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Harley Davidson 2008 FLHTCUSE3 Model. Service Manual Supplement - page 5

5. Use HOSE CLAMP PLIERS (Part No. HD-97087-65B) to

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install clamp.

6. Install a new oil filter. See ENGINE OIL/FILTER in the

1

Touring Models Service Manual.

2

Oil level cannot be accurately measured on a cold engine.

For pre-ride inspection, with motorcycle leaning on jiffy

stand on level ground, oil should register on dipstick

between arrows when engine is cold. Do not add oil to

bring the level to the FULL mark on a COLD engine.

(00185a)

7. Perform an oil level COLD CHECK. See the Touring

Models Service Manual.

NOTE

Add only enough oil to bring the level between the two arrows

on the dipstick.

3

Do not operate the engine when the oil level is below the

1. Supply port

add mark on the dipstick at operating temperature. Engine

2. Return port

damage will result. (00187b)

3. Oil filter gasket surface

8. Start engine and check for oil leaks.

Figure 3-38. Oil Line Fittings on Adapter

9. When at operating temperature, perform an oil level HOT

CHECK. See the Touring Models Service Manual.

3-26 2008 FLHTCUSE3 Service: Engine

AIR CLEANER COVER

4.1

GENERAL

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The air cleaner assembly is functionally identical to that of the

standard models, with the exception of the air cleaner cover,

decorative cover trim and cover mounting screws.

3

For other air cleaner assembly procedures, see the Service

2

Manual.

REMOVAL

1. See Figure 4-1. Remove two screws (3) and decorative

cover trim (2).

2. See Figure 4-2. Remove screw (2) and air cleaner cover

(1).

1

INSTALLATION

1. See Figure 4-2. Install air cleaner cover (1). Make sure

rubber cover seal (3) fits all the way around the cover.

2. Install screw (2). Tighten to 36-60 in-lbs (4.1-6.8 Nm).

1. Air cleaner cover

2. Screw

3. See Figure 4-1. Install decorative cover trim (2) and two

3. Cover seal

screws (3).

Figure 4-2. Air Cleaner Cover and Screw

4. Tighten to 27-32 in-lbs (3.1-3.6 Nm).

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2

3

1

1. Air cleaner cover

2. Decorative cover trim

3. Screw (2)

Figure 4-1. Air Cleaner Cover Trim and Screws

2008 FLHTCUSE3 Service: Fuel System 4-1

SPECIFICATIONS: DRIVE

6.1

GENERAL

Table 6-4. Drive Ratios

Table 6-1. Primary Chaincase Lubricant

GEAR

TRANSMISSION

OVERALL

1

3.34

9.312

ITEM

DRY FILL

WET FILL

2

2.31

6.421

Amount

45 oz (1.32 l)

38 oz (1.12 l)

3

1.72

4.774

Part No.

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

quart)

4

1.39

3.926

5

1.18

3.279

NOTES

6

1.00

2.790

•

A dry fill is required any time the primary cover has been

removed and replaced.

NOTES

•

A wet fill is required when the primary chain case lubricant

•

Transmission gear ratios indicate the number of mainshaft

has only been drained through the primary drain plug.

revolutions required to drive the output sprocket one

revolution.

Table 6-2. Drive Belt Deflection (at loosest spot on belt)

•

Overall gear ratios indicate the number of engine revolu-

tions required to drive the rear wheel one revolution.

DEFLECTION

IN.

MM

On jiffy stand without rider or

1/4-7/16 in. at

6.4-11.1 mm

luggage, with 10-PSI (69 kPa)

10 lbs force

at 4.5 kg force

in rear shocks, and transmis-

sion in neutral

Table 6-3. Sprockets

SPROCKET

NUMBER OF TEETH

Engine

34

Clutch

46

T

ransmission (output

32

sprocket)

Rear wheel

66

2008 FLHTCUSE3 Service: Drive 6-1

CLUTCH RELEASE BEARING AND PUSHROD

6.2

REMOVAL

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To prevent accidental vehicle start-up, which could cause

death or serious injury, disconnect negative (-) battery

cable before proceeding. (00048a)

1. Remove seat. See SEAT in Service Manual.

2. Remove negative cable from battery.

5

2

3. See Figure 6-1. To access clutch release bearing, remove

clutch inspection cover.

4

4. See Figure 6-2. Remove bearing plate retaining ring (1).

5. Pull out release bearing plate (3) with release bearing (4)

3

and push rod (5).

6. Remove push rod retainer (2).

7. Press release bearing out of bearing plate.

1

INSTALLATION

1. Bearing plate retaining ring

1. See Figure 6-2. Pressing on the outer race, press a new

2. Push rod retainer

release bearing (4) into bearing plate (3).

3. Release bearing plate

2. Assemble push rod (5) to bearing.

4. Release bearing

5. Push rod

3. Snap in push rod retainer (2).

Figure 6-2. Push Rod and Release Bearing

4. Slide push rod and clutch release bearing assembly

through clutch pack to secondary clutch actuator.

Measure Release Plate Movement

5. Snap in bearing plate retaining ring (1).

1. Attach the standoff of a dial indicator to one of the 1/4-20

NOTE

clutch-inspection (derby) cover mounting holes, or use a

Before installing clutch inspection cover check push rod and

magnetic base and dial indicator mounted suitably. Posi-

release plate movement as follows.

tion the indicator anvil (rod) to the end of the push rod.

sm04071

Insufficient clutch-release plate movement can lead to

difficulty or inability to shift, causing loss of control, which

could result in death or serious injury. (00345a)

2. Actuate the clutch lever to measure the axial movement

of the push rod and the clutch-release plate assembly.

The axial movement must be at least 0.065 in. (1.65 mm).

NOTE

Proper bleeding of the system will typically yield plate move-

ment of greater than

0.065 in. (1.65 mm). If clutch release

plate movement is less than 0.065 in. (1.65 mm), the system

must be bled and plate movement measured again.

Install Clutch Inspection Cover

Figure 6-1. Clutch Release Bearing

1. Thoroughly clean all gasket material from clutch inspection

cover and mating surface on primary cover.

2. See Figure 6-3. Install clutch inspection cover with new

gasket. Make sure the correct side of the gasket faces the

clutch inspection cover. In sequence shown, tighten

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

3. Connect negative (-) battery cable to battery.

6-2 2008 FLHTCUSE3 Service: Drive

sm04073

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

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

causing loss of control, which could result in death or

serious injury. (00070b)

1

4. Install seat. See SEAT in Service Manual.

4

3

2

5

Figure 6-3. Clutch Inspection Cover Torque Sequence

2008 FLHTCUSE3 Service: Drive 6-3

SPECIFICATIONS: TRANSMISSION

7.1

GENERAL

Table 7-2. Transmission Gear Ratios

Table 7-1. Transmission Data

GEAR

RATIO

1

3.34

ITEM

DATA

2

2.31

Type

6-speed Cruise Drive™

forward - constant mesh

3

1.72

SYN3 20W50

Quart

Part No. 99824-03/00QT

4

1.39

Capacity (dry)

32 oz. (946 ml)

5

1.18

6

1.00

NOTE

Transmission gear ratios indicate the number of mainshaft

revolutions required to drive the output sprocket one revolution.

2008 FLHTCUSE3 Service: Transmission 7-1

CLUTCH RELEASE COVER

7.2

REMOVAL

sm04074

1. Remove filler plug and dipstick.

2. Place a suitable container under transmission. Remove

magnetic drain plug at bottom right of oil pan and drain

1

1

transmission lubricant.

3. Remove seat.

2

To prevent accidental vehicle start-up, which could cause

death or serious injury, disconnect negative (-) battery

cable before proceeding. (00048a)

4. Remove negative battery cable.

5. To access the clutch release cover assembly, remove

right side exhaust system. See EXHAUST SYSTEM,

REMOVAL in the Service Manual.

1. Hole for locating dowel

6. Place a pan under clutch release cover. Remove cap and

2. Secondary clutch actuator

open bleeder valve. Loosen flare nut and allow clutch fluid

Figure 7-1. Inside Clutch Release Cover

to drain.

7. Remove flare nut on outside of the clutch release cover.

Remove clutch fluid line and drain line. See 1.3 BLEEDING

INSTALLATION

CLUTCH FLUID LINE.

1. See Figure 7-2. Place a new clutch release gasket (2) on

NOTE

locating dowels (1) and position clutch release cover on

Dispose of clutch fluid in accordance

with local regulations.

transmission side door.

8. See Figure 7-3. Discard o-ring on end of clutch fluid line.

2. Install

fasteners with the two short fasteners at the top of

the release cover.

Tighten fasteners to

120-144 in-

NOTE

lbs (13.5-16.3 Nm).

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

3. See Figure 7-3. Install a new clutch fluid line o-ring on the

debris.

end of the clutch fluid line.

9. Remove clutch release cover fasteners, cover and gasket.

4. Install clutch fluid line flare nut to clutch release cover.

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

10. Clean and inspect clutch release cover. Clean with dena-

tured alcohol or D.O.T. 4 HYDRAULIC BRAKE FLUID

(Part No. 99953-99A) only.

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NOTE

If required, replace locating dowels in transmission side door.

1

1

11. See Figure 7-1. Disassemble and inspect secondary clutch

2

actuator (2). Rebuild if required. See 7.3 SECONDARY

CLUTCH ACTUATOR.

1. Locating dowels

2. Gasket

Figure 7-2. Transmission Side Door

7-2 2008 FLHTCUSE3 Service: Transmission

2. Inspect o-ring on transmission lubricant drain plug and

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replace as necessary. Install drain plug and tighten to 14-

21 ft-lbs (19.0-28.5 Nm).

3. Fill the transmission with

32 oz. (946 ml) of transmission

lubricant or until the lubricant level on the dipstick of the

filler plug is at the F (FULL) mark with the motorcycle level

and upright and the filler plug resting on the threads. Use

only Harley-Davidson FORMULA+ TRANSMISSION AND

PRIMARY CHAINCASE LUBRICANT, Part No. 998851-

05 (quart).

4. Inspect the filler plug and dipstick o-ring and install filler

plug/dipstick. Tighten the plug to 25-75 in-lbs (2.8-8.5

Nm).

5. Install exhaust system. See EXHAUST, INSTALLATION

in the Service Manual.

6. Install negative battery cable.

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

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

causing loss of control, which could result in death or

serious injury. (00070b)

Figure 7-3. Clutch Fluid Line O-ring

7. Install seat.

FILL AND BLEED

1. Fill clutch reservoir and bleed clutch fluid system. See

1.3 BLEEDING CLUTCH FLUID

LINE.

2008 FLHTCUSE3 Service: Transmission 7-3

SECONDARY CLUTCH ACTUATOR

7.3

7. While pushing piston into actuator bore, use a wooden

REPLACEMENT

tooth pick or the end of a cable wrap to prevent primary

1. Remove the clutch release cover. See 7.2 CLUTCH

cup from rolling over.

RELEASE COVER.

8. Install the clutch release cover. See

7.2 CLUTCH

RELEASE COVER.

Compressed air can pierce the skin and flying debris from

sm04077

compressed air could cause serious eye injury. Wear

safety glasses when working with compressed air. Never

1

use your hand to check for air leaks or to determine air

2

flow rates. (00061a)

2. Remove piston.

a. If the bleeder valve was removed, reinstall.

3

b. Support on a wooden block and apply low pressure

compressed air to clutch fluid line hole to remove

piston from cover bore.

3. See Figure 7-4. If necessary, wiggle piston from actuator

bore to completely remove.

4. Remove the spring. Discard spring and piston assembly.

Avoid leakage. Prevent damage to piston or piston bore.

Use non-metallic tools when servicing clutch actuator.

1. Piston

(00328a)

2. Primary cup

5. Lubricate new piston assembly and piston bore with the

3. Spring

service kit lubricant.

Figure 7-4. Secondary Clutch Actuator Components

6. Install new spring.

7-4 2008 FLHTCUSE3 Service: Transmission

ELECTRICAL PROTECTION

8.1

FUSES AND RELAYS

Table 8-1. Fuse and Relay Block

See Figure 8-1. The fuse and relay block is located in the left

POSITION

CIRCUIT

AMPS

electrical caddy, under the left side cover. Refer to Figure 8-2

and Table 8-1 for locations.

1

Brake

15

The MAXIFUSE is also located in the left electrical caddy.

2

Accessory

15

3

P&A

15

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1

2

4

Radio/Siren

15

5

Radio Memory

15

6

Battery

15

7

ECM power

15

8

Power Lock

15

9

Fuel pump

15

10

System Relay

-

11

Start Relay

-

12

P&A Ignition

2 (max)

4

13

Instruments

15

3

14

Ignition

15

1. Smart siren

15

Engine Control

15

2. MAXIFUSE (40 Amps)

16

Brake Relay

-

3. ABS diode pack

4. Datalink connector

17

Headlamp

15

Figure 8-1. Left Electrical Caddy and Fuse

18

Lights

15

19

Spare

5

20

Heated Grips

5

21

Spare

15

ed01576

22

ABS

30

23

Amplifier

30

1

2

3

4

24

Spare

30

5

6

7

8

See Figure 8-3. The ignition relay is located under the seat.

ed01577

10

11

9

12

13

14

15

17

18

19

16

20

21

22

23

24

Figure 8-2. Fuses: FLHTCUSE3

Figure 8-3. Ignition Relay (Under Seat)

2008 FLHTCUSE3 Service: Electrical 8-1

BULB CHART

8.2

GENERAL

Table 8-3. Bulb Chart

LAMP DESCRIPTION (ALL LAMPS 12

V)

NO.

OF BULBS

AMPS

HARLEY-DAVIDSON

PART NO.

Headlamp, high beam (domestic)

1

2.7

68096-04

Headlamp, low beam (domestic)

1

4.3

68881-01

Headlamp, high beam/low beam (HDI)

1

4.58/5.0

68329-03

Position lamp (HDI)

1

0.32

53438-92

T

our-Pak lamp (LED assembly)

1

0.06

54359-06

2008 FLHTCUSE3 Service: Electrical 8-3

HEADLAMP

8.3

GENERAL

ed01579

See Figure 8-4.The FLHTCUSE3 headlamp assembly contains

two headlamp bulbs: a low beam bulb (1) and a separate high

2

beam bulb (2).

REMOVAL

1. Place a clean shop cloth or fender protector over front

fender.

2. See Figure 8-5. Remove screw (1). Pull straight out gently

on bottom of headlamp door (2). When bottom of door

clears headlamp lens, lift up on door slightly and remove

from vehicle.

3. See Figure 8-6. Support glass headlamp shell (2) and

remove three phillips head retaining ring screws (1).

Remove retaining ring (3). Lay headlamp shell on fender

protector.

4. See Figure 8-7. Pinch latches (4) together and remove

connectors from headlamp bulbs.

NOTE

See Figure 8-8. Sockets on back of headlamp shell are part

1

of bulb assemblies.

1. Screw

2. Headlamp door

Figure 8-5. Headlamp Door

Handle bulb carefully and wear eye protection. Bulb con-

tains gas under pressure, which, if not handled carefully,

could cause serious eye injury. (00062b)

5. Grasp bulb socket, turn counterclockwise approximately

ed01580

1/8 turn and pull straight out to remove bulb from headlamp

shell. Discard bulb.

1

3

ed01578

2

1

1

1

2

1. Screw (3)

2. Headlamp shell

3. Retaining ring

Figure 8-6. Headlamp Mounting

1. Low beam bulb

2. High beam bulb

Figure 8-4. Headlamp Assembly

8-4 2008 FLHTCUSE3 Service: Electrical

1.

Install new bulb(s) into headlamp shell.

ed01581

a. Hold headlamp shell upright. Insert bulb into appro-

priate hole in shell with bulb socket hanging down at

approximate 4 o'clock position. Insert low beam bulb

3

(green label) on top, high beam bulb (yellow label) on

bottom.

b. Turn bulb clockwise approximately 1/8 turn to lock in

4

4

place.

2.

Attach harness connectors to bulb sockets.

a. Attach connector [38LOB] (labeled "LOW") to the low

beam (top) bulb.

2

b. Attach connector [38HIB] (labeled "HIGH") to the high

beam (bottom) bulb.

c. Push connectors onto sockets until they click in place.

3.

See Figure 8-9. Position headlamp shell into mounting

1

ring

(1). Hold in place with retaining ring (2). Secure

retaining ring with three screws (3). Tighten to 23-28 in-

lbs (2.6-3.2 Nm).

4.

See Figure 8-10. Make sure rubber gasket (2) is in place

1.

Headlamp shell

in headlamp door (1) and not deformed or otherwise

2.

Low beam harness connector [38LOB]

damaged. Make sure gasket springs (3) are holding gasket

3.

High beam harness connector [38HIB]

in place. Make sure top spring (4) is in place and located

4.

Latch (2 per connector)

at top center of door.

Figure 8-7. Headlamp Bulb Connectors

5.

Install headlamp door.

a. Angle top of door in over top of headlamp assembly.

b. Fit square-shaped portion of top spring into slot at top

of backplate.

ed01582

c. Carefully press door down around headlamp lens.

When finished,

equal amounts of gasket should be

visible between door and headlamp shell.

6.

Secure door at bottom with screw. Tighten to 9-18 in-

lbs (1.0-2.0 Nm).

ed01583

3

1

2

Figure 8-8. Headlamp Bulb

INSTALLATION

Never touch the quartz bulb. Fingerprints will etch the

glass and decrease bulb life. Grab the bulb with paper or

1. Mounting ring

a clean, dry cloth. Failure to do so could result in bulb

2. Retaining ring

damage. (00210a)

3. Screw (3)

Figure 8-9. Headlamp Support

2008 FLHTCUSE3 Service: Electrical 8-5

ed01584

4

3

1

2

1. Headlamp door

2. Rubber gasket

3. Gasket spring (2)

4. Top spring

Figure 8-10. Headlamp Door Assembly

8-6 2008 FLHTCUSE3 Service: Electrical

8. Remove auxiliary lamp assembly (4) and rubber isolator

REMOVING LAMP BRACKET

(5) from bracket (6) while slowly pulling wire through con-

duit and bracket.

1. Remove turn signal assembly. See 8.5 FRONT TURN

SIGNALS.

Table 8-4. Turn Signal/Auxiliary Lamp Connector [31]

2. See Figure 8-11. Remove two screws (7) and washers

(8).

Left Side [31LA]

Right Side [31RA]

3. Remove bracket from motorcycle.

WIRE COLOR

TER-

WIRE COLOR

TER-

MINAL

MINAL

INSTALLING LAMP BRACKET

GY/BK

4

GY/BK

4

1. Align bracket with mounting holes on front fork assembly.

(left aux lamp)

(right aux lamp)

2. Install washers and screws.

3. Tighten screws to 15-20 ft-lbs (20.3-27.1 Nm).

ed01585

4. Install turn signal assembly. See 8.5 FRONT TURN SIG-

NALS.

INSTALLING LAMPS

Mount Lamp

4

1. Thread socket terminal and wire lead through bracket and

up through conduit to the connector [31].

NOTES

•

If mechanic's wire remains in conduit, attach wire to socket

9

10

terminal and pull mechanic's wire to draw socket terminal

back through mounting bracket and conduit. Carefully

remove mechanic's wire to avoid damage to terminals.

8

•

Liquid glass cleaner may be used to aid in pulling wires

7

through conduit.

2. Position rubber isolator and auxiliary lamp assembly onto

auxiliary lamp bracket.

3. Install clamp block, lockwasher and nut.

4. See Figure 8-13. Orient lamps straight ahead and hori-

zontal. Finger tighten nut.

NOTE

5

Align the lamps and tighten the nut to the specified torque

6

before operating the motorcycle.

3

5. Install terminals into numbered cavity of socket housing.

NOTE

2

See APPENDIX B AMP MULTILOCK in Touring Models Service

Manual for wire lead terminal service procedures.

1

6. Mate pin and socket halves of auxiliary lamp connector.

Final Assembly

1. Install turn signal assembly. See 8.5 FRONT TURN SIG-

NALS.

1.

Nut

2. Install outer fairing. See OUTER FAIRING/WINDSHIELD

2.

Lockwasher

in Touring Models Service Manual.

3.

Clamp block

4.

Lamp assembly

5.

Rubber isolator

6.

Bracket

7.

Bracket screws (2)

8.

Washers (2)

9.

Socket terminal

10. Socket housing

Figure 8-11. Auxiliary Lamps and Brackets

8-8 2008 FLHTCUSE3 Service: Electrical

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