Harley Davidson 2008 FLHTCUSE3 Model. Service Manual Supplement

CLUTCH FLUID LINE

2.11

REMOVAL

sm03996

1. Remove outer fairing. See Touring Models Service Manual

for procedure.

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

when adding fluid. Traction can be adversely affected,

which could result in loss of control and death or serious

injury. (00294a)

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)

1. Flare nut

•

Do not wipe any spilled brake fluid off from finished sur-

2. Clutch fluid line

faces. Always flush the affected components with water

3. Clutch release cover

(not soapy).

Figure 2-43. Clutch Flare Nut and Fluid Line

2. Loosen the clutch master cylinder/reservoir cover.

3. See Figure 2-43. Place a suitable container under clutch

release cover (3).

sm03997

4. Loosen flare nut (1) and allow clutch fluid to drain.

5. Remove flare nut from clutch release cover.

6. Drain clutch fluid line.

NOTE

Dispose of clutch fluid in accordance with local regulations.

7. See Figure 2-44. Remove and discard o-ring.

NOTE

Clutch fluid line o-ring may stick to inside of clutch release

cover. Use a non-metallic pick to remove old o-ring and other

debris.

8. See Figure 2-45. Remove banjo bolt (5) and two washers

(4). Discard washers.

9. See Figure 2-46. Carefully pull banjo fitting end of clutch

fluid line out through inner fairing grommet.

10. See Figure 2-47. Loosen clamps along right side frame

down tube.

a. Top clamp is secured with engine guard bolt.

b. Bottom clamp is secured to crossbrace.

Figure 2-44. Clutch Fluid Line O-ring

11. See Figure 2-48. Cut cable ties securing clutch fluid line

at original locations on inner fairing bracket and behind

cam cover.

Route clutch fluid line down right side frame tube, through

12. Remove clutch fluid line.

clamps, under cam cover and up to clutch release cover.

Install new o-ring on end of clutch fluid line.

INSTALLATION

Install flare nut to clutch release cover and finger tighten.

1. Route clutch fluid line through fairing grommet retracing

original path of line.

See Figure 2-48. Secure clutch fluid line at original loca-

tions on inner fairing bracket, and behind cam cover using

2. Loosely install banjo bolt and new washers.

cable ties.

2008 FLHTCUSE3 Service: Chassis 2-29

7. See Figure 2-47. Tighten right side frame tube clamps.

sm04000

a. Engine guard bolt to 15-20 ft-lbs (21-27 Nm).

b. Clutch fluid line clamp bolt to 96-120 in-lbs (11-13

Nm).

8. Replace the clutch fluid and bleed the clutch fluid line. See

1.3 BLEEDING CLUTCH FLUID LINE.

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Figure 2-47. Clamp Locations on Frame Down Tube

1. Clutch lever

2. Clutch master cylinder/reservoir

3. Clutch fluid line assembly

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4. Banjo bolt washer (2)

5. Banjo bolt

Figure 2-45. Clutch Master Cylinder Assembly and

Fluid

Line

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Figure 2-48. Cable Tie Location Around Clutch Fluid Line

Figure 2-46. Clutch Fluid Line Inner Fairing Grommet

2-30 2008 FLHTCUSE3 Service: Chassis

SEAT

2.12

GENERAL

sm04003

The FLHTCUSE3 is equipped with a heated seat. Individual

controls, mounted on left side of seat, provide warmth to the

rider seat and passenger pillion separately. For electrical dia-

gnostics, see 8.6 HEATED SEAT.

NOTE

Heater elements are not serviceable. If heater fails, seat must

be replaced.

REMOVAL

1. Remove rider backrest. See 2.13 RIDER BACKREST.

2. Remove left saddlebag. See 2.15 SADDLEBAGS.

3. See Figure 2-49. Remove fastener with flat washer holding

one side of passenger grabstrap.

4. See Figure

2-50. Remove screw

(3) securing seat

mounting bracket (5) to fender.

5. Slide seat backward to free tongue (4) on bottom front of

seat from slot in frame backbone.

6. See Figure 2-50. Unplug seat heater harness connector

Passenger grab strap

[191]. Remove seat.

Seat

Screw

Tongue

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Mounting bracket

Retention nut

Retention washer

Screw (2)

Figure 2-50. Seat Components

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Figure 2-49. Passenger Grab Strap Fastener

Figure 2-51. Heated Seat Connector [191]

2008 FLHTCUSE3 Service: Chassis 2-31

CLEANING AND INSPECTION

INSTALLATION

1. See Figure 2-51. Set seat on frame. Plug in seat heater

harness connector [191]. Tuck harness down into frame

cavity. Make sure harness will not be pinched between

Do not use bleach or detergents containing bleach on

seat pan and vehicle frame.

saddlebags, seats, tank panels or painted surfaces. Doing

so can result in equipment damage. (00229a)

2. See Figure 2-50. Slide seat forward until tongue

(4)

engages slot in frame backbone.

•

Do not use ordinary soap to clean leather. It could dry

or remove the oils from the leather.

3. Push seat forward until retention nut (6) in fender is

centered in hole of mounting bracket (5). Install screw (3)

•

Use ONLY a good quality saddle soap to clean leather.

and tighten securely.

Be sure to rinse saddle soap off thoroughly before

treating leather.

•

Never try to dry leather quickly, using artificial means.

Always let leather dry naturally at room temperature.

After installing seat, pull upward on seat to be sure it is

locked in position. While riding, a loose seat can shift

NOTE

causing loss of control, which could result in death or

Harley-Davidson Leather Dressing (Part No. 98261-91V) has

serious injury. (00070b)

been tested and approved for materials used in FLHTCUSE3

4. Pull up on seat to verify that it is properly secured.

seats.

5. See Figure

2-49. Install passenger grabstrap to left

1. Inspect seat, wiring harness and connector for wear or

saddlebag mounting bracket.

damage.

6. Install left saddlebag.

2. Clean underside of pillion and seat. Clean fender and

frame mounting surfaces.

7. Install rider backrest.

2-32 2008 FLHTCUSE3 Service: Chassis

RIDER BACKREST

2.13

GENERAL

sm04006

The FLHTCUSE3 is equipped with a removable rider backrest.

It is adjustable vertically, front to rear and has an adjustable

tilt angle. The backrest is spring loaded to assist the passenger

in mounting and dismounting the vehicle.

REMOVAL

1. See Figure 2-52. Spread the seat covering at the base of

the backrest to expose the two spring loaded support arms.

2. Squeeze together the spring loaded support arms.

3. Pull upward to remove the backrest from the mounting

bracket.

INSTALLATION

1. See Figure 2-53. Spread the seat covering (1) to expose

the backrest mounting bracket (2).

2. Squeeze together the two spring loaded support arms on

1. Seat covering

the backrest.

2. Backrest mounting bracket

3. See Figure 2-54. Insert the support arms into the mounting

Figure 2-53. Mounting Bracket Through Seat

bracket (1).

Vertical Adjustment: For rider posture, move the backrest

up or down to select one of the three sets of vertical

adjustment holes (2).

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4. Release to lock the backrest in the bracket.

5. Test to assure the backrest is secured into the bracket.

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1. Backrest mounting bracket

2. Vertical adjustment holes

Figure 2-54. Backrest Mounting Bracket

ADJUSTING TILT ANGLE

1. See Figure 2-55. Insert a 3/16 inch Allen wrench through

Figure 2-52. Remove/Install Backrest

the tilt angle adjustment access hole.

2. Engage the Allen screw and tighten to tilt the backrest

forward, or loosen to tilt the backrest backward.

ADJUSTING FRONT TO REAR

1. Remove backrest and seat.

2. See Figure 2-56. Loosen, but do not remove, screw (3) at

base of support strap.

2008 FLHTCUSE3 Service: Chassis 2-33

3. Remove nut (5) and screw (4). Pivot support strap (2) out

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of the way.

4. Remove nuts (6) and lift mounting bracket (1) off threaded

studs.

5. With the large nylon washers in place, reposition bracket

in selected pair of horizontal adjustment holes (7).

6. Install nuts and tighten to 60-96 in-lbs (6.8-10.8 Nm).

7. Pivot support strap back into position, line up attachment

holes, and install screw and nut. Tighten to 11-15 ft-

lbs (15-20 Nm).

8. Finally, tighten support strap fastener to 60-96 in-lbs (6.8-

10.8 Nm).

After installing seat, pull upward on seat to be sure it is

Backrest mounting bracket

locked in position. While riding, a loose seat can shift

Support strap

causing loss of control, which could result in death or

Screw

serious injury. (00070b)

Nut

Nut (2)

9. Install seat.

Horizontal adjustment holes

10. Make sure backrest fits properly and can be installed cor-

Figure 2-56. Backrest Mounting Bracket

rectly in mounting holes in backrest mounting bracket.

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Figure 2-55. Adjust Rider Backrest Tilt Angle

2-34 2008 FLHTCUSE3 Service: Chassis

TOUR-PAK

2.14

REMOVAL

sm04010

NOTE

The following procedure is best performed with the aid of an

assistant.

Remove maxi-fuse.

Remove both saddlebags. See 2.15 SADDLEBAGS.

Remove seat. See 2.12 SEAT.

Open Tour-Pak and remove bottom liner.

See Figure 2-57. Separate interior connections:

a. Tour-Pak power lock connector [213T] (1).

b. One-place CB antenna connector [104] (2).

c. Harness clip (3).

1. Power lock connector [213T]

d. AM/FM/WB antenna cable connector [29] (5).

2. One-place CB antenna connector [104]

e. Harness clip (6).

3. Clip

4. Right rear exit hole

Interior light harness connector [190] (7).

5. AM/FM/WB antenna cable connector [29]

6. Clip

Feed CB antenna harness and connector [104] through

7. Tour-Pak light connector [190]

right rear exit hole (4).

8. Split grommet and exit hole

Remove split grommet (8) and feed AM/FM/WB antenna

Figure 2-57. Interior Connections (Power Lock Removed)

cable and wiring harness through exit hole.

Slide a clean shop towel between amplifier and fender

protect rear fender finish.

See Figure 2-58. Make note of which set of five locating

sm04011

holes are used to mount Tour-Pak.

10.

See Figure 2-59. Remove four locknuts with nylon caps

(1). Remove washers (2), spacers (5), bolts (3), and large

washers (4).

11.

Lower amplifier and allow to rest on fender.

NOTE

Have an assistant hold Tour-Pak for last step.

12. Remove center-rear locknut (6). Remove washer (8),

antenna ground lead (9), center-rear bolt (7) and spacer

(5).

1. Forward location holes

2. Rearward location holes

Figure 2-58. Tour-Pak Locating Holes

2008 FLHTCUSE3 Service: Chassis 2-35

3. See Figure 2-60. From inside of Tour-Pak, install right rear

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bolt (1) and large O.D. flat washer (2) through bottom (3)

of Tour-Pak, hole in top support tube, spacer (4), amplifier

flange (5) and hole in license plate bracket (6).

Install flat washer (7) and locknut (8) with cap on right rear

bolt and tighten finger-tight.

NOTE

This fastener will keep Tour-Pak in position while remaining

fasteners are installed.

See Figure 2-59. Install center-rear bolt (7) from bottom,

through spacer, top support tube, Tour-Pak, antenna

ground lead ring terminal, and flat washer. Secure with

center-rear lock nut (6) and finger-tighten.

Position amplifier so that rear corners of mounting flange

are between spacers and license plate bracket.

In the same manner, install remaining bolts, washers,

spacers and nuts. Ensure front fasteners also secure the

front of the amplifier (11).

See Figure 2-61. In sequence shown, tighten fasteners to

96-108 in-lbs (10.9-12.2 Nm).

Feed Tour-Pak lighting harness, power lock harness and

AM/FM/WB antenna cable up through hole in bottom left

front corner and install split grommet in hole.

10.

Route antenna cable through clip in bottom of Tour-Pak.

11.

Feed CB antenna cable up through hole in bottom right

front corner of Tour-Pak and install split grommet in hole.

12.

Install CB antenna cable in its clips on bottom right side

of Tour-Pak.

13.

Verify that AM/FM/WB antenna ground strap is securely

fastened to base plate in Tour-Pak with center-rear

Locknut (4)

mounting screw.

Washer (4)

Bolt (4)

14.

Mate interior connectors:

Large washer (2)

a. Tour-Pak power lock connector [213T].

Spacer (5)

Center-rear locknut

b. One-place CB antenna connector [104].

Center-rear bolt

c. AM/FM/WB antenna cable connector [29] (finger

Washer

tight).

Antenna ground lead

10. License plate bracket

d. Interior light harness connector [190].

11. Amplifier

15.

Install molded Tour-Pak liner and close Tour-Pak lid.

Figure 2-59. Tour-Pak/Amplifier Mounting

INSTALLATION

After installing seat, pull upward on seat to be sure it is

locked in position. While riding, a loose seat can shift

1. Place two spacers, one on each side, between top support

causing loss of control, which could result in death or

tube and license plate bracket. Line up holes in spacers

serious injury. (00070b)

with rear holes in top support tube.

16. Install maxi-fuse, saddlebags, and seat.

NOTE

See Figure 2-58. For passenger comfort, the Tour-Pak can be

adjusted forward or rearward. Select the location holes for the

position selected.

2. Set Tour-Pak in place on top support tube.

NOTE

Have an assistant hold Tour-Pak in position.

2-36 2008 FLHTCUSE3 Service: Chassis

SADDLEBAGS

2.15

REMOVAL

sm03538

NOTE

To prevent dropping saddlebags and damaging finish, hold

saddlebag while removing bail head studs.

1. See Figure 2-62. Open saddlebag lids and turn bail head

studs 1/4 turn counterclockwise and remove fasteners and

washers.

NOTE

International models will require a flat bladed screwdriver to

remove the saddlebag fasteners.

2. Tilt saddlebag away from motorcycle and separate the

electrical connector for the power lock.

INSTALLATION

1. Carefully place saddlebag in position on rail.

2. Supporting the saddlebag, mate the power lock connector

housings.

3. Align the bail head studs with the support bracket holes

and push the studs into the bracket while turing 1/4 turn

1. Bail wire

clockwise.

2. Stud

3. Flat washer

4. Grommet

5. Spring plate

6. Wire form

7. Front bracket

8. Rear bracket

Figure 2-62. Saddlebag Quick-Release Fasteners

2-38 2008 FLHTCUSE3 Service: Chassis

SADDLEBAGS LATCH

2.16

REMOVAL

sm04019

1. Remove maxi-fuse.

2. Open saddlebag and lift out felt liner.

3. Remove the two screws from the check strap and the latch

cover.

4. See Figure 2-63. Loosen the lock nut (1) on the cable end

and remove the barrel and cable from the inner cam arm

(2).

5. See Figure 2-64. Remove the e-clip (1).

6. Remove the spacer (2), spring (3), inner cam (4) and outer

cam (5).

7. See Figure 2-63. Remove the two inner screws (3) to

remove the cam plate (4).

INSTALLATION

1. Install the cam plate and finger tighten the two inner

screws.

2. See Figure 2-64. Push the outer cam through the hole in

the saddlebag and cam plate. Align the inner cam to the

1. Lock nut

square stock of the outer cam.

2. Inner cam arm

3. Slide the small end of the spring over the square stock of

3. Inner screws

the outer cam. Press the spring in place with the spacer.

4. Cam plate

4. Secure the assembly with the e-clip.

Figure 2-63. Saddle Bag Cam Plate (Cover and Inner Liner

Removed)

5. Fit the barrel to the cam arm and tighten the lock

nut on

the cable end.

6. Tighten the two inner screws to 25 in-lbs (2.8 Nm).

sm04020

7. Replace the latch cover and tighten the screws to the point

where the tether fabric begins to wrinkle.

8. Replace felt liner.

9. Replace maxi-fuse.

1. E-clip

2. Spacer

3. Spring

4. Inner cam

5. Outer cam

Figure 2-64. Latch Component Alignment

2008 FLHTCUSE3 Service: Chassis 2-39

SADDLEBAG SUPPORTS

2.17

Loosely attach upper front saddlebag bracket (8): screw

REMOVAL

(7), washer (2) and bracket.

Loosely attach upper rear saddlebag bracket (1): screw

(7), washer (2), bracket, and washer (2).

To prevent accidental vehicle start-up, which could cause

Temporarily mount saddlebag, position upper saddlebag

death or serious injury, remove main fuse before pro-

mounting brackets lined up with mounting holes in

ceeding. (00251b)

saddlebag and tighten screws to 15-20 ft-lbs (20.4-27.1

1. See Touring Models Service Manual and remove the fol-

Nm). Remove saddlebag.

lowing items:

Install rubber mount (17) onto saddlebag support. Slide

a. Left and right side covers.

muffler mounting bracket (20) into rubber mount.

b. Maxi-fuse.

Attach muffler (16) to muffler mounting bracket with two

screws (18) and lockwashers (19). Tighten to 96-144 in-

2. Remove saddlebags. See 2.15 SADDLEBAGS.

lbs (10-9-16.3 Nm).

3. See Figure 2-65 and Figure 2-66. Remove two screws

10.

Install saddlebag filler strip (3) with spacer (4), two screws

(14), washers (15) and spacer (4) securing saddlebag filler

(14) and washers (15). Tighten to 15-20 ft-lbs (20.4-27.1

strip (3) to vehicle.

Nm).

4. Remove two screws (18) and lockwashers (19) securing

11.

Repeat above steps for opposite side of vehicle.

muffler (16) to saddlebag support (12). Remove muffler

mounting bracket (20) and rubber mount (17).

12.

See Touring Models Service Manual and install the fol-

lowing items:

5. Remove screw (11) and locknut (10) securing front of

saddlebag support to saddlebag guard (22).

Maxi-fuse.

6. Remove two screws (13) and locknuts (6) securing rear

Left and right side covers.

of saddlebag support to support bracket (5). Remove

Saddlebags.

saddlebag support from vehicle.

7. Remove upper front saddlebag bracket (8): screw (7),

washer (2) and bracket.

sm04021

8. Remove upper rear saddlebag

bracket (1): screw (7),

washer (2), bracket, and washer

(2).

9. Remove screws (21), support bracket (5) and trim.

10. Repeat above steps on opposite side of vehicle.

INSTALLATION

1. See Figure 2-66. Position support bracket (5) and trim on

vehicle. Secure with screws (21). Tighten to 15-20 ft-

lbs (20.4-27.1 Nm).

2. Slide front end of saddlebag support (12) into tube in

saddlebag guard (22). Loosely attach rear of saddlebag

support to support bracket with two screws (13) and lock-

nuts (6).

3. Loosely install screw

(11) and locknut

(10) through

saddlebag guard and saddlebag support.

Figure 2-65. Removing Filler Strip

4. Tighten screws securing rear of saddlebag support to 15-

20 ft-lbs (20.4-27.1 Nm). Tighten screw securing front of

saddlebag support to 70-100 in-lbs (7.9-11.3 Nm).

2-40 2008 FLHTCUSE3 Service: Chassis

sm04022

1. Upper rear saddlebag bracket (2)

2. Washer (6)

3. Saddlebag filler strip (2)

4. Spacer (2)

5. Support bracket (2) (right side shown)

6. Locknut (4)

7. Screw (4)

8. Upper front saddlebag bracket (2)

9. Receptacle (4)

10. Locknut (2)

11. Screw (2)

12. Saddlebag support (2) (right side shown)

13. Screw (4)

14. Screw (4)

15. Washer (4)

16. Muffler (2)

17. Rubber mount (2)

18. Screw (4)

19. Lockwasher (4)

20. Muffler mounting bracket (2)

21. Screw (4)

22. Saddlebag guard (2) (right side shown)

Figure 2-66. Saddlebag Support Components

2008 FLHTCUSE3 Service: Chassis 2-41

MUFFLER END CAP

2.18

REPLACEMENT

sm05061

1. Let motorcycle cool.

2. Loosen three clamps on muffler heat shield (2) and rotate

heat shield to access all three Torx fasteners.

3. See Figure 2-67. Loosen and remove three fasteners (1)

holding muffler end cap.

4. Remove end cap.

5. If necessary, remove and replace clip nut ring and clip

nuts.

6. Install clip nut ring and clip nuts in end cap.

7. Rotate fit to fastener holes in end cap and muffler. Install

and tighten fasteners to 84-108 in-lbs (9.5-12.2 Nm).

8. Return heat shield to original orientation and tighten three

clamps to 20-40 in-lbs (2.3-4.5 Nm).

1. Fastener

2. Heat shield

Figure 2-67. Muffler End Cap Fastener Locations

2-42 2008 FLHTCUSE3 Service: Chassis

SPECIFICATIONS: ENGINE

3.1

GENERAL

MANUFACTURING TOLERANCES

NOTE

Table 3-3. Rocker Arms Specifications

This chapter provides unique information for models equipped

with Twin-Cam 110 engines. For models manufactured for sale

ROCKER ARMS

IN.

in the country of Japan that are equipped with Twin-Cam 96

Shaft fit in bushing (loose)

0.0005-0.0020

0.013-0.051

engines, see the Service Manual for specifications and service

procedures.

End clearance

0.003-0.013

0.08-0.33

Bushing

fit in rocker arm (tight)

0.002-0.004

0.051-0.102

Table 3-1. Engine: TWIN-CAM 110

ITEM

SPECIFICATION

Table 3-4. Rocker Arm Shaft Specifications

Number of cylinders

ROCKER ARM SHAFTS

IN.

Type

4-cycle, 45°

Shaft fit in rocker arm support

0.0007-0.0022

0.018-0.056

V-Type, air cooled

plate (loose)

Torque

115 ft-lbs (156 Nm) @ 3000

RPM

Table 3-5. Hydraulic Lifter Specifications

Bore

4.000 in. (101.60 mm)

HYDRAULIC

IN.

Stroke

4.38 in. (111.13 mm)

LIFTERS

Piston

displacement (approx.)

110 cu. in. (1800 cc)

Fit in crankcase

0.0008-0.0020

0.02-0.05

Compression ratio

9.3:1

(loose)

Cam system

Twin cams, chain driven with

hydraulic tensioners

Table 3-6. Cylinder Heads

Max.

sustained engine speed

5500 RPM

ITEM

IN.

Idle speed

1000 RPM ± 50

Valve guide in head

0.0020-0.0033

0.051-0.084

(tight)

Table 3-2. Oiling System

Intake valve seat in

0.004-0.0055

0.102-0.140

head (tight)

ITEM

SPECIFICATION

Exhaust

valve set in

0.003-0.0045

0.076-0.114

Oil tank capacity

4 qt (3.78 L)

head (tight)

with filter

Head gasket sur-

0.0-0.006

0.0-0.0152

Preferred oil

SYN3 20W50 (Part No. 99824-03/00QT

face (flatness)

quart)

Pump

Twin gerotor, dual scavenge, crank

Table 3-7. Valves

mounted and driven, internal oil pump,

dry sump

ITEM

IN.

Pressure

30-38 psi (207-262 kN/m²) at 2000 RPM

Fit in guide (intake

0.0011-0.0029

0.028-0.074

and normal operating temperature of

and exhaust)

230° F (110° C)

Seat width

0.034-0.062

0.86-1.57

Filtration

5 micron media, filtered between pump

Stem protrusion

1.990-2.024

50.55-51.41

and engine

from cylinder head

Cooling

Thermostat controlled oil cooler

boss

Table 3-8. Valve Springs Specifications

ITEM

PRESSURE

DIMENSION

Closed

175 lbs (79 kg)

1.800 in (45.7 mm)

Open

432 lbs (196 kg)

1.250 in. (31.8 mm)

Free length

n/a

2.210 in (56.1 mm)

2008 FLHTCUSE3 Service: Engine 3-1

Table 3-9. Pistons

Table 3-11. Flywheels

ITEM

IN.

ITEM

IN.

Fit in cylinder

0.0018-0.0027

0.046-0.069

Runout (shaft measured

0.000-0.010

0.0-0.254

in case)

Piston pin fit (loose)

0.0005-0.0009

0.013-0.023

Runout (measured in

0.000-0.004

0.0-0.102

Ring end gap:

truing stand)

op compression ring

0.016-0.024

0.406-0.610

End play

0.003-0.010

0.076-0.254

2nd compression ring

0.014-0.022

0.356-0.559

Oil control ring

0.010-0.030

0.254-0.762

Table 3-12. Crankshaft/Sprocket Shaft Bearing

Ring side clearance:

Specifications

op compression ring

0.00098-0.0024

0.025-0.061

CRANK-

IN.

2nd compression ring

0.00098-0.0024

0.025-0.061

SHAFT/SPROCKET

SHAFT BEARINGS

Oil control ring

0.002-0.004

0.051-0.102

Roller bearing fit (loose)

0.0002-0.0015

0.005-0.038

Bearing fit in crankcase

0.0038-0.0054

0.097-0.137

Table 3-10. Connecting Rods

(tight)

ITEM

IN.

Bearing inner race on

0.0004-0.0014

0.010-0.036

Piston pin fit (loose)

0.0006-0.0012

0.015-0.030

crankshaft (tight)

Side play between fly-

0.005-0.015

0.13-0.38

wheels

Connecting rod to

0.0004-0.0017

0.0102-0.0432

crankpin (loose)

3-2 2008 FLHTCUSE3 Service: Engine

SERVICE

WEAR LIMITS

3.2

GENERAL

Table 3-17. Cylinders

Wear limits can be used as a guide when deciding whether to

ITEM

REPLACE IF WEAR EXCEEDS

reuse engine parts. Replace used parts whenever the following

wear limits are exceeded.

IN.

aper

0.002

0.051

Table 3-13. Rocker Arm/Rocker Arm Shaft

Out of round

0.002

0.051

ROCKER

ARM/ROCKER

REPLACE IF WEAR EXCEEDS

Warpage of gasket or

0.006

0.152

ARM SHAFT

O-ring surfaces: top

IN.

Shaft

fit in bushing (loose)

0.0035

0.089

Warpage of gasket or

0.004

0.102

O-ring surfaces: base

End clearance

0.025

0.635

Shaft fit in rocker arm

0.0035

0.089

Table 3-18. Cylinder Bore

support (loose)

ITEM

REPLACE IF WEAR EXCEEDS

Table 3-14. Hydraulic Lifters

IN.

ITEM

REPLACE IF WEAR EXCEEDS

Standard

4.002

101.65

IN.

0.005 in.

oversize

4.007

101.78

Fit in crankcase

0.003

0.08

0.010 in.

oversize

4.012

101.90

Roller fit

0.0015

0.038

Table 3-19. Pistons

Roller end clearance

0.015

0.38

ITEM

REPLACE IF

WEAR EXCEEDS

Table 3-15. Cam Support Plate

IN.

CAM SUPPORT PLATE

REPLACE IF

Fit in cylinder (loose)

0.003

0.076

IN.

Piston pin

fit (loose)

0.0009

0.023

Cam

chain tensioner shoe

More than 0.090

More than 2.29

Ring end gap

op compression

0.034

0.864

1/2

thickness of shoe

2nd compression

0.032

0.813

Crankshaft bushing max-

More than

imum ID

0.8545

21.704

Oil control ring rails

0.030

0.762

Camshaft bore

1.1023

27.998

Ring

side clearance

op compression

0.0032

0.081

2nd compression

0.0032

0.081

Table 3-16. Cylinder Heads

Oil control ring rails

0.004

0.102

ITEM

REPLACE IF

Table 3-20. Connecting Rods

IN.

Valve guide (tight)

Less than 0.002

Less than 0.051

ITEM

REPLACE IF WEAR

(intake and

EXCEEDS

exhaust)

IN.

Intake seat (tight)

Less than 0.004

Less than 0.102

Piston pin fit (loose)

0.002

0.051

Exhaust

seat (tight)

Less than 0.003

Less than 0.076

Side play between flywheels

0.020

0.51

Head warpage

Greater than 0.006

Greater than 0.152

Fit on crankpin (loose)

0.002

0.05

Table 3-21. Flywheels

ITEM

REPLACE IF WEAR EXCEEDS

IN.

Runout (shaft measured

0.012

0.305

in case)

Runout (measured in

0.005

0.127

truing stand)

End play

0.010

0.254

2008 FLHTCUSE3 Service: Engine 3-3

Table 3-22. Crankshaft Roller Bearing

Table 3-23. Breather Assembly

ITEM

REPLACE IF

BREATHER ASSEMBLY

REPLACE IF WEAR

EXCEEDS

IN.

Roller bearing fit (loose)

More than

0.0015

0.038

Breather cover warpage

0.005

0.13

Crankshaft runout

More than

Breather baffle warpage

0.005

0.13

0.003

0.076

Bearing fit in crankcase (tight)

Less than

Table 3-24. Valve Stem to Guide

0.0038

0.097

VALVE STEM TO GUIDE

REPLACE IF WEAR EXCEEDS

Inner race on crankshaft (tight)

Less than

0.0004

0.010

IN.

Intake

0.0038

0.0965

Exhaust

0.0038

0.0965

3-4 2008 FLHTCUSE3 Service: Engine

CYLINDER HEAD

3.3

GENERAL

sm04037

For service wear limits, refer to Table 3-16.

REMOVAL

See the Service Manual for removal of cylinder heads.

NOTE

Separate ACR connectors from the rear [203R] and front [203F]

cylinder heads when removing the heads from the cylinders.

DETERMINING SERVICE

To determine if cylinder head disassembly and reconditioning

is necessary.

1. Raise valve ports of cylinder head to strong light source.

If light is visible around edges of seats, then move to

DISASSEMBLY to recondition cylinder head.

2. Fill ports at top of cylinder head with solvent. Wait ten full

seconds and then check for leakage into combustion

chamber. If solvent leakage into combustion chamber is

evident, then move to DISASSEMBLY to recondition cyl-

inder head.

sm04036

Figure 3-2. Spring/Valve Stack and ACR

DISASSEMBLY

PART NUMBER

TOOL NAME

HD-34736-B

VALVE SPRING COMPRESSOR

HD-39786

CYLINDER HEAD HOLDING FIXTURE

HD-48498

ACR SOLENOID SOCKET

1. Use the ACR SOLENOID SOCKET (Part No. HD-48498)

to remove the ACR. See 8.16 AUTOMATIC COMPRES-

SION RELEASE.

2. See Figure 3-3. Obtain the CYLINDER HEAD HOLDING

FIXTURE (Part No. HD-39786) and proceed as follows:

a. Thread the 12 mm end of the tool into the spark plug

hole of the cylinder head.

b. See Figure 3-4. Clamp tool in vise at a 45 degree

angle (or one that offers a comfortable working posi-

tion).

Figure 3-1. Combustion Chamber

3. See Figure

3-5. Obtain the VALVE SPRING COM-

PRESSOR (Part No. HD-34736-B) and proceed as follows:

a. Place tool over cylinder head so that the blunt end is

centered on the valve head and adapter at end of

forcing screw is seated on the valve spring retainer.

b. Rotate forcing screw to compress valve springs.

c. If spring retainer has not broken free of tapered

keepers, give head of tool a sharp tap with a soft

mallet. Using magnetic rod or small screwdriver,

remove the keepers from the valve stem groove.

d. Rotate forcing screw to release the valve spring

compression.

2008 FLHTCUSE3 Service: Engine 3-5

Harley Davidson 2008 FLHTCUSE3 Model. Service Manual Supplement - page 3