Harley Davidson 2008 FLHTCUSE3 Model. Service Manual Supplement

Assembly

2-14

MAINTENANCE

Pull Wire Leads

2-14

Install Switch Housings

2-15

1.1 SCHEDULED MAINTENANCE

Install Wire Lead Terminals

2-16

General

1-1

Installing Handlebars

2-17

Clamp Handlebars to Risers

2-17

1.2 HYDRAULIC CLUTCH FLUID

Assemble Brake Controls

2-17

Assemble Clutch Controls

2-18

General

1-2

Returning to Service

2-19

Clutch Fluid Level

1-2

2.8 HANDGRIPS

1.3 BLEEDING CLUTCH FLUID LINE

General

2-20

Draining and Filling

1-3

Preparing Motorcycle

2-20

Bleed Clutch Master Cylinder

1-4

Separating Connectors

2-20

Bleed Fluid Line and Actuator

1-4

Replacing Handgrips

2-20

Return Motorcycle to Service

1-4

Remove Left Handgrip

2-20

1.4 ENGINE LUBRICATION SYSTEM

Install Left Handgrip

2-21

Remove Right Handgrip

2-22

General

1-5

Install Right Handgrip

2-22

Mating Connectors

2-23

1.5 CRITICAL FASTENERS

Returning to Service

2-23

Inspection

1-6

2.9 CLUTCH MASTER CYLINDER AND

CHASSIS

RESERVOIR

General

2-24

2.1 SPECIFICATIONS: CHASSIS

Removal

2-24

General

2-1

Disassembly

2-25

Assembly

2-26

2.2 VEHICLE IDENTIFICATION NUMBER

Installation

2-26

(V.I.N.)

2.10 CLUTCH HAND LEVER

Vehicle Identification Number (V.I.N.): FLHTCUSE3

2-2

Removal

2-28

General

2-2

Installation

2-28

Location

2-2

Abbreviated V.I.N

2-2

2.11 CLUTCH FLUID LINE

2.3 FOOTBOARDS AND CONTROLS

Removal

2-29

Installation

2-29

Rider Footboards

2-3

Removal

2-3

2.12 SEAT

Installation

2-4

Shift Levers

2-5

General

2-31

Replace Pegs

2-5

Removal

2-31

Replace Heel-Toe Shift Levers

2-5

Cleaning and Inspection

2-32

Rear Brake Pedal

2-6

Installation

2-32

Adjustable Passenger Footboards

2-6

Remove

2-6

2.13 RIDER BACKREST

Disassemble

2-6

General

2-33

Assemble

2-7

Removal

2-33

Install

2-8

Installation

2-33

Adjust

2-8

Adjusting Tilt Angle

2-33

Adjusting Front to Rear

2-33

2.4 HIGHWAY PEGS

2.14 TOUR-PAK

Disassembly

2-9

Removing Clamp

2-9

Removal

2-35

Installing Clamp

2-9

Installation

2-36

Assembly

2-10

2.15 SADDLEBAGS

2.5 FRONT AXLE COVERS

Removal

2-38

Replacement

2-11

Installation

2-38

2.6 LOWER TRIPLE CLAMP COVER

2.16 SADDLEBAGS LATCH

Replacement

2-12

Removal

2-39

Installation

2-39

2.7 HANDLEBARS

Removal

2-13

2.17 SADDLEBAG SUPPORTS

Disassembly

2-14

Removal

2-40

III

TABLE OF CONTENTS

Installation

2-40

FUEL SYSTEM

2.18 MUFFLER END CAP

4.1 AIR CLEANER COVER

Replacement

2-42

General

4-1

ENGINE

Removal

4-1

Installation

4-1

3.1 SPECIFICATIONS: ENGINE

ELECTRIC STARTER

General

3-1

Manufacturing Tolerances

3-1

5.1 SPECIFICATIONS: STARTER

3.2 SERVICE WEAR LIMITS

General

5-1

General

3-3

DRIVE

3.3 CYLINDER HEAD

General

3-5

6.1 SPECIFICATIONS: DRIVE

Removal

3-5

General

6-1

Determining Service

3-5

Disassembly

3-5

6.2 CLUTCH RELEASE BEARING AND

Cleaning

3-6

PUSHROD

Inspection

3-8

Removal

6-2

Cylinder Head

3-8

Installation

6-2

Valve Guides

3-8

Measure Release Plate Movement

6-2

Valves

3-8

Install Clutch Inspection Cover

6-2

Valve Springs

3-8

Tapered Keepers

3-8

TRANSMISSION

Valve Seats

3-8

Replacing Valve Guides

3-9

Removal

3-9

7.1 SPECIFICATIONS: TRANSMISSION

Installation

3-10

General

7-1

Assembly

3-13

Installation

3-15

7.2 CLUTCH RELEASE COVER

3.4 PISTONS

Removal

7-2

Installation

7-2

General

3-16

Fill and Bleed

7-3

Measuring Piston

3-16

7.3 SECONDARY CLUTCH ACTUATOR

3.5 BORING AND HONING CYLINDERS

Replacement

7-4

Inspection

3-17

Cylinder Bore Finished Size

3-18

ELECTRICAL

Piston Orientation

3-19

3.6 CRANKCASE ASSEMBLY

8.1 ELECTRICAL PROTECTION

General

3-20

Fuses and Relays

8-1

Assembly

3-20

8.2 BULB CHART

3.7 OIL COOLER

General

8-3

Operation

3-23

8.3 HEADLAMP

Removal

3-23

Installation

3-23

General

8-4

Removal

8-4

3.8 OIL COOLER ADAPTER

Installation

8-5

Removal

3-25

8.4 AUXILIARY LAMPS AND BRACKETS

Disassembly

3-25

Assembly

3-25

Removing Lamps

8-7

Installation

3-25

Removing Lamp Bracket

8-8

Installing Lamp Bracket

8-8

Installing Lamps

8-8

Mount Lamp

8-8

Final Assembly

8-8

IV TABLE OF CONTENTS

TABLE OF CONTENTS

Align Lamps

8-9

8.14 ADVANCED AUDIO AMPLIFIER

Replacing Bulb

8-10

General

8-33

Removal

8-33

8.5 FRONT TURN SIGNALS

Installation

8-33

Removal

8-12

Installation

8-12

8.15 GARAGE DOOR OPENER

Transmitter

8-35

8.6 HEATED SEAT

Removal

8-35

General

8-14

Installation

8-35

Controls

8-14

Receiver

8-35

Warm-Up

8-14

Installation

8-35

Diagnostics

8-14

Remote Control Garage Door Opener

8-36

Diagnostic Tips

8-14

FCC Notices

8-36

Diagnostic Notes

8-14

Program the Receiver and Transmitter

8-36

8.7 HEATED HANDGRIPS

8.16 AUTOMATIC COMPRESSION RELEASE

General

8-17

General

8-37

Diagnostics

8-17

Removal

8-37

Diagnostic Tips

8-17

Installation

8-37

Diagnostic Notes

8-17

Compression Test

8-38

Diagnostics

8-39

8.8 FAIRING CAP AND SWITCHES

Diagnostic Tips

8-39

Removal

8-21

Diagnostic Notes

8-39

Installation

8-21

8.17 TWIST GRIP SENSOR (TGS)

8.9 PASSENGER HEADSET RECEPTACLE

Removal

8-42

Repair

8-23

Installation

8-42

Replace Weather Cap

8-23

Reset TGS/ECM

8-43

8.10 XM SATELLITE RADIO

8.18 POWER LOCKS

General

8-24

General

8-44

XM Antenna

8-24

Power Lock Lockset: Tour-Pak

8-44

Remove

8-24

Removal

8-44

Installation

8-24

Installation

8-44

XM Module

8-25

Actuator: Tour-Pak

8-44

Removal

8-25

Removal

8-44

Installation

8-25

Assembly

8-45

Activation

8-25

Power Locks: Saddlebags

8-45

Removal

8-45

8.11 GPS NAVIGATION

Installation

8-45

General

8-27

Actuator: Saddlebag

8-46

GPS Antenna

8-27

Disassembly

8-46

Removal

8-27

Assembly

8-47

Installation

8-27

Power Lock Module

8-48

GPS Navigation Module

8-28

Removal

8-48

Removal

8-28

Installation

8-48

Installation

8-28

Power Lock Fob

8-48

General

8-48

8.12 RADIO SOFTWARE UPDATE

Entering Program Mode

8-48

Program Mode

8-48

General

8-29

Replacing the Battery

8-49

Opening Diag Test Display

8-29

Diagnostics

8-49

Identifying Version Number

8-29

Diagnostic Tips

8-49

Updating Receiver Software

8-29

Diagnostic Notes

8-49

Confirming Version Number

8-30

8.19 HARLEY-DAVIDSON SMART SECURITY

8.13 ADVANCED AUDIO RADIO

SYSTEM

Removing Advanced Audio

8-31

Installing Advanced Audio

8-31

General

8-52

HFSM

8-52

Removal

8-52

Installation

8-52

TABLE OF CONTENTS V

SCHEDULED MAINTENANCE

1.1

Table 1-1. In addition to this supplement, see the Touring

GENERAL

Models Service Manual for service procedures.

The scheduled maintenance table in this section lists the

maintenance requirements for the FLHTCUSE3. Refer to

Table 1-1. Scheduled Maintenance Intervals

ITEM SERVICED

PROCEDURE

1000 MI.

5000 MI.

10,000 MI.

15,000 MI.

20,000 MI.

25,000 MI.

NOTES

1600 KM

8000 KM

16,000 KM

24,000 KM

32,000 KM

40,000 KM

Engine oil and filter

Replace

Oil lines and brake system

Inspect for leaks

Air cleaner

Inspect, service as required

Tires

Check pressure, inspect

tread

Primary chaincase lubricant

Replace

ransmission lubricant

Replace

Clutch fluid

Replace

Rear belt and sprockets

Inspect, adjust belt

Rear wheel sprocket isol-

Inspect for wear

ators

Brake and clutch controls

Check, adjust and lubricate

Jiffy stand

Inspect and lubricate

Fuel lines and fittings

Inspect for leaks

Fuel tank filter

Replace

Brake fluid

Check levels and condition

Brake pads and discs

Inspect for wear

Spark plugs

Inspect

Replace

Electrical equipment and

Check operation

switches

Front fork oil

Replace

1, 2

Steering head bearings

Lubricate

Adjust

Air suspension

Check pressure, operation

and leakage

Windshield bushings (if

Inspect

applicable)

Fuel door, Tour-Pak, saddle-

Lubricate

hinges and latches

bags

Critical fasteners

Check tightness

Engine mounts and

Inspect

stablizers

Battery

Check battery and clean

connections

Exhaust system

Inspect

for leaks, cracks, and

loose or missing fasteners or

heat shields

Road test

Verify component and

system functions

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.

2008 FLHTCUSE3 Service: Maintenance 1-1

HYDRAULIC CLUTCH FLUID

1.2

GENERAL

The clutch is hydraulically actuated. The hand lever actuated

Do not allow dirt or debris to enter the master cylinder

master cylinder creates pressure in the clutch fluid line that

reservoir. Dirt or debris in the reservoir can cause improper

activates a secondary clutch actuator mounted in the clutch

operation and equipment damage. (00205c)

release cover. The secondary clutch actuator piston extends

and contacts a pushrod to disengage the clutch.

1. Stand motorcycle upright. Turn handlebars to level reser-

voir.

2. Remove two screws, clutch master cylinder/reservoir cover

and cover gasket.

D.O.T. 4 hydraulic brake fluid is used in the hydraulic

clutch. Do not use other types of fluids as they are not

NOTE

compatible and could cause equipment damage. (00353a)

Clutch fluid volume in reservoir actually increases with clutch

wear. Do NOT overfill reservoir.

3. See Figure 1-1. If fluid level is below FILL LEVEL on ledge

D.O.T. 4 brake fluid will damage painted and body panel

in reservoir, add D.O.T. 4 HYDRAULIC BRAKE FLUID

surfaces it comes in contact with. Always use caution and

(Part No. 99953-99A) to raise fluid level. Do not exceed

protect surfaces from spills whenever brake work is per-

FILL LEVEL.

formed. Failure to comply can result in cosmetic damage.

4. Carefully place cover gasket and cover on clutch master

(00239b)

cylinder/reservoir.

•

Do not wipe any spilled brake fluid off of finished surfaces.

5. Secure cover with two screws. Tighten screws to 6-8 in-

Always flush the affected components with water (not

lbs (0.7-0.9 Nm).

soapy).

sm01748

Direct contact of D.O.T. 4 brake fluid with eyes can

cause

irritation. Avoid eye contact. In case of eye contact flush

with large amounts of water and

get medical attention.

Swallowing large amounts of D.O.T. 4 brake fluid can

cause

digestive discomfort. If swallowed, obtain medical

atten-

tion. Use in well ventilated area. KEEP OUT OF REACH OF

CHILDREN. (00240a)

CLUTCH FLUID LEVEL

Even though a clear sight glass in the reservoir cover indicates

low clutch fluid, remove the reservoir cover to check fluid level.

Figure 1-1. Fill Level (Reservoir Cover Removed)

1-2 2008 FLHTCUSE3 Service: Maintenance

BLEEDING CLUTCH FLUID LINE

1.3

9. Fill clutch master cylinder/reservoir with D.O.T.

DRAINING AND FILLING

HYDRAULIC BRAKE FLUID (Part No. 99953-99A). Initial

fluid level should not exceed FILL LEVEL with reservoir

in a level position.

Be sure no clutch fluid gets on tires, wheels or brakes

NOTE

when adding fluid. Traction can be adversely affected,

The shelf life of a bottle of unopened D.O.T. 4 HYDRAULIC

which could result in loss of control and death or serious

BRAKE FLUID is one year. The shelf life of an uncontaminated

injury. (00294a)

bottle that has been resealed is one week.

10. Bleed master cylinder. See 1.3 BLEEDING CLUTCH

FLUID LINE, Bleed Clutch Master Cylinder.

Direct contact of D.O.T. 4 brake fluid with eyes can cause

11. Bleed clutch fluid line and secondary actuator. See

irritation. Avoid eye contact. In case of eye contact flush

1.3 BLEEDING CLUTCH FLUID LINE, Bleed Fluid Line

with large amounts of water and get medical attention.

and Actuator.

Swallowing large amounts of D.O.T. 4 brake fluid can cause

digestive discomfort. If swallowed, obtain medical atten-

tion. Use in well ventilated area. KEEP OUT OF REACH OF

sm03946

CHILDREN. (00240a)

D.O.T. 4 brake fluid will damage painted and body panel

surfaces it comes in contact with. Always use caution and

protect surfaces from spills whenever brake work is per-

formed. Failure to comply can result in cosmetic damage.

(00239b)

•

Do not wipe any spilled brake fluid off of finished surfaces.

Always flush the affected components with water (not

soapy).

Figure 1-2. Actuator Bleeder Valve

Do not allow dirt or debris to enter the master cylinder

reservoir. Dirt or debris in the reservoir can cause improper

operation and equipment damage. (00205c)

sm03947

1. Cover exhaust with towel and place a suitable pan under

clutch release cover to catch excess clutch fluid.

2. See Figure 1-2. Remove plastic cap and loosen bleeder

valve.

3. Run hose from bleeder valve to pan.

4. Loosen the clutch master cylinder/reservoir cover.

5. Allow clutch fluid to drain into pan.

6. See Figure 1-3. Remove flare nut (1) on outside of the

clutch release cover. Discard o-ring and drain fluid line (2)

into pan.

NOTE

Dispose of clutch fluid in accordance with local regulations.

7. Hand tighten valve and replace cap.

1. Flare nut

8. Install clutch line flare nut with a new o-ring and tighten

2. Clutch fluid line

to 72-120 in-lbs (8.1-13.6 Nm).

Figure 1-3. Clutch Fluid Line and Flare Nut

NOTE

When filling an empty clutch fluid line, a Snap-on Basic Vacuum

Brake Bleeder with a fitting that mates to the secondary actu-

ator bleeder valve can be used to initially draw the fluid down

the clutch line.

2008 FLHTCUSE3 Service: Maintenance 1-3

4. Fill reservoir to FILL LEVEL and repeat the previous step

BLEED CLUTCH MASTER CYLINDER

three times or more until only a steady flow of clutch fluid

NOTE

escapes banjo fitting and fluid level in reservoir is at FILL

Clutch fluid volume in reservoir actually increases with clutch

LEVEL with motorcycle in an upright position.

wear. Do NOT overfill clutch reservoir.

BLEED FLUID LINE AND ACTUATOR

1. Stand motorcycle upright. Turn handlebars to level reser-

1. While holding reservoir cover in place:

voir.

a. Pump clutch hand lever 5 times.

2. Add D.O.T. 4 HYDRAULIC BRAKE FLUID (Part No.

99953-99A) to clutch master cylinder/reservoir. Initial fluid

b. Hold clutch hand lever against handlebar.

level should not exceed FILL LEVEL with reservoir in a

c. Run hose from bleeder valve to suitable container.

level position.

d. Loosen actuator bleeder valve.

NOTE

e. Watch bleeder valve for air bubbles.

The shelf life of a bottle of unopened D.O.T. 4 HYDRAULIC

BRAKE FLUID is one year. The shelf life of an uncontaminated

Tighten bleeder valve.

bottle that has been resealed is one week.

g. Release clutch hand lever.

NOTE

Clutch fluid volume in reservoir actually increases with clutch

D.O.T. 4 brake fluid will damage painted and body panel

wear. Do NOT overfill clutch reservoir.

surfaces it comes in contact with. Always use caution and

protect surfaces from spills whenever brake work is per-

2. With reservoir level, fill reservoir to FILL LEVEL and repeat

formed. Failure to comply can result in cosmetic damage.

the previous step three times or more until only a steady

(00239b)

flow of clutch fluid escapes bleeder valve and fluid level

in reservoir is at FILL LEVEL with motorcycle in an upright

•

Do not wipe any spilled brake fluid off of finished surfaces.

position.

Always flush the affected components with water (not

soapy).

RETURN MOTORCYCLE TO SERVICE

NOTE

1. Test pressure by squeezing clutch hand lever.

Loosen banjo bolt only enough to allow air bubbles to escape.

2. Tighten fasteners as follows:

Clutch fluid under pressure can squirt a steady stream several

a. Clutch master

cylinder banjo bolt to 12.5-14.5 ft-

feet.

lbs (16.9-19.7 Nm).

3. While holding reservoir cover in place:

b. Clutch line flare nut to 72-120 in-lbs (8.1-13.6 Nm).

a. Pump clutch hand lever 5 times.

c. Actuator bleeder valve to 12-15 in-lbs (1.4-1.7 Nm).

b. Hold clutch hand lever against handlebar.

d. Reservoir cover screws to 6-8 in-lbs (0.7-0.9 Nm).

c. Hold shop towel under fitting and loosen master cyl-

inder banjo bolt.

3. Remove hose from bleeder valve and replace protective

cap.

d. Watch banjo fitting for air bubbles.

4. Test ride motorcycle. Incorrect pressure or fluid level can

e. Retighten banjo fitting.

cause:

Release hand lever.

a. Dragging clutch.

b. Hard shifting.

1-4 2008 FLHTCUSE3 Service: Maintenance

ENGINE LUBRICATION SYSTEM

1.4

GENERAL

The engine of this model is initially filled with Screamin' Eagle

Do not switch lubricant brands indiscriminately because

SYN3 Synthetic Motorcycle Lubricant.

some lubricants interact chemically when mixed. Use of

If oil needs to be added to the engine to bring the fill level to

inferior lubricants can damage the engine. (00184a)

FULL on the dipstick and SYN3 is not available, the first choice

If it is necessary to add oil and the recommended Harley-

would be to add H-D 360 SAE 20W50 to the SYN3 for engine

Davidson lubricant is not available, use an oil certified for diesel

lubrication. Although H-D 360 is compatible with SYN3, we

engines.

suggest the mixture of the fluids be changed as soon as pos-

sible.

At the first opportunity, see a Harley-Davidson dealer to change

back to 100 percent Harley-Davidson oil.

If H-D 360 is not available, the second choice would be to add

an acceptable diesel engine oil. We again suggest the mixture

Acceptable diesel engine oil designations include:

of the fluids be changed as soon as possible. DO NOT add

•

CF-4

diesel engine oil to the primary chaincase or transmission.

•

CG-4

Refer to Table 1-2. To switch lubricant to H-D 360, completely

drain the SYN3 before filling with H-D 360. A residual amount

•

CH-4

of fluid will remain. It is not required to flush out the residual

•

CI-4

fluid.

The preferred viscosities for the diesel engine oils, in des-

cending order are:

•

20W50

Prolonged or repeated contact with used motor oil may

be harmful to skin and could cause skin cancer. Promptly

•

15W40

wash affected areas with soap and water. (00358b)

•

10W40

If swallowed, do not induce vomiting. Contact a physician

immediately. In case of contact with eyes, immediateley

flush with water. Contact a physician if irritation persists.

(00357b)

Table 1-2. Recommended Oil Grades

HARLEY-

VISCOSITY

HARLEY-

LOWEST

COLD

DAVIDSON TYPE

DAVIDSON

AMBIENT

WEATHER

RATING

TEMPERATURE

STARTS

BELOW

50°F (10°C)

Screamin' Eagle® SYN3 Synthetic Motorcycle

SAE 20W50

HD 360

Above 40°F (4°C)

Excellent

Lubricant

H.D.

Multi-Grade

SAE 10W40

HD 360

Below 40°F (4°C)

Excellent

H.D.

Multi-Grade

SAE 20W50

HD 360

Above 40°F (4°C)

Good

H.D.

Regular Heavy

SAE 50

HD 360

Above 60°F (16°C)

Poor

H.D.

Extra Heavy

SAE 60

HD 360

Above 80°F (27°C)

Poor

2008 FLHTCUSE3 Service: Maintenance 1-5

CRITICAL FASTENERS

1.5

Refer to Table 1-3. Tighten all critical fasteners, except head

INSPECTION

bolts, to service manual specifications. Replace any damaged

Inspect critical fasteners, except head bolts:

or missing hardware.

Table 1-3. Critical Fasteners: 2008 Touring Models

SYSTEM

FASTENER

TORQUE

Axle

Front axle nut

60-65 ft-lbs

81.3-88.1 Nm

Rear axle cone nut

95-105 ft-lbs

129-142 Nm

Brakes

Banjo

bolt, rear master cylinder

12.5-14.5 ft-lbs

16.9-19.7 Nm

Banjo

bolt, front master cylinder

14.5-16.0 ft-lbs

19.7-21.7 Nm

Banjo bolts, ABS housing

14.5-22.0 ft-lbs

19.7-29.8 Nm

Banjo bolt, brake caliper

17-19 ft-lbs

23.1-25.8 Nm

Brake bleeders

80-100 in-lbs

9.1-11.3 Nm

Front brake disc mounting

16-24 ft-lbs

21.7-32.5 Nm

screws

Front brake caliper mounting

28-38 ft-lbs

38.0-51.6 Nm

bolts

Rear brake caliper mounting

43-48 ft-lbs

58.3-65.1 Nm

bolts

Brake caliper pad pins

75-102 in-lbs

8.5-11.5 Nm

Rear brake disc mounting

30-45 ft-lbs

40.7-61.1 Nm

screws

Rear

master cylinder mounting

10.5-12.5 ft-lbs

14.2-16.9 Nm

nut

Reservoir cover screws, rear

12-15 in-lbs

1.4-1.7 Nm

master cylinder

Reservoir cover screws, front

8-10 in-lbs

0.9-1.1 Nm

master cylinder

Front forks

Axle holder nuts

132-180 in-lbs

14.9-20.4 Nm

Hand controls

Clutch master cyl-

72-84 in-lbs

8.1-9.5 Nm

inder/handlebar clamp

Brake master cyl-

72-84 in-lbs

8.1-9.5 Nm

inder/handlebar clamp screws

Upper/lower switch housing

35-45 in-lbs

4.0-5.1 Nm

screws

Handlebars

Lower clamp (riser) bolts

30-40 ft-lbs

40.7-54.3 Nm

Rear fork pivot shaft

Locknut

43-47 ft-lbs

58.3-63.7 Nm

Swingarm bracket bolts

30-40 ft-lbs

40.7-54.2 Nm

1-6 2008 FLHTCUSE3 Service: Maintenance

Table 1-3. Critical Fasteners: 2008 Touring Models

SYSTEM

FASTENER

TORQUE

Engine

Engine mounting bracket to

30-35 ft-lbs

40.7-47.5 Nm

cylinder head bolts

op stabilizer link to top engine

18-22 ft-lbs

24.4-29.9 Nm

mounting bracket bolt

op stabilizer link to frame

18-22 ft-lbs

24.4-29.9 Nm

weldment bolt

Front stabilizer link to frame

18-22 ft-lbs

24.4-29.9 Nm

weldment bolt

Front stabilizer link to front

18-22 ft-lbs

24.4-29.9 Nm

engine mounting bracket bolt

Center front engine mounting

15-20 ft-lbs

20.3-27.1 Nm

bracket to rubber mount bolt

Front engine mount to frame

15-20 ft-lbs

20.4-27.1 Nm

crossmember bolts

Engine

to front engine mounting

36-40 ft-lbs

48.9-54.2 Nm

bracket bolts

Engine to transmission bolts

30-35 ft-lbs

40.7-47.5 Nm

Clutch

Banjo bolt

12.5-14.5 ft-lbs

16.9-19.7 Nm

Clutch fluid line flare nut

72-120 in-lbs

8.1-13.6 Nm

Secondary actuator bleeder

12-15 in-lbs

1.4-1.7 Nm

valve

Reservoir cover screws

6-8 in-lbs

0.7-0.9 Nm

2008 FLHTCUSE3 Service: Maintenance 1-7

SPECIFICATIONS: CHASSIS

2.1

GENERAL

Table 2-2. Weight

Table 2-1. Dimensions: 2008 FLHTCUSE3

ITEM

LB.

Dry

Weight*

864

392

ITEM

IN.

GVWR

1259

572

Wheel base

63.5

1613

GAWR - Front

500

227

Overall length

97.57

2478

GAWR - Rear

827

375

Overall width

38.2

970

* As shipped from the factory

Road clearance

4.9

124.5

Overall height

57.1

1450

Table 2-3. Capacities

Saddle height*

28.7

729

ITEM

U.S.

LITERS

*With 180 lb. (81.7 kg) rider.

Fuel tank (total)

6 gal

22.7

Oil tank with filter

4.0 quarts

3.78 L

ransmission (approximate)

32 fl.

oz.

946 mL

Primary (drained)

38 fl.

oz.

1100 mL

Primary (cover removed)

45 fl.

oz.

1330 mL

Front Fork*

VOLUME

HEIGHT

IN.

10.8

319

5.59

142

* Front fork is functionally identical to FLHTCU. See Touring

Models Service Manual for appropriate front fork service

procedures.

NOTE

Gross Vehicle Weight Rating (GVWR) (maximum allowable

loaded vehicle weight) and corresponding Gross Axle Weight

Ratings (GAWR) are given on a label located on the inside of

the right front frame downtube.

2008 FLHTCUSE3 Service: Chassis 2-1

VEHICLE IDENTIFICATION NUMBER (V.I.N.)

2.2

bearing the V.I.N. code is also affixed to the left side of the

VEHICLE IDENTIFICATION NUMBER (V.I.N.):

steering head.

FLHTCUSE3

Abbreviated V.I.N.

General

An abbreviated V.I.N. is stamped on the left side of the crank-

See Figure 2-1. A unique 17-digit serial or Vehicle Identification

case below the engine cylinders.

Number (V.I.N.) is found on each motorcycle. For a description

of each item in the V.I.N., refer to Table 2-4.

Example: PR88111000

See Figure 2-1 for the complete V.I.N. as it appears on the

Location

steering head.

The full 17-digit serial or Vehicle Identification Number (V.I.N.)

NOTE

is stamped on the right side of the frame backbone at the rear

of the steering head under the main wiring harness. A label

Always give the full 17-digit Vehicle Identification Number when

ordering parts or making any inquiry about your motorcycle.

om00927

1 HD 1 PR 8 1 7 8 Y 111000

Figure 2-1. Typical Harley-Davidson V.I.N.: 2008 FLHTCUSE3 Models

Table 2-4. Harley-Davidson V.I.N. Breakdown: 2008 FLHTCUSE3 Models

POSITION

DESCRIPTION

POSSIBLE VALUES

Market designation

1=Originally manufactured for sale within the United States

5=Originally manufactured for sale outside of the United States

Manufacturer

HD=Harley-Davidson

Motorcycle type

1=Heavyweight motorcycle (901 cc or larger)

Model

PR=FLHTCUSE3 Screamin' Eagle^® Ultra Classic^® Electra Glide^®

PR=FLHTCU3-CVO (Japan only)

Engine type

4=96 cu. in. (1584 cc) air cooled, fuel injected

8=110 cu. in. (1800 cc) air cooled, fuel injected

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

.I.N. check digit

Can be 0-9 or X

Model year

8=2008

Assembly plant

Y=York, PA U.S.A.

Sequential number

Varies

2-2 2008 FLHTCUSE3 Service: Chassis

FOOTBOARDS AND CONTROLS

2.3

RIDER FOOTBOARDS

sm03952

Removal

NOTES

•

Unless the footboards are being replaced, they do not

have to be removed from footboard brackets.

•

See Figure 2-2. The right and left footboard frame mounts

allow a small variance in height and angle of footboards.

If footboard brackets are to be removed, note the position

in the adjustment holes in the frame mounts. Reinstall

footboard brackets in same positions.

1. Position motorcycle upright on a lift or jack stand so that

the motorcycle is not resting on jiffy stand.

2. See Figure 2-3. With footboards in up position, use a

screwdriver to work cover rubber collars out through foot-

boards.

3. See Figure 2-4. Remove front and rear footboard pivot

bolts (3) and nuts (4) and remove footboards.

Figure 2-2. Footboard Position Adjustment Holes

4. Remove fasteners (12), lockwasher (8) and left rear foot-

board bracket (14).

NOTE

sm03953

Fasteners for left rear bracket thread through the jiffy stand

bracket.

5. Remove screw (7), lockwasher

(8), washer (9) and left

front footboard bracket (13).

6. Remove screws (7), lockwashers (8), washers (9) and

both front (10) and rear (11) right footboard brackets.

Figure 2-3. Footboard Insert Rubber Collars

2008 FLHTCUSE3 Service: Chassis 2-3

sm03954

1. Footboard insert (RH)

8. Lockwasher (5)

2. Footboard insert (LH)

9. Washer (3)

3. Pivot bolt (4)

10. Front support bracket (RH)

4. Locknut (4)

11. Rear support bracket (RH)

5. Footboard bottom (RH)

12. Fastener (2)

6. Footboard bottom (LH)

13. Front support bracket (LH)

7. Screw (3)

14. Rear support bracket (LH)

Figure 2-4. Rider Footboards

4. Tighten both left rear footboard bracket fasteners to 15-

Installation

20 ft-lbs (21-27 Nm).

NOTE

5. Install left footboard bottom assembly onto footboard

Avoid contacting chrome surfaces with abrasive materials

brackets. Install and tighten pivot bolts and locknuts to

(stones, sand, etc.) as damage will result.

60-80 in-lbs (6.8-9.0 Nm).

1. Install left front footboard bracket with washer, lockwasher

6. Tighten left front footboard bracket cap screw to 30-35 ft-

and screw. Tighten screw finger-tight.

lbs (41-47 Nm).

2. Install fastener and lock washer through the left rear foot-

7. Install right footboard brackets with washers, lockwashers,

board bracket through the jiffy stand bracket into the boss

and cap screws. Tighten screws finger-tight.

in the frame.

8. Install right footboard bottom assembly onto footboard

3. Install fastener and lockwasher from the inside of the frame

brackets. Install and tighten pivot bolts and locknuts to

through the jiffy stand bracket and into the left rear foot-

60-80 in-lbs (6.8-9.0 Nm).

board bracket.

2-4 2008 FLHTCUSE3 Service: Chassis

9. Tighten right footboard bracket cap screws to 30-35 ft-

sm03963

lbs (41-47 Nm).

10. Moisten footboard cover rubber collars with soapy water.

11. With footboard bottom in up position, hold new footboard

insert assembly in position.

12. From underside of footboard use a pliers to pull each

rubber collar through footboard hole.

SHIFT LEVERS

Replace Pegs

1. See Figure 2-5. Remove the fastener and the shift lever

peg.

2. See Figure 2-6. Assemble chrome cover (2) over rubber

pad (1).

3. Insert sleeve (4) and fasten to shift lever with fastener (3)

and lockwasher (5).

1. Rubber pad

4. Rotate pegs for rider posture and tighten Torx fastener to

2. Chrome cover

14-16 ft-lbs (19-21 Nm).

3. Fastener

4. Sleeve

5. Lockwasher

sm04242

Figure 2-6. Shift Lever Peg

Replace Heel-Toe Shift Levers

1. See Figure 2-8. Loosen and remove Allen head clamp

bolts.

2. Pull shift levers off splined shaft.

3. Position shift levers

on splined shaft for rider posture.

4. Install and tighten clamp bolts to 18-22 ft-lbs (25-29 Nm).

sm04244

Figure 2-5. Shift Lever Peg

Figure 2-7. Shift Levers

2008 FLHTCUSE3 Service: Chassis 2-5

sm03964

sm03962

1. Screw (2)

2. Chrome cover

3. Rubber pad

Figure 2-8. Heel-Toe Shift Lever Clamp Bolts

4. Metal backing plate

5. Acorn nut

6. Offset washer

REAR BRAKE PEDAL

7. Fastener

See Figure 2-9. Remove screws (1), brake pedal cover

8. Foot brake lever

(2) and pad (3) from metal backing plate (4).

Figure 2-9. Rear Brake Pedal

Remove acorn nut (5), offset washer (6), metal backing

plate and fastener (7) from foot brake lever (8).

ADJUSTABLE PASSENGER FOOTBOARDS

Install metal backing plate to foot brake lever. Secure with

offset washer and acorn nut. Tighten nut to 25-29 ft-

Remove

lbs (33.9-39.4 Nm).

1. See Figure 2-10. Remove the upper (1) adjustment bolt,

Assemble chrome cover and rubber pad to metal backing

wave spring and the footboard assembly.

plate. Secure with screws. Tighten to 20-22 in-lbs (2.3-

2. Remove the lower adjustment bolt (3), wave spring and

2.5 Nm).

the rotating arm (2).

3. Remove screw and lockwasher to remove footboard

bracket from rear fork pivot bracket.

Disassemble

1. See Figure 2-11. Pivot support 90° to access and back

set screw out of insert.

2. Pull the insert out of the footboard.

3. Press the pivot pins into the center cavity and remove.

NOTE

With the support and the footboard base at 90°, squeeze the

support against the footboard to release tension on the pins.

It maybe necessary to tap the pins with a brass drift.

4. Retain ball and spring from hole in support.

2-6 2008 FLHTCUSE3 Service: Chassis

4. See Figure 2-13. Release the support and footboard to

sm03955

hold the pins centered in the lugs of the footboard.

5. See Figure 2-14. With soapy water, moisten rubber beads

(1) and rubber sockets (2) on new insert.

6. Position in footboard and press on insert until beads have

engaged footboard pins and footboard pins have engaged

insert sockets.

sm03957

1. Upper adjustment bolt

2. Rotating arm

3. Lower adjustment bolt

Figure 2-10. Passenger Footboard Adjustment Bolts

sm03956

1. Spring

2. Hole

3. Ball

Figure 2-12.

Support and Footboard

sm03958

Figure 2-11. Insert Set Screw

Assemble

1. See Figure 2-12. Place spring (1) into hole (2) in support

and place ball (3) on top of spring.

2. Orient the support to the footboard to fit the rotating arm.

Mate the support to the floorboard to capture the ball and

Figure 2-13. Centered Pin

spring.

3. Install pivot pins from the outboard side. Center the pins

in lugs of footboard.

NOTE

To slide the pins in the lugs, squeeze the support against the

footboard to compress the spring and relieve the tension on

the pins. It maybe necessary to tap the pins in place with a

brass drift.

2008 FLHTCUSE3 Service: Chassis 2-7

NOTE

sm03961

Passenger footboards can be installed in one of three positions.

To move footboards to a new position, remove plastic plugs

from holes in rear fork pivot bracket as necessary.

2. Install screw and lockwasher. Tighten to 30-35 ft-lbs (41-

47 Nm).

3. Install rotating arm and lower adjustment bolt with wave

spring.

4. Install footboard assembly with upper adjustment bolt and

wave spring.

Adjust

1. Raise the footboard and loosen the lower adjustment bolt

enough to rotate the rotating arm. Rotate arm to desired

footboard height.

NOTE

Passenger footboards may adjusted to one of five positions.

2. Tighten lower adjustment bolt to 25-30 ft-lbs (34-40 Nm).

1. Rubber beads

3. Loosen upper adjustment bolt enough to allow footboard

2. Rubber sockets

mount to be rotated.

Figure 2-14. Footboard and New Insert

NOTE

The horizontal position of tilt of the footboard may be further

adjusted for passenger comfort.

Install

4. Move footboard mount to desired footboard horizontal

1. Insert locating pin of footboard bracket into hole in rear

position or tilt.

fork pivot bracket.

5. Tighten upper adjustment bolt to 25-30 ft-lbs (34-40 Nm).

2-8 2008 FLHTCUSE3 Service: Chassis

Harley Davidson 2008 FLHTCUSE3 Model. Service Manual Supplement - page 1