Harley Davidson 2008 Touring Models. Service Manual

sm02881

Horizontal brace - thick (rear)

Horizontal brace - thin (front)

Vertical brace (right side)

Vertical brace (left side)

Stepped ends

Figure 2-157. Windshield Braces

Apply one drop of Loctite Medium Strength Threadlocker
243 (blue) to threads of three short screws. Slide screws
through the middle and outer holes of the horizontal
braces. Loosely install acorn nuts on rear side.

10. Remove paper backing from adhesive strip on vertical

brace. With the stepped end overlapping the installed
horizontal brace (and the slight bend on the opposite end
angled outward), align holes in brace with vertical set of
holes in windshield, and press into position. See

Figure 2-157

11. Position mounting bracket on rear side of windshield with

the wireform facing inboard. Align three holes in mounting
bracket with those in vertical brace.

12. Apply one drop of Loctite Medium Strength Threadlocker

243 (blue) to threads of two short screws and one long
screw. Slide screws through holes in vertical brace and
mounting bracket, the longer screw at the stepped end
where the vertical brace overlaps the horizontal brace.
Loosely install acorn nuts on rear side.

13. Repeat previous steps to install second vertical brace and

mounting bracket.

14. Holding acorn nuts on rear side, alternately tighten nine

T27 TORX screws to 20-25 in-lbs (2.3-2.8 Nm) in the
pattern shown in

Figure 2-158

15. Install windshield. See

2.44 WINDSHIELD: FLHR/C

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Figure 2-158. Windshield Torque Sequence

2008 Touring Service: Chassis 2-129

2.45

HEADLAMP NACELLE: FLHR/C

REMOVAL

Remove windshield. See

2.44 WINDSHIELD: FLHR/C

Remove the Phillips screw at the bottom of the headlamp
door (chrome ring). Remove the headlamp door.

Remove the seven Phillips screws to free the headlamp
housing from the headlamp nacelle.

Remove headlamp connector [38] at back of headlamp
bulb. Remove the headlamp housing assembly from the
motorcycle.

Reaching inside the headlamp nacelle, remove the flange
nut to release the chrome strip at the top of the nacelle.
See

Figure 2-159

Carefully pry off the fork lock plate at the rear of the
handlebar clamp shroud. Remove two Phillips screws
beneath the lock plate.

Loosen the Phillips screw from tab at the front of the
handlebar clamp shroud (but do not remove Keps nut and
flat washer).

Remove the two acorn nuts from the left side fork bracket
studs. Remove acorn nuts from the right side fork bracket
studs.

Cover the front fender with suitable material to protect the
fender paint. Remove the auxiliary lamp bracket from the
left and right side fork bracket studs and carefully set on
front fender.

10. Remove the grommets (and clutch cable clamp) from the

left and right side fork bracket studs.

11. Raise the handlebar clamp shroud, and after separating

the halves of the headlamp nacelle slightly, slide the
shroud forward running the shaft of the Phillips screw down
the gap. See

Figure 2-160

12. Reaching inside the headlamp nacelle, disconnect

accessory switch connector [67] and auxiliary lamp switch
connector [109]. See

Figure 2-161

13. Carefully separate the halves of the headlamp nacelle and

remove from motorcycle.

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Headlamp nacelle (left side

Trim strip

Flange nut

Chrome strip

Fork lock plate

Handlebar clamp shroud

Phillips screw (2)

Phillips screw

Flat washer

10. Keps nut

Figure 2-159. Headlamp Nacelle Assembly

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Figure 2-160. Handlebar Clamp Shroud and Screw

Assembly

2-130 2008 Touring Service: Chassis

INSTALLATION

Fit halves of the headlamp nacelle together engaging the
holes in the nacelle with the left and right side fork bracket
studs.

Reaching inside the headlamp nacelle, connect accessory
switch connector [67] and auxiliary lamp switch connector
[109]. See

Figure 2-161

If disassembled, install Phillips screw, flat washer and
Keps nut on the handlebar clamp shroud as shown in

Figure 2-160

Part the halves of the headlamp nacelle slightly. With the
flat washer on the inboard side of the nacelle, slide the
shroud rearward running the shaft of the Phillips screw
down the gap. Position the shroud over the flange at the
top of the nacelle.

Mate the halves of the headlamp nacelle and tighten the
Phillips screw to 10-20 in-lbs (1.1-2.3 Nm).

Install two Phillips screws to secure handlebar clamp
shroud to the fork lock mechanism. Alternately tighten
screws to 10-20 in-lbs (1.1-2.3 Nm). Install fork lock plate.

NOTE

To avoid possible damage to the brake hose and/or handlebar
switch wires, verify that trim strips are installed on inside edges
of the headlamp nacelle. Cutting or severe chafing of the brake
hose and/or handlebar switch wires could cause loss of function
while riding.

Verify that trim strips are installed on inside edges of
headlamp nacelle. Install new trim strips if cracked, broken
or missing.

Inserting the weld stud on the chrome strip into the hole
at the top of the headlamp nacelle, reach inside the nacelle
to install flange nut. Tighten flange nut to 15-20 in-lbs (1.7-
2.3 Nm).

Install the grommets on the left and right side fork studs.

10. Slide the auxiliary lamp bracket onto the left and right side

fork bracket studs. Verify that the four grommets are in
place on the inboard side of the auxiliary lamp brackets.

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Accessory switch [67]

Auxiliary lamps switch [109]

Figure 2-161. Headlamp Nacelle (FLHRC)

11. Install the acorn nuts on the fork bracket studs and tighten

to 72-108 in-lbs (8.1-12.2 Nm). Be sure to capture the
clutch cable clamp on the upper left stud before installing
the acorn nut.

12. Install headlamp connector [38] at back of headlamp bulb.

13. Align holes in headlamp housing with wellnuts in headlamp

nacelle (headlamp door bracket at bottom). Install the
seven Phillips screws and alternately tighten to 9-18 in-
lbs (1.0-2.0 Nm).

14. Fit the square-shaped portion of the headlamp door spring

into the slot at the top of the headlamp housing and then
snap the headlamp door (chrome ring) into place. Install
Phillips screw at the bottom of the headlamp door and
tighten to 9-18 in-lbs (1.0-2.0 Nm).

15. Install windshield. See

2.44 WINDSHIELD: FLHR/C

2008 Touring Service: Chassis 2-131

Harley Davidson 2008 Touring Models. Service Manual - page 2