2008 Harley Davidson FLHTCUSE3 Service Manual Supplement 99500-08 – PDF DOWNLOAD
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DESCRIPTION:
2008 Harley Davidson FLHTCUSE3 Service Manual Supplement 99500-08 – PDF DOWNLOAD
ABOUT THIS MANUAL:
GENERAL:
- This Service Manual Supplement has been designed to be used with the current Service Manual and has been prepared with two purposes in mind.
- First, it will acquaint the user with the construction of the Harley-Davidson product and assist in the performance of basic maintenance and repair.
- Secondly, it will introduce to the professional Harley-Davidson Technician the latest field-tested and factory-approved major repair methods.We sincerely believe that this Service Manual Supplement will make your association with Harley-Davidson products more pleasant and profitable.
HOW TO USE YOUR SERVICE MANUAL SUPPLEMENT:
Use the TABLE OF CONTENTS (which follows this FOREWORD) and the INDEX (at the back of this manual) to quickly
locate subjects. Sections and topics in this manual are sequentially numbered for easy navigation.
NO. CHAPTER
1 Maintenance
2 Chassis
3 Engine
4 Fuel System
5 Electric Starter
6 Drive
7 Transmission
8 Electrical
A Appendix A Wiring
B Appendix B Glossar
TABLE OF CONTENTS:
2008 Harley Davidson FLHTCUSE3 Service Manual Supplement 99500-08 – PDF DOWNLOAD
1 1 SCHEDULED MAINTENANCE
General 1-1
1 2 HYDRAULIC CLUTCH FLUID
General 1-2
Clutch Fluid Level 1-2
1 3 BLEEDING CLUTCH FLUID LINE
Draining and Filling 1-3
Bleed Clutch Master Cylinder 1-4
Bleed Fluid Line and Actuator 1-4
Return Motorcycle to Service 1-4
1 4 ENGINE LUBRICATION SYSTEM
General 1-5
1 5 CRITICAL FASTENERS
Inspection 1-6
CHASSIS
2 1 SPECIFICATIONS: CHASSIS
General 2-1
2 2 VEHICLE IDENTIFICATION NUMBER
(V I N )
Vehicle Identification Number (V I N ): FLHTCUSE3 2-2
General 2-2
Location 2-2
Abbreviated V I N 2-2
2 3 FOOTBOARDS AND CONTROLS
Rider Footboards 2-3
Removal 2-3
Installation 2-4
Shift Levers 2-5
Replace Pegs 2-5
Replace Heel-Toe Shift Levers 2-5
Rear Brake Pedal 2-6
Adjustable Passenger Footboards 2-6
Remove 2-6
Disassemble 2-6
Assemble 2-7
Install 2-8
Adjust 2-8
2 4 HIGHWAY PEGS
Disassembly 2-9
Removing Clamp 2-9
Installing Clamp 2-9
Assembly 2-10
2 5 FRONT AXLE COVERS
Replacement 2-11
2 6 LOWER TRIPLE CLAMP COVER
Replacement 2-12
2 7 HANDLEBARS
Removal 2-13
Disassembly 2-14
Assembly 2-14
Pull Wire Leads 2-14
Install Switch Housings 2-15
Install Wire Lead Terminals 2-16
Installing Handlebars 2-17
Clamp Handlebars to Risers 2-17
Assemble Brake Controls 2-17
Assemble Clutch Controls 2-18
Returning to Service 2-19
2 8 HANDGRIPS
General 2-20
Preparing Motorcycle 2-20
Separating Connectors 2-20
Replacing Handgrips 2-20
Remove Left Handgrip 2-20
Install Left Handgrip 2-21
Remove Right Handgrip 2-22
Install Right Handgrip 2-22
Mating Connectors 2-23
Returning to Service 2-23
2 9 CLUTCH MASTER CYLINDER AND
RESERVOIR
General 2-24
Removal 2-24
Disassembly 2-25
Assembly 2-26
Installation 2-26
2 10 CLUTCH HAND LEVER
Removal 2-28
Installation 2-28
2 11 CLUTCH FLUID LINE
Removal 2-29
Installation 2-29
2 12 SEAT
General 2-31
Removal 2-31
Cleaning and Inspection 2-32
Installation 2-32
2 13 RIDER BACKREST
General 2-33
Removal 2-33
Installation 2-33
Adjusting Tilt Angle 2-33
Adjusting Front to Rear 2-33
2 14 TOUR-PAK
Removal 2-35
Installation 2-36
2 15 SADDLEBAGS
Removal 2-38
Installation 2-38
2 16 SADDLEBAGS LATCH
Removal 2-39
Installation 2-39
2 17 SADDLEBAG SUPPORTS
Removal 2-40
III
TABLE OF CONTENTS
Installation 2-40
2 18 MUFFLER END CAP
Replacement 2-42
ENGINE
3 1 SPECIFICATIONS: ENGINE
General 3-1
Manufacturing Tolerances 3-1
3 2 SERVICE WEAR LIMITS
General 3-3
3 3 CYLINDER HEAD
General 3-5
Removal 3-5
Determining Service 3-5
Disassembly 3-5
Cleaning 3-6
Inspection 3-8
Cylinder Head 3-8
Valve Guides 3-8
Valves 3-8
Valve Springs 3-8
Tapered Keepers 3-8
Valve Seats 3-8
Replacing Valve Guides 3-9
Removal 3-9
Installation 3-10
Assembly 3-13
Installation 3-15
3 4 PISTONS
General 3-16
Measuring Piston 3-16
3 5 BORING AND HONING CYLINDERS
Inspection 3-17
Cylinder Bore Finished Size 3-18
Piston Orientation 3-19
3 6 CRANKCASE ASSEMBLY
General 3-20
Assembly 3-20
3 7 OIL COOLER
Operation 3-23
Removal 3-23
Installation 3-23
3 8 OIL COOLER ADAPTER
Removal 3-25
Disassembly 3-25
Assembly 3-25
Installation 3-25
FUEL SYSTEM
4 1 AIR CLEANER COVER
General 4-1
Removal 4-1
Installation 4-1
ELECTRIC STARTER
5 1 SPECIFICATIONS: STARTER
General 5-1
DRIVE
6 1 SPECIFICATIONS: DRIVE
General 6-1
6 2 CLUTCH RELEASE BEARING AND
PUSHROD
Removal 6-2
Installation 6-2
Measure Release Plate Movement 6-2
Install Clutch Inspection Cover 6-2
TRANSMISSION
7 1 SPECIFICATIONS:TRANSMISSION
General 7-1
7 2 CLUTCH RELEASE COVER
Removal 7-2
Installation 7-2
Fill and Bleed 7-3
7 3 SECONDARY CLUTCH ACTUATOR
Replacement 7-4
ELECTRICAL
8 1 ELECTRICAL PROTECTION
Fuses and Relays 8-1
8 2 BULB CHART
General 8-3
8 3 HEADLAMP
General 8-4
Removal 8-4
Installation 8-5
8 4 AUXILIARY LAMPS AND BRACKETS
Removing Lamps 8-7
Removing Lamp Bracket 8-8
Installing Lamp Bracket 8-8
Installing Lamps 8-8
Mount Lamp 8-8
Final Assembly 8-8
IV TABLE OF CONTENTS
TABLE OF CONTENTS
Align Lamps 8-9
Replacing Bulb 8-10
8 5 FRONT TURN SIGNALS
Removal 8-12
Installation 8-12
8 6 HEATED SEAT
General 8-14
Controls 8-14
Warm-Up 8-14
Diagnostics 8-14
Diagnostic Tips 8-14
Diagnostic Notes 8-14
8 7 HEATED HANDGRIPS
General 8-17
Diagnostics 8-17
Diagnostic Tips 8-17
Diagnostic Notes 8-17
8 8 FAIRING CAP AND SWITCHES
Removal 8-21
Installation 8-21
8 9 PASSENGER HEADSET RECEPTACLE
Repair 8-23
Replace Weather Cap 8-23
8 10 XM SATELLITE RADIO
General 8-24
XM Antenna 8-24
Remove 8-24
Installation 8-24
XM Module 8-25
Removal 8-25
Installation 8-25
Activation 8-25
8 11 GPS NAVIGATION
General 8-27
GPS Antenna 8-27
Removal 8-27
Installation 8-27
GPS Navigation Module 8-28
Removal 8-28
Installation 8-28
8 12 RADIO SOFTWARE UPDATE
General 8-29
Opening Diag Test Display 8-29
Identifying Version Number 8-29
Updating Receiver Software 8-29
Confirming Version Number 8-30
8 13 ADVANCED AUDIO RADIO
Removing Advanced Audio 8-31
Installing Advanced Audio 8-31
8 14 ADVANCED AUDIO AMPLIFIER
General 8-33
Removal 8-33
Installation 8-33
8 15 GARAGE DOOR OPENER
Transmitter 8-35
Removal 8-35
Installation 8-35
Receiver 8-35
Installation 8-35
Remote Control Garage Door Opener 8-36
FCC Notices 8-36
Program the Receiver and Transmitter 8-36
8 16 AUTOMATIC COMPRESSION RELEASE
General 8-37
Removal 8-37
Installation 8-37
Compression Test 8-38
Diagnostics 8-39
Diagnostic Tips 8-39
Diagnostic Notes 8-39
8 17 TWIST GRIP SENSOR (TGS)
Removal 8-42
Installation 8-42
Reset TGS/ECM 8-43
8 18 POWER LOCKS
General 8-44
Power Lock Lockset: Tour-Pak 8-44
Removal 8-44
Installation 8-44
Actuator: Tour-Pak 8-44
Removal 8-44
Assembly 8-45
Power Locks: Saddlebags 8-45
Removal 8-45
Installation 8-45
Actuator: Saddlebag 8-46
Disassembly 8-46
Assembly 8-47
Power Lock Module 8-48
Removal 8-48
Installation 8-48
Power Lock Fob 8-48
General 8-48
Entering Program Mode 8-48
Program Mode 8-48
Replacing the Battery 8-49
Diagnostics 8-49
Diagnostic Tips 8-49
Diagnostic Notes 8-49
8 19 HARLEY-DAVIDSON SMART SECURITY
SYSTEM
General 8-52
HFSM 8-52
Removal 8-52
Installation 8-52
TABLE OF CONTENTS V
TABLE OF CONTENTS
Antenna 8-52
Remove 8-52
Install 8-52
Smart Siren 8-53
Remove 8-53
Install 8-53
Replace Battery 8-53
Troubleshooting 8-54
APPENDIX A WIRING
A 1 CONNECTORS
Connectors A-1
Function and Location A-1
Place and Color A-1
Connector Number A-1
Repair Instructions A-1
A 2 WIRING DIAGRAMS
Wiring Diagram Information A-2
Wire Color Codes A-2
Wiring Diagram Symbols A-2
Wiring Diagrams A-3
APPENDIX B GLOSSARY
B 1 GLOSSARY
Acronyms and Abbreviations B-1
REFERENCE MATERIAL
TOOLS I
TORQUE VALUES III
INDEX VII
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