Harley Davidson 2008 FLHTCUSE3 Model. Service Manual Supplement

HIGHWAY PEGS

2.4

DISASSEMBLY

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1. See Figure 2-15. Remove the end screw (4) and slide the

chrome housing (5) off the mounting peg (6).

2. Push the rubber pad (7) and the bushing (8) straight out

of the chrome housing.

3. Remove the Allen head screw (9), washer (10) and the

decorative nut (11).

4. Remove the mounting peg and the spring washer (12).

Save the spring washer.

REMOVING CLAMP

1. Remove the Allen head clamp screws (1).

2. Separate the clamp bracket (2) from the mount bracket

(3) to remove the highway peg from the engine guard.

1. Allen head clamp screws

2. Clamp bracket

3. Mount bracket

4. End screw

5. Chrome housing

6. Mounting peg

7. Rubber pad

8. Bushing

9. Allen head screw

10. Washer

11. Nut

12. Spring washer

Figure 2-15. Highway Peg

INSTALLING CLAMP

1. See Figure 2-16. Use a grease pencil to draw a line (1)

on engine guard 6.5 in. (165 mm) from top of upper rail.

2. Clamp the brackets to the engine guard just below the line

with the brackets at a 25° (2).

3. Tighten the clamp screws to 14 ft-lbs (19 Nm).

4. Clean off grease pencil mark.

2008 FLHTCUSE3 Service: Chassis 2-9

NOTES

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•

See Figure 2-17. Match the flair (1) of the clamp bracket

to the bevel (2) of the mount bracket.

•

Orient the highway pegs so that he button head Allen head

screw and the two Allen head bracket fasteners face for-

ward and the decorative nut faces the rider.

•

Do not position the highway pegs so that the mounting

brackets contact the fairing lowers.

ASSEMBLY

1. Apply LOCTITE 243 THREADLOCKER (blue) to the end

threads of the Allen head screw.

2. With the square edge of the spring washer facing the slot,

hold the spring washer to the pivot hole of the mounting

peg.

3. Orient the round edge of the pivot flat upward and install

with the Allen head screw, washer and nut. Tighten to 14-

19 ft-lbs (19-25 Nm).

4. Slip the bushing into the hole in the rubber pad.

40^o

5. Fit the pattern of the rubber pad to the metal tang of the

chrome housing and squeeze the rubber pad and bushing

into the housing.

6. Slide the chrome housing and rubber pad onto the

mounting peg.

7. Apply LOCTITE 243 THREADLOCKER (blue) to the end

6.5 in. (165 mm)

screw.

25°

40°

8. See Figure

2-16. For rider posture, rotate footpeg

approximately 40° (3) from horizontal. Tighten end screw

Figure 2-16.

Highway Peg Mounting

to 19 ft-lbs (26 Nm).

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1. Clamp flair

2. Mount bevel

Figure 2-17. Clamp and Mount Brackets

2-10 2008 FLHTCUSE3 Service: Chassis

LOWER

TRIPLE CLAMP COVER

2.6

REPLACEMENT

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1. See Figure 2-19. Loosen but do not remove the two screws

(1) on the backside of the lower triple clamp cover (3).

2. Remove screw (4) through brake line manifold on bottom

of triple clamp cover.

3. Remove two loosened screws (1) with washers (2) and

remove cover.

4. To replace cover, fit cover inside bottom of nacelle and

around lower triple clamp (5). Hold in place.

5. Install screws (1) and washers (2). Tighten finger-tight

only. Install screw (4) through brake line manifold and

cover. Tighten finger-tight only. Verify that cover is snug

against rear surface of lower triple clamp.

NOTE

Plastic plugs in locator holes in rear surface of triple clamp can

cause interference with cover. Verify that center plug has been

1. Screw (2)

removed.

2. Washer (2)

6. Tighten screws (1) to 70-110 in-lbs (7.9-12.4 Nm).

3. Lower triple clamp cover

4. Screw

7. Tighten screw (4) to 120-180 in-lbs (13.6-20.4 Nm).

5. Lower triple clamp

8. Verify that brake line does not rub on cover. Adjust line or

Figure 2-19. Lower Triple Clamp Cover

cover as necessary.

2-12 2008 FLHTCUSE3 Service: Chassis

HANDLEBARS

2.7

2. Remove outer fairing and fairing cap. See FAIRING CAP

REMOVAL

in Touring Models Service Manual.

3. See Figure 2-20. Separate handlebar switch connectors

[24] (1) and [22] (2). Separate heated handgrip power

To prevent accidental vehicle start-up, which could cause

harness connector [189] (3). Disengage connector hous-

death or serious injury, remove main fuse before pro-

ings from locating pins. Separate twist grip sensor (TGS)

ceeding. (00251b)

connector [204] (5).

1. Remove left saddlebag, left side cover and maxi-fuse.

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1. Left handlebar switch connector [24]

2. Right handlebar switch connector [22]

3. Handgrip heater power connector [189]

4. Handgrip heater interconnect [206]

5. Twist grip sensor connector [204]

Figure 2-20. Handlebar Control Connector Locations

4. See Figure 2-21. Squeeze front brake lever and insert a

6. Protect chrome and painted surfaces and tie master cyl-

5/32 in. (4 mm) thick cardboard insert (2) between front

inder, reservoir and brake line out of the way.

brake lever and lever bracket.

7. Remove fasteners and washers securing handlebar clamp

to clutch lever bracket.

8. Protect chrome and painted surfaces and tie master cyl-

Do not remove or install the master cylinder assembly

inder, reservoir and clutch fluid line out of the way.

without first positioning a 5/32-inch (4 mm) thick insert

9. Remove Advanced Audio Radio assembly. See

between the brake lever and lever bracket. Removing or

8.13 ADVANCED AUDIO RADIO.

installing the master cylinder assembly without the insert

in place may result in damage to the rubber boot and

10. Remove upper handlebar clamp and remove handlebar

plunger on the front stoplight switch. (00324a)

with wire harnesses from motorcycle.

5. Remove fasteners securing handlebar clamp to master

cylinder and front brake lever.

2008 FLHTCUSE3 Service: Chassis 2-13

NOTE

If handlebar rubber mounts require service, see HANDLEBARS

To release twist grip, a slight tug may be necessary.

in the Touring Models Service Manual.

Pull right grip off end of handlebar.

10. See Figure 2-23. Lightly lubricate conduits and tape with

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glass cleaner.

11. Gently pull twist grip sensor (TGS) out of handlebar, along

with the right handgrip heater harness.

12. Gently pull left handgrip out of handlebar, along with left

handgrip heater harness.

13. Pull left and right switch control harnesses through

handlebar.

14. Unwrap electrical tape and wire from terminals.

15. Repair or replace switches and socket wires as necessary.

See HANDLEBAR SWITCHES in Touring Models Service

Manual for handlebar switch repair procedures.

1. Groove

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5/32 in. (4 mm) thick cardboard insert

Figure 2-21. Cardboard Insert

DISASSEMBLY

1. Place handlebar assembly on work bench.

2. See Figure 2-22. Cut and discard cable straps.

3. Separate heated handgrip interconnect harness connector

[206] (4).

4. Remove terminals and wire leads from handlebar

switch

connectors [22, 24] and twist grip sensor (TGS) connector

[204].

1. LH switch control connector [24] (gray)

NOTE

2. Boot (2)

See APPENDIX B, MOLEX CONNECTORS in Touring Models

3. Heated handgrip power connector [189]

Service Manual for service procedures.

4. Heated handgrip interconnect connector [206]

5. RH switch control connector [22] (black)

5. Remove terminals and wire leads from heated handgrip

6. Twist grip sensor connector [204]

power connector [189] (3) and interconnect harness con-

nector [206] (4).

Figure 2-22. Handlebar Harness Assembly

NOTE

See APPENDIX B DEUTSCH ELECTRICAL CONNECTORS

in Touring Models Service Manual for Service Procedures.

ASSEMBLY

6. Slide boots (2) off switch control wiring harnesses. Save

Pull Wire Leads

boots for assembly.

NOTES

7. Wrap terminal ends of each wiring harness tightly in elec-

•

If mechanics wire remains in handlebars, attach wire lead

trical tape to protect terminals from damage as harness

bundles and pull mechanic's wire to draw wire leads back

is removed from handlebar.

through handlebars. and out center of handlebar. Carefully

NOTES

remove mechanic's wire to avoid damage to terminals.

•

Forming too large a bulge with electrical tape at end of

•

Liquid glass cleaner may be used to aid in pulling wires

wiring harness can make it difficult to extract harness from

through conduit.

handlebar.

•

Make sure grommets are in place in oval holes near each

•

Option: Attach mechanic's wire to the terminal/wire leads.

end of handlebar before feeding harnesses into handlebar.

After drawing the leads through the handlebar, remove

the tape and leads. Leave the mechanic's wire in the

•

It is best to pull all the harnesses for one end of handlebar

handlebar for installation.

at a time. However, if you wish to pull only one harness

8. Remove upper and lower fasteners securing left and right

switch control housing halves to handlebar.

2-14 2008 FLHTCUSE3 Service: Chassis

at a time, pull smaller harnesses first, then larger har-

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nesses.

•

As you pull on wire leaders, assist the process by gently

feeding harnesses into handlebar at other end.

•

If resistance is felt, do not pull too hard on wire leader as

this may damage wires and/or terminals, or dislodge leader

from harness.

Cut five lengths of mechanic's wire, each approximately

3 ft (91.4 cm) long. These will be used as harness wire

leaders.

Feed two wire leaders through grommeted hole near left

end of handlebar and one wire leader through left end of

handlebar tube.

Feed one wire leader through grommeted hole near right

end of handlebar and one wire leader through right end

of handlebar tube.

Extract ends of all wire leaders through center hole. Secure

leaders at center hole so they cannot be accidentally pulled

Figure 2-23. Wire Leader through Grommet at Hand Grip

back through handlebar.

End of Handlebar

Make sure grommets are installed in oval holes near each

end of handlebar.

Secure each wire leader to its harness at ends of

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handlebar as follows. Neatly wrap socket terminals and

wires of each harness with a few twists of the leader wire:

a. Left side: Attach wire leader extending from left end

of handlebar tube to left handgrip interconnect har-

ness. Attach other two wire

leaders (extending from

grommeted hole near left end of handlebar),

one

left switch control harness and the other to left hand-

grip power harness.

b. Right side: Tape right handgrip interconnect harness

terminals to TGS harnesses. Attach wire leader

extending from right end of handlebar tube to TGS

harness. Attach other wire leader (extending from

grommeted hole near right end of handlebar) to right

switch control harness.

Wrap wires and terminals of each harness tightly with

electrical tape to protect wires and terminals when

installing harnesses in handlebar.

Figure 2-24. Wire Leader through Center of Handlebar

Grommets in each of the wiring holes in the handlebar

Install Switch Housings

must remain in position after routing the wiring through

the handlebar. Operation without the grommets in place

1. See Figure 2-25 and Figure 2-26. Orient wires in switch-

can damage wires, causing a short circuit which could

housings:

result in death or serious injury. (00416d)

a. Right hand side: the RUN and STOP wires are

wrapped over the front of the handlebar, back and

8. Lubricate wire conduits with glass cleaner. Grasp end of

into the handlebar through the grommet. Make sure

wire leader and gently pull wire bundles through grommets

the wires run outboard of the clamping post cast into

and handlebar ends to the handlebar center hole. Pull

the inside of the lower housing.

harnesses until left heated handgrip and TGS are fully

seated on ends of handlebar, and no excess slack exists

b. Left hand side: the HORN and HI/LO BEAM wires are

in switch control harnesses.

also wrapped over the front of the handlebar, back

and into the handlebar through the grommet. Make

sure the wires run inboard of the clamping post cast

into the inside of the lower housing.

2008 FLHTCUSE3 Service: Chassis 2-15

2. Loosely install left and right switch housings onto

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handlebar and over inboard ends of heated handgrips.

3. Gently pull on wire leaders to remove any excess slack in

harnesses. Unwrap tape and mechanic's wire.

4. See Figure 2-22. Secure wire harnesses at exit from center

of handlebar with cable strap.

5. Reinstall boot (2) on each switch control harness. Secure

with cable strap.

6. Fit wire seal into back of Deutsch socket housings . See

APPENDIX B DEUTSCH ELECTRICAL CONNECTORS

in Touring Models Service Manual.

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1. Right turn signal control and wiring

2. Cruise control switch

3. Mode select switch

4. Lower bracket

5. Clamping post

Figure 2-26. Wiring in Lower Right Hand Control Housing

Install Wire Lead Terminals

1. Following color codes in Table

2-5, Table

2-6 and

Table 2-7, insert terminals into numbered chambers in

connector housings.

NOTE

See the Service Manual

for connector assembly guidelines.

2. Gently tug on wire ends to verify that all terminals are

locked.

3. See Figure 2-22. Mate handgrip interconnect harness

connectors [206]. Secure interconnect harness connector

assembly (4) to right hand switch control harness with

cable strap.

Figure 2-25. Run/Stop Switch Wiring in Upper Right Hand

4. Pull slack from harnesses and secure together with a cable

Control Housing

strap where harnesses exit center of handlebar.

2-16 2008 FLHTCUSE3 Service: Chassis

1. Carry handlebar with internal wire harnesses and control

Table 2-5. Handlebar Switch Connectors

housings to the motorcycle.

LH CONNECTOR [24]

RH CONNECTOR [22]

2. Set handlebar on lower clamps and loosely install upper

(16-WAY, GRAY)

(12-WAY, BLACK)

handlebar clamp and fasteners. Position wires so they exit

under radio to front of vehicle from between risers.

WIRE

COLOR

CAVITY NO.

WIRE

COLOR

CAVITY NO.

O/W

R/BE

Using excessive force to adjust handlebar can result in

damage to handlebar or clamp. (00444b)

W/BK

NOTE

W/V

W/BN

If handlebars are positioned for a rider of normal size, postpone

BK/R

adjustment until rider has checked their position. If customer

requests changing handlebar position, perform the adjustment

V/BK

BN/W

before delivering the motorcycle.

BN/BK

GY/W

3. Center handlebar laterally (sideways) in clamps.

PK/W

4. Snug front fasteners until upper clamp contacts lower

GN/BE

V/BK

clamps.

GY/GN

W/BE

5. Position handlebar for rider posture.

BE/BK

6. See Figure 2-27. In sequence shown, tighten fasteners to

V/BK

16-20 ft-lbs (20.3-27.1 Nm).

O/BK

7. Route wire harness and mate left [24] and right [22] con-

nector socket and pin housings.

8. See Figure 2-20. Mate heater and TGS connectors to main

harness.

Table 2-6. Left Heated Hand Grip Connectors

9. Secure with cable straps as necessary.

INTERCONNECT [206]

MAIN POWER [189]

(2-WAY, BLACK)

(3-WAY, BLACK)

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WIRE

COLOR

CAVITY NO.

WIRE

COLOR

CAVITY NO.

O/W

BK/W

Table 2-7. Twist Grip Sensor (TGS) Connectors

INTERCONNECT [206]

TGS [204]

(2-WAY, BLACK)

(6-WAY, BLACK)

WIRE

TERMINAL

WIRE

CONDUIT

TERMINAL

COLOR

BK/W

Figure 2-27. Handlebar Top Clamp Torque Sequence

INSTALLING HANDLEBARS

Clamp Handlebars to Risers

Assemble Brake Controls

1. Remove right switch housing fasteners.

2. Install throttle control grip and connect heated handgrip

Improperly aligned handlebars can contact the fuel tank

connector to twist grip sensor. See 2.8 HANDGRIPS.

when turned to the left or right. Contact with the fuel tank

can cause cosmetic damage. (00372a)

2008 FLHTCUSE3 Service: Chassis 2-17

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Do not remove or install the master cylinder assembly

without first positioning a 5/32-inch (4 mm) thick insert

between the brake lever and lever bracket. Removing or

installing the master cylinder assembly without the insert

in place may result in damage to the rubber boot and

plunger on the front stoplight switch. (00324a)

Assemble switch housing halves to handlebar and brake

lever bracket:

a. Position upper switch housing so wire conduit wraps

around outside of handlebar and sets in clearance at

bottom of handlebar.

b. Verify that wires will not be pinched when fasteners

are tightened.

c. Verify that throttle works freely.

d. Install switch housing fasteners.

Loosely assemble handlebar clamp to front brake control

1. Clamping surface

lever bracket master cylinder and reservoir:

2. Range marks

a. Engage tab on switch with notch at top of brake lever

Figure 2-28. RH Assembly to Handlebar

bracket.

b. Alternately tighten housing and bracket fasteners until

Assemble Clutch Controls

all components fit and wires route without interfer-

ence. Fasteners should only be snug.

1. Remove loosely installed switch control housing fasteners.

c. Verify housing and bracket clamp are tight against

2. Loosely assemble clutch master cylinder/reservoir and

handgrip shoulder/edge of bar.

clamp to handlebar. Alternately tighten fasteners until

clamp is snug to bracket.

See Figure 2-28. The assembly

can be rotated slightly

for rider posture. However, the clamp mating surface (1)

3. Install

switch housing:

must be positioned between the

two range marks

(2) on

a. Position upper switch housing so wire conduit wraps

the bottom of the handlebar.

around front of handlebar.

b. Verify wires will not be pinched when fasteners are

tightened.

Control wiring is routed inside handlebar and may be

c. Position upper switch housing so wire conduit sets in

pinched or cut if controls are rotated too far. Electrical

clearance at bottom of handlebar, and upper harness

damage to control wiring can result. (00571b)

will not be pinched when fasteners are tightened.

6. Squeeze front brake lever and remove cardboard insert

d. Engage lower switch housing tab with notch in clutch

between brake lever and bracket.

master cylinder/reservoir.

7. Tighten control lever clamps beginning with top fastener

4. Install but do not tighten switch housing fasteners.

to 72-84 in-lbs (8.1-9.5 Nm). The gap, if any must be at

clearance flat on handlebar.

5. See Figure 2-29. The switch housing and clutch master

cylinder assembly can be rotated slightly for rider posture.

8. Tighten switch housing halves beginning with bottom

However, the clamp mating surface (1) must be positioned

fastener to 35-45 in-lbs (4.0-5.1 Nm). Rear gap, if any,

between the two range marks (2) on the bottom of the

should be tighter.

handlebar.

Control wiring is routed inside handlebar and may be

pinched or cut if controls are rotated too far. Electrical

damage to control wiring can result. (00571b)

6. Tighten clutch master cylinder/reservoir clamp beginning

with top fastener to 72-84 in-lbs (8.1-9.5 Nm). Top gap,

if any, must be at handlebar clearance.

7. Tighten turn signal and cruise control housings beginning

with bottom fastener to 35-45 in-lbs (4.0-5.1 Nm). Rear

gap, if any, should be tighter.

2-18 2008 FLHTCUSE3 Service: Chassis

2. With motorcycle upright and with front fork pointed straight

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ahead, adjust mirrors.

NOTE

Adjust mirrors so a small portion of riders' shoulder is visible

in each mirror. This visually establishes the distance of vehicles

to rear of motorcycle.

3. Install outer fairing and fairing cap according to procedure

in Touring Models Service Manual.

4. Install maxi-fuse, left side cover and left saddlebag.

5. Test clutch lever and front brake lever for pressure and

operation.

6. Test for correct throttle operation.

7. Verify brake and clutch fluid line routing.

Be sure that all lights and switches operate properly before

operating motorcycle. Low visibility of rider can result in

death or serious injury. (00316a)

8. Turn ignition/light key switch to IGNITION and test

1. Clamping surface

switches for operation.

2. Range marks

Figure 2-29. LH Control Assembly to Handlebars

After repairing the brake system, test brakes at low speed.

If brakes are not operating properly, testing at high speeds

RETURNING TO SERVICE

can cause loss of control, which could result in death or

1. Verify routing of wire conduits, brake line and clutch fluid

serious injury. (00289a)

line. See 2.11 CLUTCH FLUID LINE and FRONT BRAKE

9. Apply brake lever to test stop lamp.

LINE in Touring Models Service Manual.

2008 FLHTCUSE3 Service: Chassis 2-19

HANDGRIPS

2.8

Remove fasteners securing left switch housing to

GENERAL

handlebar. Carefully separate housings from handlebar.

For electrical diagnostics, see 8.7 HEATED HANDGRIPS.

7. Apply glass cleaner to harnesses to act as a lubricant.

PREPARING MOTORCYCLE

8. See Figure 2-31. Slide handgrip off end of handlebar.

1. Remove maxi-fuse.

Grasp handgrip interconnect (2) and power (1) harnesses

and gently pull harness leads from handlebar.

2. Remove left saddlebag, left side cover and maxi-fuse.

When pulling harness leads, gently feed opposite end of

3. Remove outer fairing and fairing cap. See FAIRING CAP

harness leads and mechanic's wire into center hole of

in Touring Models Service Manual.

handlebar.

NOTE

NOTES

It is not necessary to remove the handlebars from the motor-

•

See Figure 2-31. Note that power harness (1) feeds from

cycle to replace the handgrips.

same hole in handlebar as switch control harnesses.

SEPARATING CONNECTORS

Handgrip interconnect harness (2) feeds from end of

handlebar.

1. See Figure 2-30. Cut cable straps (3, 4, 5).

•

Only pull far enough so that harness is completely free of

2. Unplug interconnect harness connector [206] (1).

handlebar. Make sure free end of wire leader is still pro-

truding from center hole in handlebar.

3. LH handgrip: Unplug power connector [189] (2).

4. RH handgrip: Unplug TGS connector [204] (6).

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REPLACING HANDGRIPS

NOTES

•

LH Handgrip: Remove terminals and wire leads from the

handgrip interconnect [206B] connector and the

power

harness connector [189].

•

RH Handgrip: No harnesses need to be removed to

replace the right handgrip. For

twist grip sensor

(TGS)

replacement, see 8.17 TWIST GRIP SENSOR (TGS).

Remove Left Handgrip

1. Remove radio, GPS, CB and XM satellite components as

an assembly. See 8.13 ADVANCED AUDIO RADIO.

2. Remove terminals and wire leads from connectors [206]

1. LH switch control connector [24] (gray)

and [189]. See APPENDIX A in Touring Models Service

2. Boot (2)

Manual for connector service guidelines.

3. Heated handgrip power connector [189]

4. Heated handgrip interconnect connector [206]

3. Attach a leader made of mechanic's wire, approximately

5. RH switch control connector [22] (black)

3 ft (91.4 cm) long, to each harness. Neatly wrap two or

6. Twist grip sensor connector [204]

three turns of leader around terminals and wire leads of

the harnesses, and wrap junction with electrical tape,

Figure 2-30. Handlebar Harness Assembly

covering terminals and end of wire leader.

4. Bend last six inches of free end of each wire leader into

an "L" shape to prevent leader from being pulled too far

into the handlebar.

Do not remove or install the master cylinder assembly

without first positioning a 5/32-inch (4 mm) thick insert

between the brake lever and lever bracket. Removing or

installing the master cylinder assembly without the insert

in place may result in damage to the rubber boot and

plunger on the front stoplight switch. (00324a)

5. Remove clutch master cylinder assembly and suspend

out of the way.

2-20 2008 FLHTCUSE3 Service: Chassis

with upper fastener, tighten fasteners to 72-84 in-lbs (8.1-

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9.5 Nm).

11. Install radio, GPS, CB and XM satellite components as an

assembly. See 8.13 ADVANCED AUDIO RADIO.

12. Tighten switch housing fasteners to 35-45 in-lbs (4.0-5.1

Nm).

Table 2-8. Left Heated Hand Grip Connectors

INTERCONNECT [206]

MAIN POWER [189]

(2-WAY, BLACK)

(3-WAY, BLACK)

WIRECOLOR

CAVITY NO.

WIRECOLOR

CAVITY NO.

O/W

1. Power harness

BK/W

2. Handgrip interconnect harness

Figure 2-31. LH Heated Handgrip

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Install Left Handgrip

1. Separate wire leaders from harnesses and attach to leads

of new harnesses. Make sure electrical tape wrap extends

over end of harness conduit.

2. Lubricate wire harness conduits with glass cleaner.

3. Grasp end of each wire leader and carefully pull harnesses

through handlebar.

NOTE

Feed harnesses into handlebar with one hand as you pull on

the leaders with the other.

4. Slide handgrip onto end of handlebar and pull slack from

wiring harnesses.

5. Remove electrical tape and wire leaders from harnesses.

6. Refer to Table 2-8. Match wire lead color to cavity number

1. Rim of handgrip

and insert wire lead terminals into connector housing

2. Switch housing grooves

cavities.

3. Power harness

NOTES

Figure 2-32. Mounting LH Handgrip

For connector service, see APPENDIX B, DEUTSCH in Touring

Models Service Manual.

7. Orient wires in switch-housings. The horn and HI/LO beam

wires are also wrapped over the front of the handlebar,

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and into the handlebar through the grommet. Make sure

the wires run inboard of the clamping post cast into the

inside of the lower housing.

8. See Figure 2-32. Install switch housings onto handlebar

and over inboard end of handgrip. Make sure rim (1) of

handgrip fits into grooves (2) in switch housings. Loosely

install fasteners.

9. See Figure 2-33. Orient handgrip so that power harness

fits in notch in lower switch housing groove. Be careful not

to pinch harness.

NOTE

Control wiring is routed inside the handlebar and may be

pinched or cut if controls are rotated too far.

Figure 2-33. Notch for Power Harness

10. See Figure 2-34. Install clutch master cylinder. Align for

operator comfort with clamping surface (1) located within

the range marks (2) stamped into the handlebar. Beginning

2008 FLHTCUSE3 Service: Chassis 2-21

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1. Groove

5/32 in. (4 mm) thick cardboard insert

Figure 2-35. Cardboard Insert

Install Right Handgrip

1. See Figure 2-36. Ensure twist grip sensor is properly

1. Clamping surface

installed in end of handlebar.

2. Range marks

2. Remove end cap (1) from handgrip.

Figure 2-34. LH Control Assembly to Handlebars

3. Press handgrip onto twist grip sensor and handlebar until

it is seated. Rotate handgrip to ensure proper engagement.

Remove Right Handgrip

4. Using needle nose pliers, reach through the hole in the

end of the handgrip and insert prongs of connector (2) into

connector holes (3) located in end of twist grip sensor.

Install end cap (1).

Do not remove or install the master cylinder assembly

without first positioning a 5/32-inch (4 mm) thick

insert

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between the brake lever and lever bracket. Removing or

installing the master cylinder assembly without the insert

in place may result in damage to the rubber boot and

plunger on the front stoplight switch. (00324a)

1. See Figure 2-35. Squeeze front brake lever and insert a

5/32 in. (4 mm) thick cardboard insert between front brake

lever and lever bracket.

2. Remove master cylinder and front brake lever and suspend

out of the way.

3. Remove fasteners securing right switch control housing

halves to handlebar.

NOTE

To remove the throttle handgrip, a slight tug may necessary.

1. End cap

2. Heated grip connector

4. Separate switch housings and pull handgrip off end of

3. Recepticle in TGS

handlebar.

Figure 2-36. Right Handgrip Heater Connector

2-22 2008 FLHTCUSE3 Service: Chassis

5. Assemble right switch control housing halves:

sm04496

a. Position upper switch housing so wire conduit wraps

around outside of handlebar and sets in clearance at

bottom of handlebar.

b. Verify that wires will not be pinched when fasteners

are tightened.

c. Install switch housing fasteners finger tight.

d. Verify that throttle works freely.

6. Loosely install front brake master cylinder and reservoir:

a. Engage tab on switch with notch at top of brake lever

bracket.

b. Alternately tighten housing and bracket fasteners until

all components fit and wires route without interfer-

ence. Fasteners should only be snug.

NOTE

Control wiring is routed inside the handlebar and may be

pinched or cut if controls are rotated too far.

1. Clamping surface

7. See Figure 2-37. Rotate brake master cylinder assembly

2. Range marks

slightly for most comfortable riding position. Make sure

Figure 2-37. RH Assembly to Handlebar

assembly is positioned so that clamp mating surface (1)

is located in area between range marks (2).

8. Tighten master cylinder clamps beginning with top fastener

MATING CONNECTORS

to 72-84 in-lbs (8.1-9.5 Nm). The gap, if any must be at

1. Mate heated handgrip power connector [189] housings

clearance flat on handlebar.

and interconnect harness connector [206] housings.

9. Tighten switch housing fasteners beginning with bottom

2. Install handgrip interconnect harness cable strap and

fastener to 35-45 in-lbs (4.0-5.1 Nm). Rear gap,

if any,

harness bundle cable strap.

should be tighter.

RETURNING TO SERVICE

10. Squeeze front brake lever and remove cardboard

insert.

Check operation of brake light while squeezing brake lever.

1. Install fairing cap and outer fairing. See FAIRING CAP in

Touring Models Service Manual.

11. Verify throttle operates freely.

2. Install maxi-fuse, left sidecover and left saddlebag.

Be sure that all lights and switches operate properly before

operating motorcycle. Low visibility of rider can result in

death or serious injury. (00316a)

3. Test heated handgrips and handlebar switches for opera-

tion.

2008 FLHTCUSE3 Service: Chassis 2-23

CLUTCH

MASTER CYLINDER AND RESERVOIR

2.9

GENERAL

The clutch is hydraulically actuated. Squeezing the clutch hand

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

lever causes the clutch master cylinder to apply pressure via

when draining fluid. Traction can be adversely affected,

the clutch fluid in the clutch line to the secondary clutch actuator

which could result in loss of control and death or serious

mounted in the clutch release cover. The secondary clutch

injury. (00295a)

actuator piston extends and contacts the clutch release bearing

which disengages the clutch.

A bleeder valve at the secondary clutch actuator is used to

bleed air from the clutch line. D.O.T. 4 HYDRAULIC BRAKE

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

FLUID (Part No. 99953-99A) is used in the clutch system and

surfaces it comes in contact with. Always use caution and

is referred to as clutch fluid in this manual.

protect surfaces from spills whenever brake work is per-

Check the clutch fluid level in the clutch fluid reservoir on left

formed. Failure to comply can result in cosmetic damage.

handlebar. If the sight glass is dark, the fluid level in the

(00239b)

reservoir is above the sight glass prism and the reservoir is

•

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

full. If the sight glass appears clear, the fluid level is below the

Always flush the affected components with water (not

sight glass prism and the fluid level should be checked. Clutch

soapy).

fluid should be level with the internal shelf marked FILL LEVEL

with the motorcycle upright and the gasket surface level.

NOTE

Place a large cup under the banjo fitting. Hydraulic fluid will

begin draining from the reservoir as the banjo bolt is removed.

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

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

compatible and could cause equipment damage. (00353a)

Avoid leakage. Be sure gaskets, banjo bolt(s) and clutch

line are clean and undamaged before assembly. (00329a)

NOTE

Clutch fluid volume in reservoir actually increases with clutch

5. Slowly loosen banjo bolt (9) and allow clutch fluid from

wear. Do NOT overfill clutch reservoir.

reservoir to drain into cup.

NOTE

REMOVAL

Dispose of clutch fluid in accordance with local regulations.

1. Remove acorn nut, lockwasher and rear view mirror with

6. Remove banjo bolt (9) and two steel/rubber washers (8).

washer. Support turn signal bullet housing and bracket.

Discard steel/rubber washers.

2. Loosen left handlebar switch housing fasteners.

NOTE

To prevent the rest of the clutch fluid from draining from the

clutch line and secondary clutch actuator, support the banjo

fitting and clutch fluid line upright. Plug the banjo bolt hole with

Do not allow dirt or debris to enter the master cylinder

a finger to transfer the assembly to a workbench without spilling

reservoir. Dirt or debris in the reservoir can cause improper

clutch fluid.

operation and equipment damage. (00205c)

7. Remove master cylinder clamp screws and remove clutch

3. See Figure 2-38. Loosen, but do not remove, fasteners

master cylinder/reservoir assembly.

(1) that secure handlebar clamp to clutch master cyl-

inder/reservoir.

4. Loosen both cover screws (2) to relieve pressure in master

cylinder/reservoir.

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)

2-24 2008 FLHTCUSE3 Service: Chassis

sm04672

Avoid leakage. Prevent damage to piston or piston bore.

Use non-metallic tools when servicing components.

(00529d)

6. Remove cups (5, 7) from piston using a toothpick.

7. See Figure 2-38. If necessary, push the sight glass (10)

into the reservoir to remove. Remove and discard o-ring

(11).

Use denatured alcohol to clean clutch system components.

Do not use mineral-based solvents (such as gasoline or

1. Clamp screw

paint thinner), which will deteriorate rubber parts even

2. Cover hold down screws

after assembly. Deterioration of these components can

3. Cover

cause clutch failure, which could result in death or serious

4. Pivot pin

injury. (00296a)

5. Internal components

8. Wipe the housing with a lint free cloth. With a clean air

6. Clutch hand lever

supply, blow out drilled passages and bore in the master

7. Retaining ring

cylinder housing.

8. Steel/rubber washers

9. Banjo bolt

NOTE

10. Sight glass

Do not use a wire or sharp instrument to clean drilled passages.

11. O-ring

9. Inspect cylinder housing bore for scoring, pitting or corro-

Figure 2-38. Clutch Master Cylinder/Reservoir

sion. Also check outlet port for damage. Replace housing

if necessary.

10. Inspect the cover, sight glass, and gasket for cuts, tears

DISASSEMBLY

or general deterioration.

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)

1. Remove master cylinder cover and gasket. Turn housing

upside down to remove remaining clutch fluid from reser-

voir.

Wear safety glasses or goggles when removing or

installing retaining rings. Retaining rings can slip from the

pliers and could be propelled with enough force to cause

serious eye injury. (00312a)

2. See Figure 2-38. Remove retaining ring (7) from pivot pin

(4).

NOTE

To remove piston spring load from the pivot pin, gently force

the clutch lever toward the piston (as if operating the clutch).

3. Remove pivot pin (4) and clutch lever.

4. See Figure 2-39. Using a toothpick or small screwdriver,

gently pry outer edge of piston boot (1) out of piston bore.

5. Remove piston (2) and spring (4).

2008 FLHTCUSE3 Service: Chassis 2-25

7. Align and install piston assembly into bore. Firmly press

sm03992

on flat end of piston, compressing spring, until the entire

assembly slides into cylinder bore.

NOTE

When installing the piston sealing boot, be careful not to tear,

perforate or damage the piston sealing boot.

8. Compress piston until it is even with the end of bore. Using

a small dull bladed screwdriver or similar tool, gently work

around sealing edges of boot until entire circumference

of boot is seated in cylinder bore groove.

9. Install cover with new gasket on master cylinder/reservoir.

Install two screws to fasten the cover to reservoir, but do

not tighten.

Wear safety glasses or goggles when removing or

installing retaining rings. Retaining rings can slip from the

pliers and could be propelled with enough force to cause

serious eye injury. (00312a)

10. Install clutch hand lever, pivot pin, and a new retaining

ring.

Boot

sm03993

Piston

Shoulder

Spring

Primary cup

Groove - primary cup

Secondary cup

Groove - secondary cup

Figure 2-39. Clutch Master Cylinder Components

ASSEMBLY

1. Boot installed in piston groove

2. Secondary cup

To rebuild clutch master cylinder, use the components found

3. Primary cup

in the Service Parts Kit.

Figure 2-40. Assembled Cups and Piston

1. See Figure 2-38. If removed, install sight glass (10) using

a new o-ring (11) lubricated with lubricant provided with

Service Parts Kit.

INSTALLATION

NOTE

1. See Figure

2-41. Attach master cylinder/reservoir to

See Figure 2-40. The flared ends of the primary cup and the

handlebar with handlebar clamp. Orient lever to rider

secondary cup must face the spring end of the piston.

position, with mating surface joint (1) within range marks

2. See Figure 2-40. Using lubricant provided with SERVICE

(2) in handlebar. Tighten clamp fasteners to 60-80 in-

PARTS KIT, lightly lubricate inside of primary cup (3) and

lbs (6.8-9.0 Nm).

fit over lip on spring end of piston.

2. Tighten handlebar switch housing screws to 35-45 in-

3. Using lubricant provided with SERVICE PARTS KIT, lightly

lbs (4.0-5.1 Nm).

lubricate inside of secondary cup (2) and fit over the lip

3. Attach banjo fitting to master cylinder using new

on outboard end of piston.

steel/rubber washers. Tighten banjo bolt finger tight.

4. Install boot (1), large sealing ID first, on piston until seal

4. Fill reservoir with D.O.T. 4 HYDRAULIC BRAKE FLUID

on smaller ID fits snugly into thin groove in piston.

(Part No. 99953-99A). Allow fluid to fill clutch line until a

5. Using lubricant in SERVICE PARTS KIT, thoroughly coat

steady flow of clutch fluid flows from bleeder valve. Finger

outside diameters of primary and secondary cups and

tighten bleeder valve.

master cylinder piston bore.

5. Bleed clutch line. See 1.3 BLEEDING CLUTCH FLUID

6. Install spring into piston assembly.

LINE.

6. Verify that fluid level in clutch fluid reservoir is at FILL

LEVEL with motorcycle upright and gasket surface level.

2-26 2008 FLHTCUSE3 Service: Chassis

NOTE

sm04496

Clutch fluid volume in reservoir actually increases with clutch

wear. Do NOT overfill clutch reservoir.

7. Verify operation by squeezing clutch hand lever.

8. Tighten fasteners as follows:

a. Banjo bolt to 12.5-14.5 ft-lbs (16.9-19.7 Nm).

b. Bleeder screw to 12-15 in-lbs (1.4-1.7 Nm).

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

9. Install rear view mirror and turn signals with bracket. See

8.5 FRONT TURN SIGNALS.

Be sure that all lights and switches operate properly before

operating motorcycle. Low visibility of rider can result in

death or serious injury. (00316a)

10. Test ride motorcycle.

1. Clamping surface

2. Range marks

Figure 2-41. RH Assembly to Handlebar

2008 FLHTCUSE3 Service: Chassis 2-27

CLUTCH HAND LEVER

2.10

REMOVAL

INSTALLATION

1. See Figure 2-42. Slide bushing cups onto pins of roller

(3).

To prevent accidental vehicle start-up, which could cause

NOTE

death or serious injury, remove main fuse before pro-

Be careful when handling the bushing cups. The bushing cups

ceeding. (00251b)

are hard plastic and easily broken.

1. Remove the maxi-fuse.

2. With connector bow portion of the bushing cups parallel

with groove in clutch handle, snap roller pin and bushing

2. See Figure 2-42. Remove the retaining ring (1) from the

cups into clutch lever roller groove. Roller/bushing

pivot pin (2).

assembly will install with a snap and will be held securely.

3. Remove pivot pin and lever.

3. Lightly grease pivot bushing (5) and install into clutch hand

4. Disassemble roller pin (3) and bushing cups (4).

lever pivot hole. Position bushing until it is flush with both

sides of lever.

5. Remove pivot bushing (5).

NOTE

If the clutch master cylinder/reservoir is full of clutch fluid under

sm04674

pressure, it may be necessary to apply force to the hydraulic

piston in order to align the clutch hand lever and to allow the

pivot pin to be inserted.

4. Orient clutch lever in lever mounting bracket. Insert pivot

pin from top.

5. Install new retaining ring on pivot pin.

6. Install maxi-fuse.

7. Verify clutch lever operation.

1. Retaining ring

2. Pivot pin

3. Roller pin

4. Bushing cups

5. Pivot bushing

Figure 2-42. Clutch Hand Lever

2-28 2008 FLHTCUSE3 Service: Chassis

Harley Davidson 2008 FLHTCUSE3 Model. Service Manual Supplement - page 2