87 86
D
F
C
15A
E
15A
15A
15A
G
15A
85 30
31579-04
12VOC
87 86
H
G
15A
15A
D
F
J
30A
H
J
Figure A-5.
Harness with ABS (1 of 2)
Figure A-5.
Harness with ABS (1 of 2)
Yellow Tubing
Ignition
Coil
Crank Pos.
Sensor
Front
Injector
[78A]
A B
A B
[90B]
[78B]
Power
Ion Sense
Coil Rear
Coil Front
BK
W
R
BK
W
R
A B C D
[83A]
[83B]
A B C D
[85A]
[85B]
[84A]
[80A]
A B
A B
A B
A B
[84B]
Y/GN
W/Y
[204B]
1 2 3 4 5 6
PK/Y
BK/W
ECM
[90A]
1 2 3 4 5 6
Y/GN
GN/GY
[91A]
(GY)
BK/GN
LGN/V
GY
1 2 3 4
[204A]
Y/GN
GY/BE
Y/BE
BE/O
Data Link
Connector
BK/GY
V/Y
R/W
BK/W
BE/GN
BN/O
Engine Temp
Sensor
Throttle Control
Actuator
TMAP
Sensor
Black Tubing
[211A]
[79A]
1 2
[80B]
1 2 3 4
1 2
6 5 4 3 2 1
1 2 3 4
[211B]
6 5 4 3 2 1
[79B]
R
BK
Rear
Injector
BN/V
BN/O
BN/R
BK/O
BK/PK
BK/W
Twist Grip
Sensor
R
W
BK
R
W
BK
BK/GY
LGN/Y
R/W
V/W
1 2 3 4 5 6
et00097
ACR
Purge Solenoid
Exhaust Actuator
Cruise/Set/Coast
Rear Injector
TMAP Sensor Input
Brake Switch
19
20
21
22
23
24
25
19
20
21
22
23
24
25
V/GY
GY/Y
V/O
BE/BK
GN/GY
V/W
R/BE
System Relay Enable
Front Injector
Twist Grip High
Twist Grip Low
27
28
29
30
27
28
29
30
GN/O
W/Y
BK/O
BK/PK
Ion Sense
Cruise Resume/Accelerate
Cruise Enable
Throttle Pos. Sensor 2
Throttle Pos Sensor 1
Exhaust Feedback
Twist Grip Sensor 2
Vehicle Speed Input
33
34
35
36
37
38
39
40
33
34
35
36
37
38
39
40
GY/BE
W/BE
R/GN
BN/R
BN/V
V/BE
V/Y
W/GN
Crank Position Sensor (-)
43
43
+BK
Rear O2 Sensor (Unheated)
46
46
PK/GN
Intake Air Temperature
5V Sensor Power 1
Engine Temperature
12 V Power
49
50
51
52
49
50
51
52
LGN/Y
BN/O
PK/Y
Y/GN
Rear Coil
Front Coil
53
54
53
54
Y/BE
BE/O
Jiffy Stand Sensor
56
56
GN/BN
Twist Grip Sensor 1
59
59
BE/GN
5V Sensor Ground 1
5V Sensor Ground 2
Crank Position Sensor (+)
Vehicle Speed Ground
61
62
63
64
61
62
63
64
BK/W
BK/GY
R
BK/Y
Front O 2 Sensor (Unheated)
66
66
PK/O
5V Sensor Power 2
Serial Data
68
69
68
69
R/W
LGN/V
12V Battery
12V Run/Stop Switch
71
72
71
72
BE/GY
W/BK
BE/GY
W/BK
Ground
73
73
BK/GN
BK
BE/BK
R/BE
GN/O
BK/GN
W/BE
R/GN
GY
Y/GN
Active
Exhaust
(HDI Only)
Purge
Solenoid
Front
O2 Sensor
1 2 3
1 2 3
Rear
O2 Sensor
Vehicle
Speed
Sensor
Jiffy Stand
Sensor
(HDI Only)
Figure A-6. 2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Main Harness (2 of 2)
[203FB]
1
2
Front
ACR
[203RB]
V/GY
[133B]
1 2
Y/GN
[65B]
BN/O
GN/BN
BK/GN
[137B]
V/GY
1 2
BN/O
W/GN
BK/Y
[138B]
PK/GN
BK/W
[95B]
B A
Y/GN
5 4 3 2 1
PK/O
BK/W
[179B]
GY/Y
Y/GN
LGN/R
V/BE
V/O
BK
LGN/R
Twisted
Pair
1
2
Rear
ACR
From Main Harness Page 1
LGN/V
Figure A-6.
Harness (2 of 2)
Figure A-6.
Harness (2 of 2)
6
4 3 2 1
[70A]
3
[116B]
[110B]
1 2
1
W
Hi_Beam
2
Voltmeter
2
[110A]
O
BK
3
BK
BK
1 2
[117A]
1
[117B]
2
3
[111A]
[111B]
O
BK
1
Fuel
[116A]
O
BK
Y
Lo_Beam
12 11
O
BK
Y/W
Headlamp
[38A]
1 2 3 4 5 6 7
Y/PK
PK/BK
TN/BK
O/BE
[32A]
[21A]
Ground
(BK)
To Upper
Triple Clamp
GND 3
GN/R
BK
BE
2
1
To Siren Amplifier
Harness
[70B]
BK
BK
Front Fender
Tip Lamp
[32B]
(BK)
BN
GN/Y
W
V
BK
O
TN
To Indicator
Lamps
[21B]
et00088
GND
HDI Only
[29B]
[38B]
BK
O/W
To
Right Hand
Controls
[22A]
(BK)
1
2
3
4
5
6
7
8
9
O/W
R/BE
GY
W/BK
W/BN
BK/R
O/V
GY/BK
GN/R
[1A]
[22B]
GN/BK
Y/PK
TN/BK
PK/BK
7
6
5
4
3
2
1
BK/R
Y/BK
W/V
W
BE
Y
O/W
13
W/V
W/BN
O/BE
BN
V
W/BK
O/W
O/R
GY
O/V
O
11
10
9
8
7
6
5
4
3
2
1
To
Main
Harness
[1B]
(BK)
[2A]
BK
1 2
5 6 7 8 9
11
[39A]
1 2
5 6 7 8 9
11
[108B]
[108A]
(GY)
(BK)
GN/R
BN/GY
O/W
BK/GN
BN/GY
O/W
BK/GN
BK
Y/W
[39B]
O
LGN/V
O
LGN/V
[24B]
1 2
4 5 6 7
1 2
4 5 6 7
BK/GN
BK/R
TN
GN/BK
12
11
10
9
O/R
Y/BK
Y/W
BN/GY
BE
BK/R
R/BE
7
6
5
4
3
2
1
BK
D
BE
B
4 3 2 1
RH Front
Turn Signal
[31RA]
4 3 2 1
[31LA]
LH Front
Turn Signal
Rpm x 100
Odometer
Reset
Switch
[154A]
Pursuit
Flasher
Speedometer
Figure A-7. 2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Interconnect Harness
Tachometer
To
Main
Harness
[15B]
(BK)
Cigar
Lighter
O/W
BK
BK
L1 L2 B
BK
L1 L2 B
[69A]
GY/V
BK
V
BE
[69B]
To
Main
Harness
[2B]
(GY)
[15A]
[132B] [132A]
GY/BN
BK
BN
BE
GY/BN
GY/V
GY/BK
To
Left Hand
Controls
[24A]
(GY)
12
11
10
9
LGN/V
Figure A-7.
2008 FLHTP, DOMESTIC and INTERNATIONAL Models,
Interconnect Harness
Figure A-7.
Interconnect Harness
et00071
From Main
Harness
[7A]
1 2 3 4 5 6 7 8
BK
R/Y
BE
BN
O/W
V
[7B]
From
Fairing
Harness
[32A]
Rear Lighting
V/BN
68772-06
Right Rear
Directional
Lamp
BK
[32B]
BK
R/Y
O/W
BE/W
BK
V
R/Y
BE
BN
O/W
BK
O/W
2 1
[94B]
Tail Lamp
Brake Light
6 5 4 3 2 1
[143B] [143A]
Fender Tip Lamp
(DOM Only)
6 5 4 3 2 1
[94A]
[19B]
O/W
BK
O/W
BK
1
2
1
2
O/W
BK
1
2
1
2
V/BN
BK
[19A]
[18A]
License
Plate Lamp
(HDI Only)
Running Light (DOM )
BK
BK
[18B]
1
2
BK
1
2
3
1
2
1
2
3
BK
V/BN
BK
From
Fairing
Harness
[31RA]
From
Fairing
Harness
[31LA]
4
3
2
1
BK
R/Y
O/W
BE/W
[31LB]
BK
[73RB]
GY/BK
Right
Directional
and DOM
Running Lamp
BE
BN
Left
Directional
and DOM
Running Lamp
BK
BE
V
BK
BK
Fender Tip Lamp
(DOM Only)
[93A] [93B]
GY/BK
BK
V
BE
GY/BK
BK
BN
BE
Right
Pursuit
Lamp (Blue)
FLHTP
4
3
2
1
4 3 2 1
4 3 2 1
[31RB]
[45B] [45A]
Running Light (HDI)
GY/BK
BK
[73LB]
BK
Left
Pursuit
Lamp (Red)
FLHTP
Figure A-8. 2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Pursuit Lamps, Directional Lamps, Tail Lamp and Fender Tip Lamps
V/BN
BK
Left Rear
Direction
Lamp
Figure A-8.
2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Pursuit
Lamps, Directional Lamps, Tail Lamp and Fender Tip Lamps
Figure A-8.
2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Pursuit
Lamps, Directional Lamps, Tail Lamp and Fender Tip Lamps
et00070
Charging System
[208A] [208B]
HFSM
1
2
3
4
Receive Antenna
Xmit Antenna A
Xmit Antenna B
Unused
1
2
3
4
Y/BK
O/Y
BK
O/Y
BK
1
2
Stator
Xmit Antenna A
Xmit Antenna B
[77B]
[46A]
[46B]
2
1
2
3
4
1
2
3
4
BN/GY
GY
LGN/V
TN
Clutch Switch 10
9
10
TN/GN
BK/R
Ground 12
12
BK/GN
1
BK
TSM/TSSM/HFSM
Battery
Ignition
Serial Data
Neutral Switch
[77A]
DC
AC
BK
BK
BK
BK
BK
BK
40 A
MAXIFUSE
Starting System
[5B]
B
A
Red
Band
40 A
MAXIFUSE
BK
BK
ECM
R
Serial Data 69
69
LGN/V
72
72
W/BK
12V Run/Stop Switch Power
3
4
3
4
GY
W/BK
BK/R
6
6
BK/R
Red
Band
[5B]
GN
GY
W/BK
3
6
R
Starter
BK
BK/GN
(Black)
[1A] [1B]
Left Dirty
GND
Powertrain
Grounds
GY
W/BK
3
6
Left
GND 1
Right
GND 2
[33B]
R/GY
R
R/BK
IGNITION SWITCH LEGEND
1
2
3
Ignition
Switch
[33A]
[64B]
1F
(Gray)
[2A] [2B]
7
BK/R
BK
12
12
BK/GN
R/BK
GY
Battery - 15A
12
11
12
11
BK/GN
BK/R
BK/R
2
2
BK/R
[126A]
2C
R
BN/GY
BK/GN
BK/R
R/GY
TN
Left Hand
Controls
5
[21B]
5 6
GND 1A
R/GY
3H 30 3
GN
4G 87 5
BK/R
4H 86 1
TN/GN
3G 85 2
2G
Start
Relay
LH GND
Stud
(Dirty)
TN
BK
(BK)
TN
O
[21A]
Lighting
Relay
Neutral
TN
[126B]
R/BK
BK
R
7
1E
GY
2D
BK/R
Ignition - 15A
86(1)
85(2)
30(3)
87A(4)
87(5)
(Gray)
[24A] [24B]
Starter
Battery
BK
GN
Clutch
Lockout
Switch
BK
[128B]
A B
Starter Switch
(Black)
[22A]
[22B]
GY
W/BK
[128A]
BK
BK
[78A] [78B]
Engine Off/Run Switch
R
Battery
[30A] [30B]
R
Right Hand
Controls
R
R
Turn Signal/
Turn Signal
Security
Module
[209A]
BK
Hands Free
Security
Module
[209B]
B
A [131]
Neutral
Switch
O
Figure A-9. 2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Starting and Charging
"X" INDICATES CONTINUITY
BETWEEN LEAD WIRES
SWITCH IN POSITION INDICATED
POSITION
RED
LOCK
OFF
IGN
ACC
X
X
X
X
RED/
GRAY
X
X
RED/
BLACK
X
Figure A-9.
2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Starting
and Charging
Figure A-9.
2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Starting
and Charging
et00089
ACC
Right
Hand
Controls
From Fairing
Harness
[21A]
O/R
BN
GN/Y
W
V
BK
O
TN
O
1 2 3 4 5 6 7 8 9 10
[21B]
(BK)
BK
Indicator
Lamps
BN
BK
Off/Aux Pursuit Switch
Right Directional Switch
Right
Turn
Engine Off/ Run Switch
Starter Switch
GN/Y
O
Oil
Pressure
Stoplamp Switch
TN
O
Neutral
W
BK
High
Beam
O/W
R/BE
V
BK
Left
Turn
GY
W/BK
W/BN
BK/R
[22A]
1
2
3
4
5
6
7
8
O/V
GY/BK
Battery
3 2 1
2
3
Neutral Switch
4
Left Turn Feed
5
Right Turn Feed
6
Right Turn Switch Input
7
Move Y/BK wire to terminal
11 when using Whelen Siren
Amplifier & 'Air Horn'
function
9
Clutch Switch
10
Alarm Signal
11
Ground
12
[24A]
O/W
Y
BE
W
W/V
Y/BK
BK/R
PK/BK
TN/BK
Y/BK
8
Start Relay Control
11
12
[105B]
1
Ignition
9
10
To Fairing
Harness
[105A]
[30A]
Serial Data
Left Turn Switch Input
GN/R
BK
O
O/R
Hands Free Security
Module (HFSM)
For Turn Signal & Security
Module (TSM/TSSM)
To Fairing
Harness
[22B]
(BK)
BK
1
2
3
4
5
6
7
8
9
10
To Fairing
Harness
[24B]
(GY)
11
12
Clutch Lockout Switch
Siren Off/Run Switch
Hands Free Antenna
Headlamp Hi/Lo Switch
1
1
Y/BK
Transmit Antenna A
2
2
O/Y
O/Y
1
1
Antenna ’A’
Transmit Antenna B
3
3
BK
BK
2
2
Antenna ’B’
Receive Antenna
Left Directional Switch
Horn/Siren Switch
[209B] [209A]
[208A] [208B]
Left
Hand
Controls
FLHTP
Only
Figure A-10. 2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Handlebar Switches, Indicator Lamps, Fairing Cap Switches and HFSM Antenna
Figure A-10.
Handlebar Switches, Indicator Lamps, Fairing Cap Switches and
HFSM Antenna
Figure A-10.
Handlebar Switches, Indicator Lamps, Fairing Cap Switches and
HFSM Antenna
et00013
[166B]
BK
3
PK/BN
Rear wheel speed (-)
Rear wheel speed (+)
Serial data
ECU/Solenoid power
Motor ground
7
8
9
10
11
7
8
9
10
11
BE/V
BE/BN
LGN/V
R/V
BK
Front brake input
13
13
R/BN
Front wheel speed (+)
Front wheel speed (-)
Ignition wake-up
Motor power
17
18
19
20
17
18
19
20
BK/BE
BK/V
GY
R/V
R/BE
R/BE
R/BN
PK/BN
A B
A B
[168B]
[167A]
A B
A B
[168A]
4
3
2
1
ABS
Diode
Pack
[201B] [201A]
BK
R/BN
PK/BN
[167B]
4
3
2
1
GY
1
3
BE/BN
BE/V
1
Rear brake input
BK/BE
BK/V
ECU/Solenoid ground
LGN/V
[166A]
R/BE
R/V
ABS
Control
Module
To main harness
page 1
Rear Wheel
Speed Sensor
Ref: Siren wires
are not polarity
sensitive
[57A]
[57B]
[72B]
Siren/PA
Speaker
[229B]
1
2
R
2
3
O
3
4
W
4
5
W/BN
5
6
BK
6
Microphone
Jack
[68]
To optional
dealer installed
strobe power
supply
3C
GY/R
3A
3A
2A
R/PK
2D
2D
2B
W/PK
1E
1E
2C
BE/PK
3F
3F
2E
3B
R/PK
Siren
Amplifier
W/PK
3E
[72A]
FLHTP-FRG
Siren Amplifier Harness
FLHTP-FRG Strobe Harness
To
interconnect
harness
[70A]
BE/PK
2F 1F 1D 1A 1C
[72B]
12
BK
11
BK
6
GN/R
2F 1F 1D 1A 1C
BK
GN
1B
3C
O/BE
1
[72B]
GY/R
Y/PK
To optional
dealer installed
strobe lights
1
2
PK/BK
[230B]
1
2
[72A]
TN/BK
Front Wheel
Speed Sensor
GN/R
BK
4
Y/PK
3
PK/BK
2
TN/BK
1
O/BE
[70B]
Figure A-11. 2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Anti-Lock Brake System (ABS) Siren Amplifier and Strobe Harness
[59B]
1
2
To optional
pole lamp
Figure A-11.
2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Anti-Lock
Brake System (ABS) Siren Amplifier and Strobe Harness
Figure A-11.
2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Anti-Lock
Brake System (ABS) Siren Amplifier and Strobe Harness
et00091
[5B]
Ignition
Switch
[222A]
B+
Connector
2
D C B A
[77B]
[160B]
R/GY
R
R/BK
1
BK
[BATT]
B
BK
R
GN
[128B]
R
[142A]
Voltage
Regulator
R
Main Power 40 Amp
at Starter MAXIFUSE
Start
Solenoid
A
Ground
9 10 1112 1314 15
Signal
1 2 3 4 5 6
Power
[20B]
V
W
GN/Y
BN
TN
O/GY
BK
1 2 3 4 5 6
[31A]
O
LGN/V
BN/GY
O/W
BK/GN
Y/W
1 BN/GY
2
GY
LGN/V
3
4
TN
5
V
6
BN
7 W/BN
8 W/V
9 TN/GN
10 BK/R
11 LGN/BN
12 BK/GN
Optional
Security
Siren
Console Harness
Interconnect
BK
BN
BE
BE
V
BK
1 2 3
Fuel Gauge
1 2
[117B]
R/BE
4
[222B]
R
O/V
BK/GN
Turn Signal/
Turn Signal Security [30A] [30B]
(GY)
Module
[142B]
BN/GY
LGN/BN
BK/GN
1 2 3
O
Y/W
Battery 1
Ignition 2
Serial Data 3
Neutral Switch 4
Left Turn Feed 5
Right Turn Feed 6
Clutch Switch 10
Alarm Signal 11
Ground 12
Front Turn
Signals
R
TSM/TSSM/HFSM
R/GY
1D
Accessory - 15A
1C
1F
P & A - 15A
1E
O/W
GN/O
O/R
3
BK
2
1
Right Hand
Control
[22B]
(BK)
R
4B
Fuel Pump - 15A
GY/V
BE/GY
GY/BN
W/BK
GN/O
GN/R
GY/BK
O/V
BK/R
W/BN
W/BK
GY
R/BE
O/W
Y/GN
3D
4C
4D
3C
30
87
86
85
3
5
1
2
System
Relay
BK/GN
[GND2]
O
O
1B
P & A - 2A
1A
1D
INSTRS - 15A
1C
1F
Ignition - 15A
1E
GY
R/BK
R/BK
LGN/R
Left Hand
Control
[24B]
(GY)
11
10
9
8
7
6
5
4
3
2
1
V/PK
TN/BK
PK/BK
BK/GN
BK/R
Y/BK
W/V
W
BE
Y
O/W
2C
2F
Lights - 15A
2E
[126A]
Lighting
Relay
3H
[122]
R/BE
O/W
TN
BK
1
1
Neutral
Switch
[131]
Oil
Pressure
[120B] Rear
Stop Light
Switch
[121]
[4A]
[67A]
1 2 3 4
Accessory
Connector
4
1
Accessory
Switch
BK
R/Y
BE
HDI Position
Lamp
2
BN
O/W
V
2
1
O
Headlamp Fender
Tip Lamp
1
A
O/R
[32A]
2
B
R/Y
O/V
O/R
R/Y
O
BK
2
Horn
Y/BK
BK
1
BK
1 2 3
[29B]
O/W
[38B]
BK
TN/BK
V/PK
GN/Y
PK/BK
1 2 3
5 6 7
BK
2B 30 3
3A 87 5
3B 86 1
R/BE
2A 85 2
Spare - 15A
Spare - 15A
4A
3G
1
BK
A
15A
2
4H
C
15A
15A
3
Brake
Relay
4
B
A
1
2
[7A]
[126B]
R/BK
4B
O/W
1D
Headlamp - 15A
BE
W
Y
BK
2F
1F
2D
BE
[24B]
To Siren
Amplifier
[72B]
[207B]
4A
O/GY
Rear GND
Stud
(Clean)
3
O
[GND1]
BK
GN/R
3
1
BK
GY/BK
[22B]
9
8
7
6
5
4
3
2
1
[GND1A]
[59B]
Pole
Lamp
(BK)
1
[207A]
R
R
BK
R/BK
GY/V
[69B]
1
2
Pursuit
Flasher
Front GND
Stud
(Dirty)
GY/BN
R
2C
R/BK
[69A]
Battery - 15A
BN/GY
BE/GY
BE/GY
Police Stealth
Amber cap removed
when stealth switch
option is used
Start
Relay
2A
2D
[73A]
2
1
1G
3
5
1
2
87(5)
87A(4)
30(3)
85(2)
86(1)
Pursuit
Lamps
(W)
30
87
86
85
R/BK
BK/R
TN/GN
LGN/V
GY
Y/GN
BE/GY
W/BK
BK
LGN/R
3H
4G
4H
3G
R/BK
GN
R/BK
BK/GN
Spare - 30A
BK
To Rear Lighting
Figure A-12. 2008 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models, Main Harness without ABS (1 of 2)
4G
3
4
B
15A
D
E
15A
15A
86 30
31579-04
12VOC
87 86
G
J
86 30
31579-04
12VOC
87 86
H
C
15A
E
15A
G
15A
86 30
31579-04
12VOC
87 86
15A
15A
D
F
H
J
Figure A-12.
2008 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models,
Main Harness without ABS (1 of 2)
Figure A-12.
Main Harness without ABS (1 of 2)
et00092
Fuel Gauge
O
Y/W
1 2
[117B]
4
[77B]
R/GY
R
R/BK
BK
BK
D C B A
[160B]
[222B]
O/V
BK/GN
Turn Signal/
[30A] [30B]
(GY)
Module
[5B]
2
[142B]
BN/GY
LGN/BN
BK/GN
1 2 3
1
Ignition
Switch
[222A]
B+
Connector
R
[BATT]
R
[128B]
1 2 3
B
R
A
[142A]
R
9 10 1112 1314 15
Voltage
Regulator
R
Main Power 40 Amp
at Starter MAXIFUSE
Start
Solenoid
GN
1 2 3 4 5 6
[20B]
O
LGN/V
BN/GY
O/W
BK/GN
Y/W
1 2 3 4 5 6
[31A]
Optional
Security
Siren
Console Harness
Interconnect
Power
Signal
Ground
BN/GY
GY
LGN/V
TN
V
BN
W/BN
W/V
TN/GN
BK/R
LGN/BN
BK/GN
BK
R/BN
BN
BE
PK/BN
R/V
LGN/V
GY
R/BE
1
2
3
4
5
6
7
8
9
10
11
12
BK
BN
BE
BE
V
BK
Battery 1
Ignition 2
Serial Data 3
Neutral Switch 4
Left Turn Feed 5
Right Turn Feed 6
Clutch Switch 10
Alarm Signal 11
Ground 12
To ABS
Front Turn
Signals
V
W
GN/Y
BN
TN
O/GY
BK
TSM/TSSM/HFSM
R/GY
1D
Accessory - 15A
1C
1F
P & A - 15A
1E
O/W
GN/O
O/R
GY/V
BK
2
1
Right Hand
Control
[22B]
(BK)
R
[GND1]
4B
Fuel Pump - 15A
GY/V
BE/GY
GY/BN
W/BK
GN/O
RH GND
Stud
(Clean)
GN/R
GY/BK
O/V
BK/R
W/BN
W/BK
GY
R/BN
O/W
Left Hand
Control
[24B]
(GY)
30
87
86
85
3
5
1
2
System
Relay
BK/GN
[GND2]
1B
P & A - 2A
1A
1D
INSTRS - 15A
1C
1F
Ignition - 15A
1E
R/BK
O
R/BK
GY
V/PK
TN/BK
PK/BK
BK/GN
BK/R
Y/BK
W/V
W
BE
Y
O/W
R/BK
2D
Headlamp - 15A
2C
2F
Lights - 15A
2E
BE
[126A]
Lighting
Relay
BE
4B
ABS - 30 A
4A
R/V
C
15A
E
15A
2
15A
15A
3
86 30
31579-04
12VOC
87 86
D
1
[122]
1
PK/BN
O/W
1
2
BK
2B 30 3
3A 87 5
3B 86 1
R/BE
2A 85 2
Brake
Relay
4
A
15A
15A
B
A
O
1
Oil
[4A]
[67A]
Pressure
1 2 3 4
4
1
Neutral
[120B] Rear
Switch
Stop Light
Accessory
Accessory
[131]
Switch
Connector
Switch
[121]
BK
R/Y
BE
HDI Position
Lamp
GN/Y
TN
BK
Y/BK
BK
2
A
BN
O/W
V
Headlamp Fender
Tip Lamp
1
B
O/R
2
2
R/Y
O/V
O/R
R/Y
O
BK
1
[29B]
Horn
BK
1 2 3
[32A]
O/W
[38B]
BK
TN/BK
V/PK
O/W
1D
PK/BK
W
Y
BK
2F
1F
[126B]
R/BK
[24B]
To Siren
Amplifier
[72B]
[207B]
Y/GN
3D
4C
4D
3C
LGN/R
11
10
9
8
7
6
5
4
3
2
1
3
[207A]
4A
O/GY
BK
GN/R
1
BK
GY/BK
[22B]
9
8
7
6
5
4
3
2
1
[GND1A]
[59B]
Pole
Lamp
(BK)
3
R
BK
R/BK
3
1
R
O
LH GND
Stud
(Dirty)
GY/BN
[69B]
1
2
Pursuit
Flasher
BE/GY
BE/GY
R
2C
R/BK
[69A]
Battery - 15A
BN/GY
[73A]
2
1
Start
Relay
2A
2D
Police Stealth
Amber cap removed
when stealth switch
option is used
1G
3
5
1
2
87(5)
87A(4)
30(3)
85(2)
86(1)
Pursuit
Lamps
(W)
30
87
86
85
R/BK
BK/R
TN/GN
LGN/V
GY
Y/GN
BE/GY
W/BK
BK
LGN/R
3H
4G
4H
3G
R/BK
GN
R/BK
BK/GN
1 2 3
5 6 7
To Rear Lighting
3H
Spare - 15 A
3G
[7A]
4H
BK
Figure A-13. 2008 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models, Main Harness with ABS (1 of 2)
Spare - 30 A
4G
1
BK
2 86 30
31579-04
12VOC
3 87
86
4 30A
B
G
F
C
15A
E
15A
15A
15A
86 30
31579-04
12VOC
87 86
H
G
15A
15A
D
F
J
15A
H
J
Figure A-13.
Main Harness with ABS (1 of 2)
Figure A-13.
Main Harness with ABS (1 of 2)
Yellow Tubing
Ignition
Coil
Crank Pos.
Sensor
Front
Injector
[78A]
A B
A B
[90B]
[78B]
Power
Ion Sense
Coil Rear
Coil Front
BK
W
R
BK
W
R
A B C D
[83A]
[83B]
A B C D
[85A]
[85B]
[84A]
[80A]
A B
A B
A B
A B
[84B]
Y/GN
W/Y
[204B]
1 2 3 4 5 6
PK/Y
BK/W
ECM
[90A]
1 2 3 4 5 6
Y/GN
GN/GY
[91A]
(GY)
BK/GN
LGN/V
GY
1 2 3 4
[204A]
Y/GN
GY/BE
Y/BE
BE/O
Data Link
Connector
BK/GY
V/Y
R/W
BK/W
BE/GN
BN/O
Engine Temp
Sensor
Throttle Control
Actuator
TMAP
Sensor
Black Tubing
[211A]
[79A]
1 2
[80B]
1 2 3 4
1 2
6 5 4 3 2 1
1 2 3 4
[211B]
6 5 4 3 2 1
[79B]
R
BK
Rear
Injector
BN/V
BN/O
BN/R
BK/O
BK/PK
BK/W
Twist Grip
Sensor
R
W
BK
R
W
BK
BK/GY
LGN/Y
R/W
V/W
1 2 3 4 5 6
et00097
ACR
Purge Solenoid
Exhaust Actuator
Cruise/Set/Coast
Rear Injector
TMAP Sensor Input
Brake Switch
19
20
21
22
23
24
25
19
20
21
22
23
24
25
V/GY
GY/Y
V/O
BE/BK
GN/GY
V/W
R/BE
System Relay Enable
Front Injector
Twist Grip High
Twist Grip Low
27
28
29
30
27
28
29
30
GN/O
W/Y
BK/O
BK/PK
Ion Sense
Cruise Resume/Accelerate
Cruise Enable
Throttle Pos. Sensor 2
Throttle Pos Sensor 1
Exhaust Feedback
Twist Grip Sensor 2
Vehicle Speed Input
33
34
35
36
37
38
39
40
33
34
35
36
37
38
39
40
GY/BE
W/BE
R/GN
BN/R
BN/V
V/BE
V/Y
W/GN
Crank Position Sensor (-)
43
43
+BK
Rear O2 Sensor (Unheated)
46
46
PK/GN
5V Sensor Power 1
Engine Temperature
12 V Power
49
50
51
52
49
50
51
52
LGN/Y
BN/O
PK/Y
Y/GN
Rear Coil
Front Coil
53
54
53
54
Y/BE
BE/O
Jiffy Stand Sensor
56
56
GN/BN
Twist Grip Sensor 1
59
59
BE/GN
5V Sensor Ground 1
5V Sensor Ground 2
Crank Position Sensor (+)
Vehicle Speed Ground
61
62
63
64
61
62
63
64
BK/W
BK/GY
R
BK/Y
Front O 2 Sensor (Unheated)
66
66
PK/O
5V Sensor Power 2
Serial Data
68
69
68
69
R/W
LGN/V
12V Battery
12V Run/Stop Switch
71
72
71
72
BE/GY
W/BK
BE/GY
W/BK
Ground
73
73
BK/GN
BK
BE/BK
R/BE
GN/O
BK/GN
W/BE
R/GN
GY
Y/GN
Active
Exhaust
(HDI Only)
Purge
Solenoid
Front
O2 Sensor
1 2 3
1 2 3
Rear
O2 Sensor
Vehicle
Speed
Sensor
Jiffy Stand
Sensor
(HDI Only)
Figure A-14. 2008 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models, Main Harness (2 of 2)
[203FB]
1
2
Front
ACR
[203RB]
V/GY
[133B]
1 2
Y/GN
[65B]
BN/O
GN/BN
BK/GN
[137B]
V/GY
1 2
BN/O
W/GN
BK/Y
[138B]
PK/GN
BK/W
[95B]
B A
Y/GN
5 4 3 2 1
PK/O
BK/W
[179B]
GY/Y
Y/GN
LGN/R
V/BE
V/O
BK
LGN/R
Twisted
Pair
1
2
Rear
ACR
From Main Harness Page 1
LGN/V
Figure A-14.
Main Harness (2 of 2)
Figure A-14.
Main Harness (2 of 2)
TSM/TSSM/HFSM
Battery
Ignition
Serial Data
Neutral Switch
Turn Signal/
Turn Signal
Security
Module
1
2
3
4
1
2
3
4
BN/GY
GY
LGN/V
TN
Clutch Switch 10
9
10
TN/GN
BK/R
Ground 12
12
BK/GN
Stator
[77B] [77A]
[30A] [30B]
[47A]
[47B]
2
BK
[78A] [78B]
BK
ECM
1
DC
BK
BK
BK
AC
BK
BK
BK
Starting System
69
69
40 Amp
MAXIFUSE
Charging System
LGN/V
BK
Serial Data
[5B]
BK
BK
B
BK
BK
BK
BK
BK
R
Right Hand
Controls
BK
B
R
Battery
A
R
[5B]
Red
Band
A
R
W/BK
R
72
R
72
MAXIFUSE
40 Amp
R
12V Run/Stop Switch
[128A] [128B]
Red
Band
GN
BK
BK/GN
Powertrain
Grounds
BK
Battery
Start Switch
GY
W/BK
BK/R
[22B]
3
4
6
3
4
6
[33B] [33A]
Rear
GND 2
GY
W/BK
IGNITION SWITCH LEGEND
Front
GND 1
R/GY
R
R/BK
BK/R
3
2
1
3
2
1
R/GY
R
R/BK
C
B
A
A
B
I
[222B] [222A]
1F Ignition - 15A 1E
GY
7
8
7
8
Lighting
Relay
R/BK
BK/R
BK/GN
2D Battery- 15A
R
[126B]
R/BK
BK
R
Clutch Lockout Switch
[126A]
2C
BN/GY
R/GY
TN
13
13
TN
[21A]
5
[21B]
5 6
[20A] [20B]
(BK)
TN
BK
Left Hand
Controls
Neutral
TN
BK
B
GND 1A
R/GY
3H 30 3
GN
BK/R
4G 87 5
TN/GN
3G 85 2
4H 86 1
SWITCH
POSITION
Start
Relay
LH GND
Stud
(Dirty)
A
[131]
Neutral
Switch
Figure A-15. 2008 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models, Starting and Charging
"X" INDICATES CONTINUITY
BETWEEN LEAD WIRES
IN POSITION INDICATED
RED
LOCK
OFF
IGN
ACC
[64B]
[24A] [24B]
BK/R
BK
Ignition
Switch
86(1)
85(2)
30(3)
87A(4)
87(5)
[22A]
TN
GY
Front
Dirty
GND
Starter
Engine Off/Run Switch
TN
BK
et00015
X
X
X
X
RED/
GRAY
X
X
RED/
BLACK
X
Starter
Figure A-15.
Starting and Charging
Figure A-15.
Starting and Charging
Ignition 1 1
Databus 2 2
NC 3 3
Pursuit 4 4
Battery 5 5
Accessory 6 6
Ground 7 7
Abs Warn 8 8
NC 9 9
Cruise Active 10 10
NC 11 11
Cruise Enable 12 12
RPM x 100
Rear Lighting Harness
GN/R
BN/GY
O/W
BK
O/BN
8 7 6 5 4 3 2 1
[177B]
[39A]
1 2 3 4 5 6
Brown Tape
To Main
Harness
[31B]
Running
BK
V/BN
BE
BE
V/BN
BK
[31R]
Running
1
2
3
4
5
6
7 8 9 10 11 12
O/W
BN
BE
R/Y
V
BK
Fuel Gauge
BK
1 2 3 4
To Main
Harness
ABCD
Full: 39.5/27.5 OHMS
1/2: 118.0/97.0 OHMS
[141A] Empty: 260.0/240.0 OHMS
GY/BK
GY/BK
Fuel Pump Assembly In Tank
TN
O
Neutral
W
BK
High
Beam
V
BK
Left
Turn
[73B]
Hands Free Security
Module (HFSM)
From Main Harness
[94B]
Brake Light
Rear view of toggle
switch with keyway down
On
Off
Normally Closed
Common
Normally Open
BK
BK
Keyway Down
BK
BK
BK
BK
[67B]
1
Ignition
2
VSS/Serial Data Link
3
Neutral Switch
4
Left Turn Feed
5
Right Turn Feed
6
Right Turn Switch Input
7
Left Turn Switch Input
8
Start Relay Control
9
Clutch Switch
10
Alarm Signal
11
Ground
12
[19B]
V/BN
BK
1
2
1
2
[19A] [93A]
1
2
1
2
[18A]
Tail
HDI Only
Tail
DOM Only
[18B]
V/BN
BK
BK
BK
1
2
3
1
2
3
[45B] [45A]
BK
R/Y
Battery
BK
R/Y
O/W
BE
6 5 4 3 2 1
[30A]
4
3
2
1
4
3
2
1
From Main
Harness
[22B]
(GY)
1
2
3
4
5
6
7
8
9
10
11
12
From Main
Harness
[24B]
Clutch
Lockout Switch
Siren Off/Run
Switch
Headlamp Hi/Lo
Switch
Left
Directional
Horn/Siren Switch
Switch
V/BN
BK
For Turn Signal & Security Module
(TSM/TSSM)
1 23 4
PK/BK
TN/BK
Y/BK
BK
Right Rear
Directional
Lamp
2 1
To Main
Harness
[67A]
O/W
Y
BE
W
W/V
Y/BK
BK/R
Oil
Pressure
GN/Y
O
Fuel
Pump
O/GY
Y/W
BK
BK
[117A]
O
Y/W
[31D]
[24A]
Right
Turn
BN
BK
(BK)
1
2
3
4
5
6
7
8
9
Move Y/BK wire to cavity 11
when using Whelen siren
amplifier & ‘air horn’ function
Indicator
Lamps
S I
To
Main
Harness
1
2
3
4
5
6
[21B]
(BK)
Turn
Left
Pursuit
Lamp
(Red)
O/W
R/BE
GY
W/BK
W/BN
BK/R
O/V
GY/BK
GN/R
1 2 3 4 5 6 7 8
G
[73L]
[22A]
[94B]
Violet Tape
GY/BK
[7B]
Stoplamp Switch
From Main Harness
[21A]
From
Main
Harness
[31A]
BK
BE
V/BN
Left
Directional
and Running
Lamp
1 2 3 4 5 6
V
W
GN/Y
BN
TN
O
BK
BK
V/BN
BE
Ground
Tri p Switch
Fuel Level
Cruise Enable
Tri p Switch
Cruise Active
Turn
To
Main
Harness
Ignition
Databus
NC
NC
Battery
Accessory
[20B]
O/W
BN/GY
O
LGN/V
GN/R
BK
Tachometer Harness
GY/BK
Off/Aux
Pursuit Switch
Right Directional
Switch
Engine Off/
Run Switch
Starter Switch
From Main
Harness [7A]
1 2
Right
Directional
and Running
Lamp
Right Hand
Controls
O
LGN/V
BE
R/Y
BK
Right
Pursuit
Lamp
(Blue)
Speedometer
[108B]
V
O/W
BN
Tachometer
[73R]
O/BN
et00093
Left Hand
Controls
Taillamp
O/W
BE
[93A]
Fendertip Lamp (DOM)
License Plate Lamp (HDI)
[93B]
BK
BK
V/BN
BK
Left Rear
Directional
Lamp
Handlebar
Ground
BK
Triple
Clamp
Ground
Accessory Switch
Receive Antenna
1
1
Y/BK
Xmit Antenna A
2
2
O/Y
O/Y
1
Antenna ‘A’
Xmit Antenna B
3
3
BK
BK
2
Antenna ‘B’
Unused
4
4
[208A] [208B]
[209B] [209A]
Hands Free Antenna
Figure A-16. 2008 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models, Handlebar Switches, Indicator Lamps, Tail Lamp, Pursuit Lamps, Directional Lamps, Accessory/Spot Switch, Speedometer, Tachometer and HFSM Antenna
Figure A-16.
Handlebar Switches, Indicator Lamps,Tail Lamp, Pursuit Lamps,
Directional Lamps, Accessory/Spot Switch, Speedometer,
Tachometer and HFSM Antenna
Figure A-16.
Handlebar Switches, Indicator Lamps,Tail Lamp, Pursuit Lamps,
Directional Lamps, Accessory/Spot Switch, Speedometer,
Tachometer and HFSM Antenna
et00090
UPS 54C / UPS 64C
Right front
strobe bulb (blue)
Use terminals and terminal
housings supplied by Whelen
for connections at power supply
POWER SUPPLY
GN
BK
R
1 2 3
#22 Ga. wires supplied by Whelen
Route through spotlight stems
4 CONTROL INPUT
1-4
2-3
GND
+12VDC
H/L
"X" Indicates unterminated
strobe harness wires in fairing
cavity on FLHTP models or
headlight nacelle on FLHP
models
F
U
S
E
Existing pole lighting wire
located at left rear side of
motorcycle
BK
Left front
strobe bulb (red)
V
GN R
GN R
GN
Power down circuit
optional
R
R
BK
BK
W
W
V
W
Existing strobe
harness (routed
under tank)
Remove GY/BK wire from terminal
"X" of the pursuit flasher and terminate
it to W/GN wire of the strobe harness
GN
"XX" indicates
unterminated strobe
harness wires located
under left side cover
Ground to left ground
stud in front of battery
Connect to O/R
wire of ACC. fuse
located under left
side cover
O
O
Not used
W GN
GY BK
Cable color
XX XX
Stripe color
R
RED
BE
TN
TAN
BK
V
VIOLET
BN
W
GN
Y
WHITE
YELLOW
O
ORANGE
GY
PK
BLUE
BLACK
BROWN
GREEN
GRAY
PINK
W
BK
R
Pursuit flasher is located in
fairing on FLHTP models and
under left side cover on
FLHP models
Extra wire and terminals
may be required to connect
harness to power supply
Figure A-17. 2008 FLHTP, FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models, Optional Strobe System
Figure A-17.
2008 FLHTP, FLHP and FLHPE, DOMESTIC and INTERNATIONAL
Models, Optional Strobe System
Figure A-17.
2008 FLHTP, FLHP and FLHPE, DOMESTIC and INTERNATIONAL
Models, Optional Strobe System
APPENDIX B GLOSSARY
SUBJECT............................................................................................................................PAGE NO.
B.1 GLOSSARY..............................................................................................................................B-1
NOTES
GLOSSARY
B.1
ACRONYMS AND ABBREVIATIONS
Table B-1. Acronyms and Abbreviations
ACRONYM OR ABBREVIATION
DESCRIPTION
A
Amperes
AC
Alternating Current
ACC
Accessory
ACR
Automatic Compression Release
AGM
Absorbed Glass Mat (battery)
AMP
Ampere
AWG
American Wire Gauge
B+
Battery Voltage
BAS
Bank Angle Sensor
BTDC
Before Top Dead Center
C
Celsius (Centigrade)
CA
California
CAL
Calibration
CC
Cubic Centimeters
CCA
Cold Cranking Amps
CKP
Crankshaft Position
cm
Centimeter
DC
Direct Current
DLC
Data Link Connector
DOM
Domestic
DTC
Diagnostic Trouble Code
DVOM
Digital Volt Ohm Meter
ECM
Electronic Control Module
ECT
Engine Coolant Temperature
EEPROM
Electrically Erasable Programmable Read Only Memory
EFI
Electronic Fuel Injection
ET
Engine Temperature
EVAP
Evaporative Emissions Control System
F
Fahrenheit
ft-lbs
Foot-Pounds
fl oz.
Fluid Ounce
g
Gram
GAL
Gallon
GAWR
Gross Axle Weight Rating
GND
Ground (electrical)
GVWR
Gross Vehicle Weight Rating
HDI
Harley-Davidson International
H-DSSS
Harley-Davidson Smart Security System
HFSM
Hands Free Security Module
Hg
Mercury
IAC
Idle Air Control
2008 FLT Police Service: Appendix B Glossary B-1
DESCRIPTION
IAT
ID
Inside Diameter
IGN
Ignition Light/Key Switch
IM
Instrument Module
In.
Inch
INJ PW
Injector Pulse Width
in-lbs
Inch-Pounds
Kg
Kilogram
Km
Kilometer
kPa
Kilopascal
km/hr
Kilometers Per Hour
L
Liter
LCD
Liquid Crystal Display
LED
Light Emitting Diode
mA
Milliampere
MAP
Manifold Absolute Pressure
ml
milliliter
mm
millimeter
MPH
Miles Per Hour
ms
millisecond
Nm
Newton-Meter
N/A
Not Applicable
no.
Number
O2
Oxygen
OD
Outside Diameter
OEM
Original Equipment Manufacturer
oz
Ounce
P&A
Parts and Accessories
PN
Part Number
PSI
Pounds per Square Inch
RES
Reserve
RPM
Revolutions Per Minute
SCFH
Cubic Feet per Hour at Standard Conditions
TCA
TDC
Top Dead Center
TGS
Twist Grip Sensor
TP
Throttle Position
TMAP
Intake Air Temperature/Manifold Absolute Pressure
TSM
Turn Signal Module
TSSM
Turn Signal/Security Module
V
Volt
VAC
Volts of Alternating Current
VDC
Volts of Direct Current
B-2 2008 FLT Police Service: Appendix B Glossary
DESCRIPTION
VIN
Vehicle Identification Number
VSS
Vehicle Speed Sensor
2008 FLT Police Service: Appendix B Glossary B-3
NOTES
B-4 2008 FLT Police Service: Appendix B Glossary
Tools Used in This Manual
PART NUMBER
TOOL NAME
NOTES
CYLINDER COMPRESSION GAUGE
8.5 AUTOMATIC COMPRESSION RELEASE, Compression Test
HD-34633
AIR SUSPENSION PUMP AND GAUGE
2.5 AIR SEAT RESERVOIR, Installation
HD-39787A
RIVET TOOL
2.6 SADDLEBAGS, Hinges
HD-41404-B
TEST CONNECTOR KIT
8.5 AUTOMATIC COMPRESSION RELEASE, Diagnostics
HD-48498
ACR SOLENOID SOCKET
8.5 AUTOMATIC COMPRESSION RELEASE, Removal
HD-48637
BREAK-OUT BOX
8.5 AUTOMATIC COMPRESSION RELEASE, Diagnostics
HD-97087-65B
HOSE CLAMP PLIERS
3.3 OIL COOLER, Installation
TOOLS
HD-33223-1
I
NOTES
II TOOLS
TORQUE VALUE
NOTES
Air cleaner cover bracket screw
40-60 in-lbs
4.5-6.8 Nm
1.1 SCHEDULED MAINTENANCE, General
Air cleaner cover screw
36-60 in-lbs
4.1-6.8 Nm
Air reservoir bracket rear/top Phillips
screws
20-30 in-lbs
2.3-3.4 Nm
Air reservoir bracket rear/top Phillips
screws
20-30 in-lbs
2.3-3.4 Nm
Air spring set screw flange nuts
50-70 in-lbs
5.7-7.9 Nm
2.4 SEAT, Air Spring Replacement
Air spring top plate fasteners
36-60 in-lbs
4.1-6.8 Nm
Automatic compression release (ACR)
11-15 ft-lbs
14.9-20.3 Nm
8.5 AUTOMATIC COMPRESSION
RELEASE, Installation / Apply three equally spaced
dots of LOCTITE 246 THREADLOCKER MEDIUM
STRENGTH/HIGH TEMPERATURE around lower
third of threads
Battery cable terminal bolt (10 mm)
60-96 in-lbs
6.8-10.9 Nm
Battery hold-down clamp T40 TORX
screw
15-20 ft-lbs
20-27 Nm
Battery terminal bolt
60-96 in-lbs
6.8-10.9 Nm
Brake caliper pad pin
75-102 in-lbs
8.5.-11.5 Nm
Chrome frame tube cover Phillips screw
25-40 in-lbs
2.8-4.5 Nm
Clutch adjuster screw locknut
72-120 in-lbs
8.1-13.6 Nm
Clutch inspection cover
84-108 in-lbs
9.5-12.2 Nm
Engine oil drain plug
14-21 ft-lbs
19.0-28.5 Nm
Handlebar switch housing screw
35-45 in-lbs
4.0-5.1 Nm
Headlamp door Phillips screw
9-18 in-lbs
1.0-2.0 Nm
2.7 TACHOMETER BRACKET: FLHP/E, Installation
Headlamp housing Phillips screws
(FLHP/E)
9-18 in-lbs
1.0-2.0 Nm
Headlamp nacelle chrome strip flange
nut (FLHP/E)
15-20 in-lbs
1.7-2.3 Nm
Headlamp nacelle handlebar clamp
shroud Phillips screw (FLHP/E)
10-20 in-lbs
1.1-2.3 Nm
License plate bracket to bottom support
tube hex bolts
15-20 ft-lbs
20.3-27.1 Nm
Luggage rack to frame tube weldment
T40 TORX screws
15-20 ft-lbs
20.3-27.1 Nm
Master cylinder reservoir cover screws,
front
7-10 in-lbs
0.8-1.1 Nm
Master cylinder reservoir cover screws,
rear
12-15 in-lbs
1.4-1.7 Nm
Oil cooler adapter inspection cover
socket screws
90-120 in-lbs
10.2-13.6 Nm
3.3 OIL COOLER, Cleaning and Inspection / Use
Loctite Medium Strength Threadlocker 243 (blue).
Oil Cooler mounting bracket flange nuts
70-100 in-lbs
7.9-11.3 Nm
3.3 OIL COOLER, Installation
18-22 ft-lbs
24.4-29.8 Nm
3.3 OIL COOLER, Oil Cooler Adapter and Thermostat Replacement / Apply Loctite High Temperature/Medium Strength Threadlocker 246.
Primary chaincase drain plug
14-21 ft-lbs
19.0-28.5 Nm
Saddlebag lockset hex nut
25-35 in-lbs
2.8-4.0 Nm
2.6 SADDLEBAGS, Lockset
Saddlebag lockset jam nut
30-45 in-lbs
3.4-5.1 Nm
2.6 SADDLEBAGS, Lockset
Saddlebag mounting bracket hex bolt
60-96 in-lbs
6.8-10.8 Nm
Saddlebag tether T15 TORX screw
20-25 in-lbs
2.3-2.8 Nm
2.6 SADDLEBAGS, Tether / Use Loctite High
Strength Threadlocker 262 (red).
Oil filter adapter
III
TORQUE VALUES
FASTENER
FASTENER
Seat bracket mount fasteners
TORQUE VALUE
NOTES
15-20 ft-lbs
20.3-27.1 Nm
2.4 SEAT, Seat Bracket Mount Replacement
Seat fairing fastener
60-120 in-lbs
6.8-13.6 Nm
2.4 SEAT, Seat Installation
Seat fairing fastener
60-120 in-lbs
6.8-13.6 Nm
Seat hex screw, front
60-120 in-lbs
6.8-13.6 Nm
Seat pivot bolt and acorn nut
48-84 in-lbs
5.4-9.5 Nm
Seat stud flange nuts, rear
96-144 in-lbs
10.9-16.3 Nm
12-18 ft-lbs
16.3-24.4 Nm
55 in-lbs
6.2 Nm
72-108 in-lbs
8.1-12.2 Nm
Top caddy clamp screw
15-20 ft-lbs
20-27 Nm
Transmission drain plug
14-21 ft-lbs
19.0-28.5 Nm
Transmission filler plug/dipstick
25-75 in-lbs
2.8-8.5 Nm
Spark plugs
Spoke nipples
Tachometer bracket acorn nuts (FLHP/E)
IV TORQUE VALUES
A
Automatic Compression Release (ACR)
Compression Test. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
B
Bulb Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
C
Service Aids
Lubricants, Greases, Sealants. . . . . . . . . . . . . . . . . . 1-3
Service Bulletins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-I
Service Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-I
Service Wear Limits
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Specifications
Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Quick Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
SPX Kent-Moore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-II
System Fuses and Relays. . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
T
F
Glossary
Acronyms and Abbreviations. . . . . . . . . . . . . . . . . . . B-1
Tachometer Bracket: FLHP/E
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Trademarks
Harley-Davidson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-II
Referenced Products. . . . . . . . . . . . . . . . . . . . . . . . . . i-II
H
V
Handlebar Switches
Clutch Interlock Switch. . . . . . . . . . . . . . . . . . . . . . . . 8-7
Horn and Siren Yelp Switch. . . . . . . . . . . . . . . . . . . . 8-6
Pursuit and Auxiliary Switch. . . . . . . . . . . . . . . . . . . . 8-8
Vehicle Identification Number (VIN). . . . . . . . . . . . . . . . . . 2-2
Foreword
Important General Information. . . . . . . . . . . . . . . . . . . i-I
G
W
Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
L
Loctite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-II
M
INDEX
Maintenance
Periodic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
O
Oil Cooler
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . 3-4
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Oil Cooler Adapter and Thermostat Replacement. . . 3-4
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
R
Rear Marker Lights
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Marker Lights Replacement. . . . . . . . . . . . . . . . . . . . 8-5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
S
Saddlebag
Hinge Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Knob and Spring Latch. . . . . . . . . . . . . . . . . . . . . . . 2-12
Lockset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Lockset Catch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Spring Latch Bracket. . . . . . . . . . . . . . . . . . . . . . . . 2-13
Tether. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Tether Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Scheduled Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Seat
Air Reservoir Installation. . . . . . . . . . . . . . . . . . . . . . 2-9
Air Reservoir Removal. . . . . . . . . . . . . . . . . . . . . . . . 2-8
Air Spring Replacement. . . . . . . . . . . . . . . . . . . . . . . 2-6
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Seat Bracket Replacement. . . . . . . . . . . . . . . . . . . . . 2-7
Seat Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Seat Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
V
NOTES
VI INDEX
INSIDE BACK COVER GOES HERE
OUTSIDE BACK COVER GOES HERE

2008 FLT Police Models Service Manual Supplement

Transcription

Similar documents

April 15, 2007 - 610-0029 and 610

Bestop Duster Cover

Installation Guides- RoofTrac® Rail System, Bonding Grounding

Website page_GearUp Accessories Catalogue all Product

User Manual

gemtor harness positioning loops

Heretic C SPECS.ai - ECOSSE | Moto works

Corbeau A4 Seats

Heretic Ag SPECS.ai - ECOSSE | Moto works

1965 to 1973 9 Inch Pinion Snubber Brackets