Harley Davidson FLT Police 2008 User Manual

Page 1

2008 FLT Police Models Service Manual Supplement

99483-08SP

Page 2

Harley-Davidson motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards and U.S.A. Environmental Protection Agency regulations effective on the date of manufacture.

To maintain the safety, dependability, and emission and noise control performance, it is essential that the procedures, specifications and service instructions in this manual are followed.

Any substitution, alteration or adjustment of emission system and noise control components outside of factory specifications may be prohibited by law.

IMPORTANT NOTICE

Harley-Davidson Motor Company

Page 3

2008 FLT Police Models

Service Manual Supplement

99483-08SP

Printed in the U.S.A.

VISIT THE HARLEY-DAVIDSON WEB SITE

http://www.harley-davidson.com

Page 4

Blank Text Here

Page 5

Blank Text Here

READER COMMENTS

Please comment on the completeness, accuracy, organization, usability, and readability of this manual.

Please list the page, item, and part number(s) of any errors you find in this manual.

Please tell us how we can improve this manual.

Occupation:

Name: Dealership:

Street: Department:

City: State: Zip:

Please clip out and mail to: Service Communications Department Harley-Davidson Motor Company P.O. Box 653 Milwaukee, WI USA 53201

The Harley-Davidson Service Communications Department maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we need user feedback - your critical evaluation of this manual.

2008 FLT Police Models Service Manual Supplement (99483-08SP)

Page 6

NOTES

Page 7

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.

NOTE

This Service Manual Supplement provides information unique to this model motorcycle. Any information not presented in this supplement can be found in the appropriate Service Manual or Electrical Diagnostic Manual.

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.

CHAPTERNO.

Maintenance1 Chassis2 Engine3 Fuel System4 Electric Starter5 Drive6 Transmission7 Electrical8 Appendix A WiringA Appendix B GlossaryB

For example, a cross-reference shown as 2.1 SPECIFICA- TIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFICATIONS.

If the subject you seek is not in this supplement, refer to the corresponding section in the appropriate Service Manual. Check the title page located in the front of each section to find the subject.

For quick and easy reference, all pages contain a section number followed by a page number. For example, page 3-5 refers to page 5 in section 3.

In figure legends, the number following the name of a part indicates the quantity necessary for one complete assembly.

PREPARATION FOR SERVICE

Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a)

Good preparation is very important for efficient service work. A clean work area at the start of each job will allow you to perform the repair as easily and quickly as possible, and will reduce the incidence of misplaced tools and parts. A motorcycle that is excessively dirty should be cleaned before work starts. Cleaning will occasionally uncover sources of trouble. Tools, instruments and any parts needed for the job should be gathered before work is started. Interrupting a job to locate tools or parts is a distraction and causes needless delay.

NOTES

• To avoid unnecessary disassembly, carefully read all relative service information before repair work is started.

• In figure legends, the number which follows the name of a part indicates the quantity necessary for one complete assembly.

• When servicing a vehicle equipped with the HarleyDavidson Smart Security System (H-DSSS), you must first disarm the security system. Either keep the fob in close proximity to the vehicle, or use Digital Technician to disable the security system while the vehicle is being serviced and re-enable the system after service is completed.

SERVICE BULLETINS

In addition to the information presented in this Service Manual Supplement and the appropriate Service Manual, HarleyDavidson Motor Company will periodically issue Service Bulletins to Harley-Davidson dealers. Service Bulletins cover interim engineering changes and supplementary information. Consult the Service Bulletins to keep your product knowledge current and complete.

USE GENUINE REPLACEMENT PARTS

Do not use aftermarket parts and custom made front forks which can adversely affect performance and handling. Removing or altering factory installed parts can adversely affect performance and could result in death or serious injury. (00001a)

To ensure satisfactory and lasting repairs, carefully follow the Service Manual instructions and use only genuine HarleyDavidson replacement parts. Behind the emblem bearing the words GENUINE HARLEY-DAVIDSON stand more than 100 years of design, research, manufacturing, testing and inspecting experience.This is your assurance that the parts you are using will fit right, operate properly and last longer.

FOREWORD

WARNINGS AND CAUTIONS

Statements in this service manual preceded by the following words are of special significance.

Page 8

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. (00119a)

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. (00139a)

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. (00140a)

NOTE

Refers to important information, and is placed in italic type. It is recommended that you take special notice of these items.

Proper service and repair is important for the safe, reliable operation of all mechanical products.The service procedures recommended and described in this service manual are effective methods for performing service operations.

When reference is made in this manual to a specific brand name product, tool or instrument, an equivalent product, tool or instrument may be substituted.

Kent-Moore Products

All tools mentioned in this manual with an "HD", "J" or "B" preface must be ordered through SPX K ent-Moore. For ordering information or product returns, warranty or otherwise, visit www.spx.com.

Loctite Sealing and Threadlocking Pr oducts

Some procedures in this manual call for the use of Loctite products. If you have any questions regarding Loctite product usage or retailer/wholesaler locations, please contact Loctite Corp. at www.loctite.com.

PRODUCT REGISTERED MARKS

Allen, Amp Multilock, Bluetooth, Brembo, Delphi, Deutsch, Dunlop, Dynojet, Fluke, G.E. Versilube, Gunk, Hydroseal, Hylomar, Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Magnaflux, Marson Thread-Setter Tool Kit, MAXI fuse, Molex, MPZ, Mulitilock, Novus, Packard, Pirelli, Permatex, Philips, PJ1, Pozidriv , Robinair , S100, Sems, Snap-on, Teflon, Threadlock er, Torca, Torco, TORX, Tufoil, Tyco, Ultratorch, Velcro, X-Acto, and XM Satellite Radio are among the trademarks of their respective owners.

Always wear proper ey e protection when using hammer s, arbor or hydraulic presses, gear pullers, spring compressors, slide hammers and similar tools. Flying par ts could result in death or serious injury. (00496b)

Some of these service operations require the use of tools specially designed for the purpose.These special tools should be used when and as recommended. It is important to note that some warnings against the use of specific service methods, which could damage the motorcycle or render it unsafe, are stated in this service manual. Howe v er, please remember that these warnings are not all-inclusive. Inadequate safety precautions could result in death or serious injury.

Since Harley-Davidson could not possibly know, evaluate or advise the service trade of all possible ways in which service might be performed, or of the possible hazardous consequences of each method, we have not undertaken any such broad evaluation. Accordingly, anyone who uses a service procedure or tool which is not recommended by HarleyDavidson must first thoroughly satisfy himself that neither his nor the operator's safety will be jeopardized as a result. F ailure to do so could result in death or serious injury.

PRODUCT REFERENCES

H-D MICHIGAN, INC.TRADEMARK INFORMATION

Harley, Harley-Davidson, H-D, Bar & Shield, Digital Tech, Digital Technician, Destroyer, Deuce, Dyna, Electra Glide, Evolution, F at Boy, Glaze, Gloss, H-D , H-Dnet.com, HD , Harley , Heritage Softail, Heritage Springer, Low Rider, Night Rod, Night Train, Profile, Revolution, Road Glide, Road King, Rocker, Softail, Sportster, Sun Ray, Sunwash, Tech Link, Twin Cam 88, Twin Cam 88B, Twin Cam 96, Twin Cam 96B, Twin Cam 103, Twin Cam 103B, Twin Cam 110, Twin Cam 110B, TourPak, Screamin' Eagle, Softail, Super Guide, Super Premium, SYN3, Ultra Glide, V-Rod, VRSC, Wide Glide, and HarleyDavidson Genuine Motor Parts and Genuine Motor Accessories are among the trademarks of H-D Michigan, Inc.

CONTENTS

All photographs, illustrations and procedures may not necessarily depict the most current model or component, but are based on the latest production information available at the time of publication.

Since product improvement is our continual goal, HarleyDavidson reserves the right to change specifications, equipment or designs at any time without notice and without incurring obligation.

Read and follow warnings and directions on all products. Failure to follow warnings and directions can result in death or serious injury. (00470b)

II FOREWORD

Page 9

MAINTENANCE

1.1 SCHEDULED MAINTENANCE

General...............................................................................1-1

CHASSIS

2.1 SPECIFICATIONS: CHASSIS

General...............................................................................2-1

2.2 VEHICLE IDENTIFICATION NUMBER (V.I.N.)

General...............................................................................2-2

Manufacturing Tolerances...................................................3-1

3.2 SERVICE WEAR LIMITS

General...............................................................................3-2

3.3 OIL COOLER

Operation............................................................................3-3

Removal.............................................................................3-3

Cleaning and Inspection.....................................................3-4

Installation..........................................................................3-4

Oil Cooler Adapter and Thermostat Replacement..............3-4

Removal......................................................................3-4

Installation...................................................................3-4

FUEL SYSTEM

2.3 TIRES

General...............................................................................2-3

2.4 SEAT

General...............................................................................2-4

Seat Removal.....................................................................2-6

Seat Installation..................................................................2-6

Air Spring Replacement.....................................................2-6

Removal......................................................................2-6

Installation...................................................................2-6

Seat Bracket Mount Replacement......................................2-7

Removal......................................................................2-7

Installation...................................................................2-7

2.5 AIR SEAT RESERVOIR

Removal.............................................................................2-8

Installation..........................................................................2-9

2.6 SADDLEBAGS

Lockset.............................................................................2-11

Removal....................................................................2-11

Installation.................................................................2-11

Lockset Catch...................................................................2-11

Removal....................................................................2-11

Installation.................................................................2-11

Hinges..............................................................................2-11

Removal....................................................................2-11

Installation.................................................................2-12

Tether................................................................................2-12

Removal....................................................................2-12

Installation.................................................................2-12

Tether Brackets.................................................................2-12

Removal....................................................................2-12

Installation.................................................................2-12

Knob and Spring Latch.....................................................2-12

Removal....................................................................2-12

Installation.................................................................2-13

Spring Latch Bracket........................................................2-13

Removal....................................................................2-13

Installation.................................................................2-13

2.7 TACHOMETER BRACKET: FLHP/E

Removal...........................................................................2-14

Installation........................................................................2-15

ENGINE

4.1 FUEL SYSTEM

No Unique Content.............................................................4-1

ELECTRIC STARTER

5.1 ELECTRIC STARTER

No Unique Content.............................................................5-1

DRIVE

6.1 DRIVE

No Unique Content.............................................................6-1

TRANSMISSION

7.1 TRANSMISSION

No Unique Content.............................................................7-1

ELECTRICAL

8.1 BULB CHART

General...............................................................................8-1

8.2 SYSTEM FUSES AND RELAYS

System Fuses.....................................................................8-3

Removal......................................................................8-3

Installation...................................................................8-4

8.3 REAR MARKER LIGHTS

Marker Lights Replacement................................................8-5

Removal.............................................................................8-5

Installation..........................................................................8-5

8.4 HANDLEBAR SWITCHES

Horn and Siren Yelp Switch................................................8-6

Removal......................................................................8-6

Installation...................................................................8-6

Clutch Interlock Switch.......................................................8-7

Removal......................................................................8-7

Installation...................................................................8-7

Pursuit and Auxiliary Switch...............................................8-8

Removal......................................................................8-8

Installation...................................................................8-8

3.1 SPECIFICATIONS: ENGINE

General...............................................................................3-1

8.5 AUTOMATIC COMPRESSION RELEASE

General.............................................................................8-10

Removal...........................................................................8-10

III

Page 10

TABLE OF CONTENTS

Installation........................................................................8-10

Compression Test.............................................................8-11

Diagnostics.......................................................................8-12

Diagnostic Tips..........................................................8-12

Diagnostic Notes.......................................................8-12

APPENDIX A WIRING

A.1 CONNECTORS

Connectors.........................................................................A-1

A.2 INDEX TO WIRING DIAGRAMS

Wiring Diagram Information...............................................A-7

Wire Color Codes........................................................A-7

Wiring Diagram Symbols............................................A-7

Wiring Diagrams.................................................................A-8

APPENDIX B GLOSSARY

B.1 GLOSSARY

Acronyms and Abbreviations..............................................B-1

REFERENCE MATERIAL

TOOLS...........................................................I

TORQUE VALUES.......................................III

INDEX...........................................................V

IV TABLE OF CONTENTS

Page 11

SUBJECT............................................................................................................................PAGE NO.

1.1 SCHEDULED MAINTENANCE.................................................................................................1-1

MAINTENANCE

Page 12

NOTES

Page 13

1.1SCHEDULED MAINTENANCE

GENERAL

The table below lists the maintenance requirements for police motorcycles. If you are familiar with the procedures, refer to the table for the recommended service interval. If necessary, refer to the quick reference table (Table 1-2) for the required

Table 1-1. Regular Service Intervals: 2008 Touring Models

1000 MI. 1600 KM

Tires

sprocket

ators

switches

Air suspension

applicable)

bags

stablizers Battery

Exhaust system

Road test

NOTES:

PROCEDUREITEM SERVICED

tread

and leakage

connections

loose or missing fasteners or heat shields

system functions

1. Should be performed by an authorized Harley-Da vidson dealer , unless you hav e the proper tools, service data and are mechanically qualified.

2. Disassemble, lubricate and inspect every 50,000 miles (80,000 kilometers).

3. Perform annually.

4. Change D.O.T. 4 and flush brake system every two years.

5. Perform at each rear tire change.

specifications. If more detailed information is needed, turn to the Touring Models Service Manual for step-by-step instructions.

Various lubricants, sealants and greases are recommended in certain service operations. Refer to Table 1-3 for the appro- priate part numbers for these items.

5000 MI. 8000 KM

10,000 MI. 16,000 KM

15,000 MI. 24,000 KM

20,000 MI. 32,000 KM

XXXReplacePrimary chaincase lubricant XXReplaceTransmission lubricant

XReplace

40,000 KM

XXXXXXReplaceEngine oil and filter

XXXXXXInspect, service as requiredAir cleaner XXXXXXCheck pressure, inspect

XXXXXXInspect for wearBrake pads and discs XXXXXInspectSpark plugs

XXXXXXCheck operationElectrical equipment and

XXXXXXLubricate hinges and latchesFuel door, Tour-Pak, saddle-

XXXXXXVerify component and

NOTES25,000 MI.

1XXXXXXInspect for leaksOil lines and brake system

1XXXCheck tightnessWheel spokes

1XXXXXXCheck adjustmentClutch 1XXXXXXInspect, adjust beltDrive belt and compensator

5Inspect for wearCompensator sprocket isol-

1XXXXXXCheck, adjust and lubricateBrake and clutch controls 1XXXXXXInspect and lubricateJiffy stand 1XXXXXXInspect for leaksFuel lines and fittings 1XReplaceFuel tank filter 4XXXXXXCheck levels and conditionBrake fluid

1, 2ReplaceFront fork oil

2XXXLubricateSteering head bearings 1XAdjust 1XXXXXXCheck pressure, operation

1XXInspectWindshield bushings (if

1XXXCheck tightnessCritical fasteners 1XXInspect, check tightnessEngine mounts and

3Check battery and clean

3XXXXXXInspect for leaks, cracks, and

2008 FLT Police Service: Maintenance 1-1

Page 14

Drive belt deflection

Table 1-2. Quick Reference Maintenance Chart: 2008 Police Models

DATASPECIFICATIONITEM SERVICED

14-21 ft-lbs (19.0-28.5 Nm)Drain plug torqueEngine oil and filter

4 qt. (3.8 L)Oil capacity Hand tighten 1/2-3/4 turn after gasket contactFilter 63798-99AChrome filter part number 63731-99ABlack filter part number

Lubricant type and capacityPrimary chain lubricant

Lubricant levelTransmission lubricant

Lubricant type and capacity

Wear

strand

Air cleaner cover screw Threadlocker

Lubricant part numberClutch cable

FORMULA+ TRANSMISSION AND PRIMARY CHAIN LUBRICATION (Part No. 99851-05) Wet: 38 oz. (1124 ml) Dry: 45 oz. (1331 ml)

14-21 ft-lbs (19.0-28.5 Nm)Primary chaincase drain plug torque 1/2-1 turnAdjuster screw free playClutch adjustment 72-120 in-lbs (8.1-13.6 Nm)Adjuster screw locknut torque

1/16-1/8 in. (1.6-3.2 mm)Free play at hand lever 84-108 in-lbs (9.5-12.2 Nm)Clutch inspection cover torque Dipstick at FULL with motorcycle on jiffy stand and

filler plug resting on threads. FORMULA+ TRANSMISSION AND PRIMARY

CHAIN LUBRICATION (Part No. 99851-05)

32 oz (0.95 liters) 14-21 ft-lbs (19.0-28.5 Nm)Transmission drain plug torque 25-75 in-lbs (2.8-8.5 Nm)Transmission filler plug/dipstick torque Front: 36 psi (248 kPA)Pressure: solo riderTire pressure and wear

Rear: 36-40 psi (248-276 kPA) Replace if less than 1/32 in. (0.8 mm) of tread

pattern 55 in-lbs (6.2 Nm) minimumSpoke nipple torqueWheel spokes 99953-99A (12 oz.)D.O.T. 4 hydraulic brake fluid part numberBrake fluid level Front: 0.20 in. (5.0 mm)Fluid level (from top of master cylinder reservoir)

Rear: 0.26 in. (6.5 mm) Front:7-10 in-lbs (0.8-1.1 Nm)Master cylinder reservoir cover screw torque

Rear: 12-15 in-lbs (1.4-1.7 Nm)

0.016 in. (0.4 mm)Minimum brake pad thicknessBrake pads and discs

75-102 in-lbs (8.5.-11.5 Nm)Brake caliper pad pin torque

Front: 0.18 in. (4.5 mm)Minimum brake disc thickness

Rear: 0.25 in. (6.3 mm)

0.008 in. (0.2 mm)Maximum brake disc lateral runout (warpage)

10 lb. (4.5 kg)Upward force applied at midpoint of bottom belt

3/8-7/16 in. (9.5-11.1 mm)FLHTP

1/4-5/16 in. (6.4-7.9 mm)FLHP/FLHPE 40-60 in-lbs (4.5-6.8 Nm)Air cleaner cover bracket screw torqueAir cleaner 36-60 in-lbs (4.1-6.8 Nm)Air cleaner cover screw torque LOCTITE MEDIUM STRENGTH THREADLOCKER

243 (BLUE) Part No. 99642-97 (6 ml)

LUBIT-8 SUPER OIL, Part No. 94968-85TV (1/4 fl. oz.)

35-45 in-lbs (4.0-5.1 Nm)Handlebar switch housing screw torque

1-2 2008 FLT Police Service: Maintenance

Page 15

Table 1-2. Quick Reference Maintenance Chart: 2008 Police Models

CCI #20 Brake Grease

Transmission and Primary Chaincase Lubricant

Loctite Prism Primer (770) Loctite Prism Superbonder (411) Loctite Superbonder 420 Adhesive

DATASPECIFICATIONITEM SERVICED

HD-6R12TypeSpark plugs

0.038-0.043 in. (0.97-1.09 mm)Gap 12-18 ft-lbs (16.3-24.4 Nm)Torque See FRONT FORK in the Touring Service Manual.AmountFront fork oil HYDRAULIC FORK OIL (TYPE E)Type and part number

Part No. 99884-80 (16 oz.) 60-96 in-lbs (6.8-10.9 Nm)Terminal bolt torqueBattery 15-20 ft-lbs (20-27 Nm)Top caddy clamp screw torque

Table 1-3. Lubricants, Greases, Sealants

PACKAGEPART NUMBERITEM

1 oz squeeze tube98960-97Anti-Seize Lubricant squeeze packet42830-05 (included in master cylinder

rebuild kit)

12 oz. bottle99953-99AD.O.T. 4 Brake Fluid 1 oz squeeze tube99861-02Electrical Contact Lubricant 1 qt bottle99851-05Genuine Harley-Davidson Formula+

squeeze packet42820-04G40M Brake Grease

1.9 oz squeeze tube99650-02Gray High Performance Sealant

3.5 oz tube99653-85HYLOMAR Gasket and Thread Sealant 6 ml squeeze tube99818-97Loctite Pipe Sealant With Teflon 565

6 ml squeeze tube99642-97Loctite Threadlocker 243 (blue) 6 ml squeeze tube94759-99Loctite Threadlocker 262 (red) 10 ml bottle98618-03Loctite Threadlocker 272 14 oz. cartridge99857-97Special Purpose Grease 1/4 fl. oz94968-85TVSuper Oil 16 oz bottle99884-80Type "E" Hydraulic Fork Oil

2008 FLT Police Service: Maintenance 1-3

Page 16

NOTES

1-4 2008 FLT Police Service: Maintenance

Page 17

SUBJECT............................................................................................................................PAGE NO.

2.1 SPECIFICATIONS: CHASSIS...................................................................................................2-1

2.2 VEHICLE IDENTIFICATION NUMBER (V.I.N.)..........................................................................2-2

2.3 TIRES........................................................................................................................................2-3

2.4 SEAT..........................................................................................................................................2-4

2.5 AIR SEAT RESERVOIR.............................................................................................................2-8

2.6 SADDLEBAGS........................................................................................................................2-11

2.7 TACHOMETER BRACKET: FLHP/E........................................................................................2-14

CHASSIS

Page 18

NOTES

Page 19

2.1SPECIFICATIONS: CHASSIS

GENERAL

Table 2-1. Capacities: 2008 Police Models

(approximate)

(drained)

(cover removed)

Table 2-2. Dimensions: 2008 Police Models

*With 180 lb. ( 81.7 kg) rider on seat.

Table 2-3.Weights: 2008 Police Models

FLHPFLHTPITEM

LITERSU.S.ITEM

22.76.0 galFuel tank (total)

3.81.0 galLow fuel warning lamp on

3.84.0 U.S. qt.Oil tank with filter

0.9532.0 fl. oz.Transmission

1.1238.0 fl. oz.Primary chaincase

1.3345.0 fl. oz.Primary chaincase

FLHPFLHTPITEM

MMIN.MMIN.

1612.963.51612.963.5Wheel base

238093.7238093.7Overall length

876.334.5990.639.0Overall width

129.55.1129.55.1Road clearance

1399.555.11549.461.0Overall height

693.427.3693.427.3Saddle height*

from factory

NOTE

Gross vehicle weight rating (GVWR) (maximum allowable loaded vehicle weight) and corresponding gross axle weight rating (GAWR) are printed on a label fix ed to the bottom of the right front frame downtube.

NOTE

See 2.3 TIRES for important information regarding tire data and tire inflation.

Table 2-4. Rear Air Suspension Pressures

SHOCK LOADING

RECOMMENDED

PRESSURES

KG.LB.KG.LB.

335739347764Weight as shipped

54412005441200GVWR 227500227500GAWR front 375827375827GAWR rear

kPa 0-241PSI 0-35

00Solo rider up to 150 lbs. (68 kg)

0-690-10Solo rider 150-200 lbs. (68-91 kg)

35-1035-15Solo rider 200-250 lbs. (91-113 kg)

138-24120-35At maximum GVWR

NOTE

Initial suspension fill pressure for a normally equipped police motorcycle is 25 psi (172.4 kPa).

2008 FLT Police Service: Chassis 2-1

Page 20

2.2VEHICLE IDENTIFICATION NUMBER (V.I.N.)

1HD 1 FM M 1 3 8 Y 111000

1 2 3 4 5 6 7 8 9 10

om01103

GENERAL

See Figure 2-1. The full 17-digit serial number, or Vehicle Identification Number (V.I.N.), is stamped on the right side of the frame backbone at the rear of the steering head (and under the main harness conduit). A label bearing the V.I.N. code is also affixed to the left side of the steering head. An abbreviated V.I.N. is stamped between the front and rear cylinders on the left side of the crankcase.

Figure 2-1.Typical Harley-Davidson V.I.N.: 2008 Police Models

Sample V.I.N. as it appears on the steering head -

1HD1FHM137Y110000

Sample abbreviated V.I.N. as it appears on the crankcase -

FHM7110000

NOTE

Always give the complete V.I.N. when ordering parts or making an inquiry about your motorcycle.

Table 2-5. Harley-Davidson V.I.N. Breakdown: 2008 Police Models

POSSIBLE VALUESDESCRIPTIONPOSITION

1=Originally manufactured for sale within the United StatesMarket designation1 5=Originally manufactured for sale outside of the United States

HD=Harley-DavidsonManufacturer2 1=Heavyweight motorcycle (901cc or larger)Motorcycle type3 See V.I.N. model tableModel4 M=Twin Cam 103™ 1690cc air-cooled, fuel injectedEngine type5 1=RegularIntroduction date6

2=Mid-year 3=California/regular 4=Cosmetic changes and/or special introductory date 5=California/cosmetic changes and/or special introductory date 6=California/mid-year

Can be 0-9 or XV.I.N. check digit7 8=2008Model year8 Y=York, PA U.S.A.Assembly plant9 VariesSequential number10

Table 2-6.V.I.N. Model Codes: 2008 Police Models

MODELCODE

FLHTPFM

FLHPFH

FLHPEFT

2-2 2008 FLT Police Service: Chassis

Page 21

2.3TIRES

GENERAL

The rear tire on FL police model motorcycles is fit for solo riding only. If converted to a two-up bike, that is, configured for passenger use (with luggage), then the rear tire needs to be changed to one with a higher weight rating. Since it has long been Harley-Davidson policy not to mix different types of tires on the same vehicle, we strongly recommend that both front and rear tires be replaced. In order to alert the customer to this safety issue, the f ollo wing w arning appears on a label fitted to the rear fender approximately 1/4 inch (6.4 mm) behind the domestic seat mounting hole.

This vehicle has tires with weight ratings for one person operation. If this vehicle is modified to carry two people, the tires must be changed. See a Harley-Davidson dealer for proper replacement tires. Using improper tires can cause tire failure which could result in death or serious injury. (00096a)

Table 2-7.Tire Data

MANUFACTURER'S DESIGNATIONSIZETIRE LOCATION

All 2008 vehicles use only Dunlop Harley-Davidson tires.

NOTE

Use the tires recommended for civilian/pleasure vehicles of the same year and model family.

Harley-Davidson front and rear tires are not the same. Interchanging front and rear tires can cause tire failure, which could result in death or serious injury. (00026a)

Tire size, manufacturer's description and inflation pressure are listed below.

NOTE

ABS motorcycles must always use tires and wheels that are the same as the original equipment. The ABS monitors the rotational speed of the wheels through individual wheel speed sensors. Changing to different diameter wheels or different size tires can alter the rotational speed. This can upset the calibration of the ABS and have an adv erse eff ect on its ability to detect and prevent lockups. Tire inflation pressure that is significantly low also can have an adverse effect.

TIRE PRESSURE

(COLD)

36 psi (248 kPa)Dunlop D402F PTMT90B 16 72HFront

36-40 psi (248-276 kPa)Dunlop D402 PTMT90B 16 72HRear

2008 FLT Police Service: Chassis 2-3

Page 22

GENERAL

om00451

Maximum air pressure for the seat is 100 psi (689 kPa). Normal air pressure is 30-45 psi (207-310 kPa). Do not operate with air pressure so low that system bottoms out on bumpy roads. (00167a)

NOTES

• Initially pressurize the seat air suspension system to 40 psi (275.8 kPa), then add or remov e pressure to the rider's comfort. DO NO T oper ate motorcycle with system underinflated.

• T o chec k minimum air pressure, ha ve rider sit on seat and bounce to simulate riding conditions. Visually check for any contact between air spring and frame components. Add air as necessary.

• See Figure 2-2. Removal and installation of retaining pin (1) requires that the air pressure be removed from the seat air suspension system. The seat will no longer pivot up because the front of the seat will hit the fuel tank. Retaining pin (1) should not be removed unless the seat is to be removed.

• The seat does not adjust forward or rearward.

2.4SEAT

1. Retaining pin

2. Rear seat bracket

3. Support post Figure 2-2. Seat Latch: Police Models

2-4 2008 FLT Police Service: Chassis

Page 23

sm04695

2. 18.10.Air fitting Retaining pinSeat bracket

5. 21.13.Fastener (2) Set screwAcorn Nut

8. 16.Rubber bumper (2) Pivot bolt

11.3. 19.Flange nut (2)Fastener (2) Air spring

14.6. 22.Seat bracket mountFlat Washer Top plate

Figure 2-3. Air Seat Assembly

17.9.1. Seat fairingSeatCap

20.12.4. Nut (2)Fastener (2)Air reservoir

23.15.7. FastenerHex scrweFlange nut (2)

2008 FLT Police Service: Chassis 2-5

Page 24

SEAT REMOVAL

sm04699

1. Remove air pressure from air spring and reservoir.

2. See Figure 2-2. Standing on left side of motorcycle , press down on rear of seat and pull pin (1) from post (3) on top plate.

3. See Figure 2-3. Remo ve front piv ot bolt (16) and n ut (13).

4. Lift seat and bracket assembly from motorcycle.

5. Remove two flange nuts (11) and he x screw (15) to release seat from seat bracket (10).

6. Inspect two rubber bumpers (8) on seat bracket for cuts, tears or general deterioration. If damaged, deteriorated or missing, replace as follows:

a. Remove old rubber bumper and discard. b. Moisten bead on new rubber bumper with soapy

water. Place rubber bumper into position at bottom of seat bracket. Feed tail on bead up through hole in seat bracket. Using a needle nose pliers, grasp tail as close to bead as possible, and then pull bead up through hole in seat bracket.

7. If necessary, remove two flange nuts (7) and washers (6) and remove seat fairing (17) under seat.

SEAT INSTALLATION

Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)

2. Disconnect battery, negative (-) cable first.

3. Remove battery from battery box.

4. Remove air pressure from air spring and reservoir.

5. Depress collar on compression fitting and remove air tube from air reservoir.

6. See Figure 2-3. Holding air spring to prevent twisting, remove two fasteners (23) to release top plate (22) from air spring (19).

7. Remove two flange nuts (20) under frame weldment (at rear of battery box). Remove air spring from motorcycle.

1. See Figure 2-3. If removed, install seat fairing (17) under seat. Tighten flange nuts (7) to 60-120 in-lbs (6.8-13.6 Nm).

2. Install seat onto seat bracket and start two flange nuts (11). Align threaded hole in seat with hole in front of seat bracket and start hex screw (15).

3. Tighten flange nuts to 96-144 in-lbs (10.9-16.3 Nm).

4. Tighten hex screw to 60-120 in-lbs (6.8-13.6 Nm).

5. Place seat and bracket assembly on motorcycle and install front pivot bolt (16).Tighten nut (13) to 48-84 in-lbs (5.4-

9.5 Nm).

6. See Figure 2-2. Align post (3) on top plate with hole in rear seat bracket.While pressing down on rear of seat, insert pin (1) into post on top plate.

Maximum air pressure for the seat is 100 psi (689 kPa). Normal air pressure is 30-45 psi (207-310 kPa). Do not operate with air pressure so low that system bottoms out on bumpy roads. (00167a)

7. Fill air reservoir to 40 psi (275.8 kPa), then add or remov e pressure to the rider's comfort. Install protective cap on air fitting.

AIR SPRING REPLACEMENT

Figure 2-4. Air Spring Assembly

Installation

1. Feed air tube through large center hole in frame weldment (at rear of battery box) and then route rearward following inboard side of right upper frame tube to air reservoir.

2. Depress collar on compression fitting of air seat reservoir, and insert air tube until it bottoms. Gently tug on tube to verify that it is locked in place.

3. Connect air tube to compression fitting at bottom of air spring, if removed.

4. See Figure 2-3. Place air spring on frame weldment while engaging the two set screws.

5. Install two flange nuts (20) onto set screws (21).Tighten flange nuts to 50-70 in-lbs (5.7-7.9 Nm).

6. Position top plate (22) onto air spring and start two fasteners (23). Holding air spring to prevent twisting, tighten screws to 36-60 in-lbs (4.1-6.8 Nm).

7. Place battery into battery box, terminal side forward.

Removal

1. Remove seat and seat fairing. See 2.4 SEAT, Seat

Removal.

2-6 2008 FLT Police Service: Chassis

Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)

Page 25

8. Connect battery cables, positive (+) cable first.Tighten to 60-96 in-lbs (6.8-10.9 Nm).

9. Apply a light coat of petroleum jelly or ELECTRICAL CONTACT LUBRICANT, Part No. 99861-02 (1 oz. tube), to both battery terminals.

10. Install hold-down clamp so that the lip (with rubber pad) rests on the edge of the battery.Tighten T40 T ORX screw to 15-20 ft-lbs (20-27 Nm).

11. Install seat fairing.Tighten fasteners to 60-120 in-lbs (6.8-

13.6 Nm).

12. Install seat and inser t pin into post on top plate or air spring. See 2.4 SEAT, Seat Installation.

Maximum air pressure for the seat is 100 psi (689 kPa). Normal air pressure is 30-45 psi (207-310 kPa). Do not operate with air pressure so low that system bottoms out on bumpy roads. (00167a)

13. Fill air reservoir to 40 psi (275.8 kPa), then add or remov e pressure to the rider's comfort. Install protective cap on air valve.

SEAT BRACKET MOUNT REPLACEMENT Removal

1. Remove seat. See 2.4 SEAT, Seat Removal.

2. See Figure 2-3. Remove two fasteners (12) to release seat bracket mount from frame backbone.

Installation

1. Install seat bracket mount using two f asteners (12).Tighten fasteners to 15-20 ft-lbs (20.3-27.1 Nm).

2. Install seat and insert pin into post on top plate of air spring. See 2.4 SEAT, Seat Installation.

2008 FLT Police Service: Chassis 2-7

Page 26

REMOVAL

om00465

om00282

sm04700

1. Remove both saddlebags.

2. On the right side of the motorcycle, locate the air seat reservoir air valve under the luggage rac k, and on the left side, the rear shock air valv e just below the chrome frame cover. See Figure 2-5 and Figure 2-6.

Use caution when bleeding air from the suspension. Moisture combined with lubricant may leak onto the rear wheel, tire and/or brake components and adversel y affect traction, which could result in death or serious injury. (00084a)

2.5AIR SEAT RESERVOIR

Figure 2-6. Rear Air Suspension Air Valve

1. Air reservoir

2. Air pressure gauge

3. Seat air valve Figure 2-5. Seat Air Valve: Police Models

Figure 2-7. Raise Luggage Rack

3. Remove protective cap from each air valve and depress pin to bleed air from both reservoir and shocks.To purge rear air suspension lines of any oil, add 3-5 psi (20.7-34.5 kPa) before releasing air . Depress collar on each compression fitting and pull out air tube.

4. Remove bolt (with flat washer) to remov e saddlebag front mounting bracket from chrome frame tube co ver . Remov e

2-8 2008 FLT Police Service: Chassis

Page 27

Phillips screw and chrome frame tube cover. Repeat step

sm04701

on opposite side of motorcycle.

5. At inboard side of rear marker lights bracket, carefully pull left and right rear marker lights connectors.

6. Remove two hex bolts to free license plate bracket from bottom support tube.

7. Remove T40 TORX screws (with spacers) on each side of motorcycle to release ends of luggage rack from frame tube weldments.

8. Raise luggage rack high enough to access air reservoir. See Figure 2-7.

9. Remove two Phillips screws (with external tooth lockwashers) from mounting plate (pole lamp) at top of luggage rack to release air reservoir bracket.

10. Remove two Phillips screws from license plate bracket to free rear of air reservoir bracket. Be sure to hold reservoir as the last screw is removed or damage to fender paint can occur if assembly is dropped. See Figure 2-8.

11. Remove fittings and/or air pressure gauge from reservoir, if necessary.

bracket. Alter nately tighten screws to 20-30 in-lbs (2.3-

3.4 Nm).

5. Place luggage rack into position inboard of frame tubes.

6. Install T40 TORX screws (with spacers) on each side of motorcycle to secure ends of luggage rack to frame tube weldments. Alternately tighten screws to 15-20 ft-lbs (20.3-

27.1 Nm).

7. Install two hex bolts to fasten license plate bracket to bottom support tube. Alternately tighten screws to 15-20 ft-lbs (20.3-27.1 Nm).

8. At inboard side of rear marker lights bracket, connect left and right rear marker lights connectors.

9. Install chrome frame tube cover on frame tube. Install Phillips screw and tighten to 25-40 in-lbs (2.8-4.5 Nm). Repeat step on opposite side of motorcycle.

10. Install bolt (with flat washer) to install saddlebag front mounting bracket, but do not tighten. Repeat step on opposite side of motorcycle.

11. Depress collar on compression fitting of air seat reservoir, and insert air tube until it bottoms. Gently tug on tube to verify that it is locked in place.

Figure 2-8. Air Seat Reservoir Assembly

INSTALLATION

TOOL NAMEPART NUMBER

HD-34633

1. Reassemble fittings and/or air pressure gauge onto air reservoir, if remov ed. Orient parts as shown in Figure 2-8. Apply PIPE SEALANT WITH TEFLON to threads before assembly.

2. Position air reservoir beneath luggage rack exercising caution to avoid scratching fender paint.

3. Slide two Phillips screws through holes in license plate bracket engaging weld nuts at rear of air reservoir br acket. Alternately tighten screws to 20-30 in-lbs (2.3-3.4 Nm).

4. Slide two Phillips screws (with external tooth lockwashers) through holes in mounting plate (pole lamp) at top of luggage rack engaging weld nuts at top of air reservoir

AIR SUSPENSION PUMP AND GAUGE

Maximum air pressure for the seat is 100 psi (689 kPa). Normal air pressure is 30-45 psi (207-310 kPa). Do not operate with air pressure so low that system bottoms out on bumpy roads. (00167a)

12. Fill air reservoir to 40 psi (275.8 kPa), then add or remov e pressure to the rider's comfort. Install protective cap on air valve. See Figure 2-5.

NOTE T o set minimum air pressure , have rider sit on seat and bounce to simulate riding conditions. Visually check for any contact between air spring and frame components. Add air as necessary.

13. Observe air pressure gauge. If leakage occurs, then

remove tube and inspect end for b urrs or damage. If either condition is found, snip off end of tube and insert back into fitting.

14. Depress collar on compression fitting of each shock and

insert air tube until it bottoms. Gently tug on tube to verify that it is locked in place.

Do not exceed maximum air pressure for rear suspension. Air components fill rapidly. Therefore, use low air line pressure. Failure to do so may result in possible damage to components. (00165a)

NOTE Initial suspension fill pressure for a normally equipped police motorcycle is 25 psi (172.4 kPa).

15. Fill shocks to 25 psi (172.4 kPa), then add or remove

pressure to the rider's comfort. Refer to Table 2-8.

2008 FLT Police Service: Chassis 2-9

Page 28

Table 2-8. Rear Air Suspension Pressures

SHOCK LOADING

ATIONS: CHASSIS)

Do not exceed the motorcycle's Gross Vehicle Weight Rating (GVWR) or Gross Axle Weight Rating (GAWR). Exceeding these weight ratings can affect stability and handling, which could result in death or serious injury. (00016e)

RECOMMENDED

PRESSURES

kPa 0-241PSI 0-35

00Solo rider up to 150 lbs. (68 kg)

0-690-10Solo rider 150-200 lbs. (68-91 kg)

35-1035-15Solo rider 200-250 lbs. (91-113 kg)

138-24120-35Maximum GVWR (see 2.1 SPECIFIC-

NOTE

An AIR SUSPENSION PUMP AND GAUGE (Part No. HD-

34633) is available at your Harley-Davidson dealer.

16. Observe air pressure gauge while filling. If leakage occurs, remove tubes and inspect ends for burrs or damage. If either condition is found, snip off end of tube and insert back into fitting.

17. When air pressure remains constant, install protective cap on air valve.

18. Install saddlebags. Tighten saddlebag front mounting bracket bolts to 60-96 in-lbs (6.8-10.8 Nm).

2-10 2008 FLT Police Service: Chassis

Page 29

LOCKSET

sm03550

sm04804

Removal

1. At inside of saddlebag lid, remove hex nut, internal tooth lockwasher, cam hook and cam washer. Remove jam nut and lock guide. See Figure 2-9.

2. At outside of saddlebag lid, remove lockset. See

Figure 2-10.

Installation

1. With cam stop facing outboard side of saddlebag lid, install lockset into hole. See Figure 2-10.

2. Install lock guide over threaded body of lockset oriented with finger on inboard side of saddlebag lid and pointing toward bottom. See Figure 2-9.

3. Install jam nut and tighten to 30-45 in-lbs (3.4-5.1 Nm).

4. Verify that groove in threaded stud of lockset is facing inboard side of saddlebag lid. Use key to rotate threaded stud, if necessary.

5. Align cam hook and cam washer as shown in Figure 2-10. With the cam hook toward the outboard side of saddlebag lid and cam washer on the inboard side, slide assembly down threaded stud.

6. Install internal tooth lockwasher and hex nut onto threaded stud.Tighten hex nut to 25-35 in-lbs (2.8-4.0 Nm).

2.6SADDLEBAGS

1. Lockset

2. Thin washer

3. Cam stop

4. Threaded stud

5. Cam washer

6. Cam hook Figure 2-10. Lockset Mechanism

LOCKSET CATCH Removal

1. Drill out two rivets using a 5/32 inch drill bit.

2. Remove backplate, lockset catch and flat washers.

Installation

1. Slide two new rivets through holes in backplate, saddlebag, lockset catch and flat washers.

2. Compress rivets using a suitable rivet tool.

HINGES

TOOL NAMEPART NUMBER

RIVET TOOLHD-39787A

Removal

1. Remove tether. See 2.6 SADDLEBAGS, Tether.

2. Drill off peened end of hinge pin rivet using a 3/8 inch drill

1. Lock guide

2. Jam nut

3. Lockset

4. Cam washer

5. Cam hook

6. Lockwasher

7. Hex nut Figure 2-9. Lockset Assembly

bit. Use a punch to tap rivet shaft out of hinge.

3. Drill out eight rivets using a 3/16 inch drill bit.

4. Remove hinge and backplates.

2008 FLT Police Service: Chassis 2-11

Page 30

sm03552

sm04702

1. Adjuster thumbscrew

2. Drive head Figure 2-11. Rivet Tool (HD-39787A)

Installation

1. Slide new rivet through holes in hinge, saddlebag and backplate.

2. Obtain RIVET TOOL (Part No. HD-39787A). See

Figure 2-11.

3. Orient tool so that head of rivet is seated in depression of drive head.Turn adjuster thumbscrew in or out of handle until both ends of rivet are captured.

4. Slowly squeeze handle of tool to compress rivet. Turn adjuster thumbscrew slightly in a clockwise direction and then squeeze handle again to further compress rivet. Repeat step as necessary until rivet is fully installed.

NOTE Compress rivet in small increments only .This method provides for best retention and alignment of parts and avoids possible damage to tool and painted surfaces of saddlebag.

5. Repeat previous steps to install remaining rivets.

6. Install lid onto saddlebag engaging upper and lower

hinges.

7. Compress new hinge pin rivet using a suitable rivet tool.

8. Install tether. See 2.6 SADDLEBAGS, Tether.

TETHER Removal

NOTE When the tether is removed, use caution to keep lid from

opening beyond its normal travel or damage to painted surf aces or hinges can occur.

1. Remove T15 TORX screw from threaded boss on tether

bracket. See Figure 2-12.

2. Remove tether eyelet and wave spring from threaded

boss.

3. Repeat previous steps to remove opposite end of tether from second tether bracket.

Installation

1. With the concave side toward the tether bracket, install wave spring onto threaded boss.

2. Install tether eyelet onto threaded boss.

3. Apply a small dab of LOCTITE HIGH STRENGTH THREADLOCKER 262 (red) to threads of T15 TORX screw.

4. Install screw into threaded boss and tighten to 20-25 in- lbs (2.3-2.8 Nm). See Figure 2-12.

5. Repeat this procedure to fasten opposite end of tether to second tether bracket.

1. Tether bracket

2. Rivet (4)

3. T15 TORX screw

4. Tether eyelet

5. Wave spring Figure 2-12.Tether and Tether Bracket

TETHER BRACKETS Removal

1. Remove tether. See 2.6 SADDLEBAGS, Tether

2. Drill out four rivets using a 3/16 inch drill bit.

3. Remove tether bracket and backplate.

Installation

1. Slide new rivets through holes in backplate, saddlebag/saddlebag lid and tether bracket (with the threaded boss on the outboard side).

2. Install rivets. See 2.6 SADDLEBAGS, Hinges.

3. Install tether. See 2.6 SADDLEBAGS, Tether.

KNOB AND SPRING LATCH Removal

1. Place multiple strips of masking tape on each side of knob to protect finished surfaces from scratches and other damage. Using a large flat blade screwdriver, alternately pry up each side of knob until free of post. See upper frame of Figure 2-13.

2-12 2008 FLT Police Service: Chassis

Page 31

2. Remove knob seal and masking tape. Remove any

sm04703

sm04704

sm04705

residual adhesive with 3M general Purpose adhesive remover (Part No. 051135). See lower frame of

Figure 2-13.

3. Drill out two rivets using a 13/64 inch drill bit. Remove spring latch. See Figure 2-14.

Installation

1. Hold spring latch at bottom of saddlebag lid with the flat side facing opposite the hinges. See Figure 2-14.

2. Slide two new rivets through holes in saddlebag lid and spring latch.

3. Compress rivets using a suitable rivet tool.

4. Peel paper backing off adhesive side of knob seal. Place knob seal over post, so that the adhesive side contacts the saddlebag lid. Press knob seal firmly into place.

5. Install knob onto post and alternately work each side down until it bottoms.

Figure 2-14. Spring Latch

SPRING LATCH BRACKET Removal

1. From outside saddlebag, loosen two Phillips screws.

2. Inside saddlebag, remove two K eps nuts and spring latch bracket. Remove Phillips screws. See Figure 2-15.

Installation

1. From outside saddlebag, slide two Phillips scre ws through holes in saddlebag.

2. Inside saddlebag, install spring latch bracket and two K eps nuts. See Figure 2-15.

3. Alternately tighten Phillips screws until snug.

1. Spring latch bracket

2. Keps nut (2)

3. Phillips screw (2) Figure 2-15. Spring Latch Bracket

Figure 2-13. Saddlebag Knob and Seal

2008 FLT Police Service: Chassis 2-13

Page 32

REMOVAL

sm04707

NOTE

The two rear holes in the handlebar clamp shroud allow the rider to adjust the handlebars without having to remove the shroud. To keep out moisture and debris, be sure to install plastic plugs back into holes after handlebar adjustment. See

Figure 2-18.

1. Remove windshield. See WINDSHIELD: FLHR/C in the Touring Models Service Manual.

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

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

4. Remove headlamp connector at back of headlamp bulb. Remove headlamp housing assembly from motorcycle.

5. From inside the headlamp nacelle: a. Disconnect tachometer harness connector [20], 6-

place Deutsch. See Figure 2-16.

b. Remove flange nut from weld stud to release chrome

strip at top of nacelle.

c. Catch Keps nut and flat washer while removing Phil-

lips screw from tab at front of handlebar clamp shroud.

2.7TACHOMETER BRACKET: FLHP/E

Figure 2-16. Disconnect Tachometer Connector

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

7. Remove the handlebar clamp shroud from the motorcycle, while gently pulling the tachometer harness conduit and connector out of the headlamp nacelle.

8. Remove two acorn nuts (with flat washers) to release tachometer bracket from studs at top of handlebar clamp shroud.

NOTE

Do not operate ABS equipped motorcycles with the tachometer removed. While the ABS remains operational, the rider will receive no warning if a malfunction occurs.The means to report DTC's also will be eliminated.

2-14 2008 FLT Police Service: Chassis

Page 33

sm04708

sm04709

1. Tachometer bracket

2. Handlebar clamp shroud

3. Fork lock plate

4. Handlebar adjustment access hole plug Figure 2-18. Install Handlebar Clamp Shroud

INSTALLATION

1. Place tachometer bracket over studs at top of handlebar clamp shroud. Install two acorn nuts (with flat washers) onto studs and alternately tighten to 72-108 in-lbs (8.1-

12.2 Nm). See Figure 2-18.

1. Headlamp nacelle

2. Keps nut

3. Flat washer

4. Flange nut

5. Chrome strip

6. Phillips screw (2)

7. Tachometer bracket

8. Acorn nut (2)

9. Fork lock plate

10. Handlebar clamp shroud

11. Stud plate Figure 2-17. Headlamp Nacelle Assembly

A peel and stick foam tape on the stud plate holds it in place on the inboard side of the handlebar clamp shroud.

2. Feed tachometer harness connector and conduit through opening at top of headlamp nacelle. Install handlebar clamp shroud over mating flange while routing tachometer harness conduit through opening for left side handlebar.

3. From inside the headlamp nacelle: a. Start flat washer and Keps nut onto Phillips screw

installed in tab at front of handlebar clamp shroud. Tighten Phillips screw to 10-20 in-lbs (1.1-2.3 Nm). See Figure 2-17.

b. Install flange nut onto weld stud of chrome strip

installed into hole at the top of headlamp nacelle. Tighten flange nut to 15-20 in-lbs (1.7-2.3 Nm).

c. Connect tachometer harness connector [20], 6-place

Deutsch. See Figure 2-16.

NOTE

4. Install two Phillips screws to fasten handlebar clamp shroud to the fork lock mechanism. Install fork lock plate.

5. Install headlamp connector at back of headlamp bulb.

6. Align holes in headlamp housing with those in headlamp nacelle (headlamp door bracket at bottom). Install seven Phillips screws and alternately tighten to 9-18 in-lbs (1.0-

2.0 Nm).

2008 FLT Police Service: Chassis 2-15

Page 34

7. Fit the square-shaped portion of the headlamp door spring into slot at top of headlamp housing and then snap the headlamp door (chrome ring) into place. Install Phillips

screw at bottom of headlamp door and tighten to 9-18 in- lbs (1.0-2.0 Nm).

8. Install windshield. See WINDSHIELD: FLHR/C in the Touring Models Service Manual.

2-16 2008 FLT Police Service: Chassis

Page 35

SUBJECT............................................................................................................................PAGE NO.

3.1 SPECIFICATIONS: ENGINE.....................................................................................................3-1

3.2 SERVICE WEAR LIMITS...........................................................................................................3-2

3.3 OIL COOLER.............................................................................................................................3-3

ENGINE

Page 36

NOTES

Page 37

3.1SPECIFICATIONS: ENGINE

GENERAL

Table 3-1. Engine: 2008 Police Models

Type

Torque

Pump

Pressure

Filtration

SPECIFICATIONITEM

2Number of cylinders

4-cycle, 45 degree

V-Type, air cooled

9.6-1Compression ratio 98 mm3.875 in.Bore

111 mm4.375 in.Stroke 1690 cc103 cu. in.Displacement

102 ft-lbs @

2500 RPM

Table 3-2. Oiling System

SPECIFICATIONITEM

Twin gerotor, dual scavenge, crank mounted and driven, internal oil pump, dry sump

30-38 psi (207-262 kN/m2) at 2000 RPM

and normal operating temperature of

230° F (110° C)

10 micron media, filtered between pump and engine

Thermostat controlled oil coolerCooling

138 Nm @ 2500 RPM

MANUFACTURING TOLERANCES

Table 3-3.Valves

MMIN.ITEM

0.038-0.0840.0015-0.0033Fit in guide (exhaust)

0.020-0.0660.0008-0.0026Fit in guide (intake)

50.55-51.411.990-2.024Stem protrusion from

cylinder head boss

Table 3-4.Valve Spring Assembly

DIMENSIONPRESSUREITEM

1.820 in. (46.2 mm)165 lbs (75 kg)Closed

1.290 in. (32.7 mm)416 lbs (189 kg)Open

2.210 in. (56.1 mm)n/aFree length

Table 3-5. Connecting Rods

MMINCHESITEM

0.008-0.0180.0003-0.0007Piston pin fit (loose)

Table 3-6. Crankshaft/Sprocket Shaft Bearing

MMINCHESITEM

0.0025-0.02540.0001-0.0010Bearing inner race on

crankshaft (tight)

2008 FLT Police Service: Engine 3-1

Page 38

3.2SERVICE WEAR LIMITS

GENERAL

Wear limits can be used as a guide when deciding whether to reuse engine parts. Replace used parts whenever the f ollowing wear limits are exceeded.

Table 3-7. Cam Support Plate

REPLACE IF WEAR EXCEEDSITEM

MMINCHES

2.03-2.290.080-0.090Cam chain tensioner

shoe

0.250.010Warpage

0.0203-0.02540.0008-0.001Crankshaft bushing fit

Table 3-8. Cylinder Bore

REPLACE IF WEAR EXCEEDSITEM

Table 3-9. Connecting Rods

REPLACE IF WEAR EXCEEDSITEM

Table 3-10. Crankshaft/Sprocket Shaft Bearing

REPLACE IF WEAR EXCEEDSITEM

Crankshaft runout

(tight)

crankshaft (tight)

Greater than

0.003

MMINCHES

98.483.877Standard

98.603.8820.005 in. oversize

98.733.8870.010 in. oversize

MMINCHES

0.0250.001Piston pin fit (loose)

MMINCHES

Greater than

0.076

0.097-0.1370.0038-0.0054Bearing fit in crankcase

Less than 0.0254Less than 0.0001Bearing inner race on

Table 3-11.Valve Stem to Guide Clearance

REPLACE IF WEAR EXCEEDSITEM

MMINCHES

0.0890.0035Intake

0.1020.0040Exhaust

3-2 2008 FLT Police Service: Engine

Page 39

OPERATION

sm04710

sm04712

Pressurized oil flows through a hole in the oil filter mount into a passage in the oil cooler adapter.The oil cooler adapter is mounted between the oil filter mount and the oil filter.

A thermostat inside the oil cooler adapter controls the flow of oil to the oil cooler.The ther mostat consists of a temperature sensitive element compressed between a spring and threaded plug. See Figure 3-1.

While the engine oil temperature is below 200° F (93° C), the thermostat is open allowing most of the engine oil to pass from the supply port directly to the return por t en route to the oil filter.

When the engine oil temperature reaches 200° F (93° C), the thermostat closes and the entire flow is directed to the oil cooler through the supply hose.

The fins on the tubes of the oil cooler dissipate heat before the flow returns to the oil cooler adapter through the return hose. The engine oil then passes through the oil filter before returning to the crankcase.

NOTE

For a complete description of the engine oil flow, see GENERAL INFORMATION in the Touring Models Service Manual.

3.3OIL COOLER

1. Return fitting

2. Supply fitting

3. Thermostat Figure 3-1. Oil Cooler Adapter

1. Flange nut (3)

2. Flat washer (3)

3. Mounting bracket

4. Oil cooler

5. Supply hose

6. Return hose

7. Hose clamp (4)

8. Oil cooler adapter

9. Oil filter adapter

10. Adhesive gasket Figure 3-2. Oil Cooler Assembly

REMOVAL

1. Place a suitable drain pan beneath the oil cooler.

2. See Figure 3-2. Remove three flange nuts with flat washers. Raise oil cooler to free threaded studs from holes in mounting bracket.

3. Using a side cutters, cut and remove clamps on oil cooler adapter side of supply and return hoses. Pull hoses from fittings.

4. Remove oil cooler from motorcycle.

5. Using a side cutters, cut and remove clamps on oil cooler side of supply and return hoses. Pull hoses from fittings.

2008 FLT Police Service: Engine 3-3

Page 40

6. Remove mounting bracket as follows: a. Remove voltage regulator and front electrical caddy.

See VOLTAGE REGULATOR in the Touring Models Service Manual.

b. Lift mounting bracket off studs on low er frame cross-

member.

CLEANING AND INSPECTION

1. Using a clean shop cloth or soft bristle brush, gently clean oil cooler fins of dirt and debris.

2. If engine failure and/or oil contamination requires inspection and cleaning of oil passageways, then remove oil cooler adapter and proceed as follows:

a. See Figure 3-3. Remove two socket screws (3) to

release inspection cover (4) and gasket (2).

b. Thoroughly flush oil passageways with solvent and

blow out with compressed air. c. Install inspection cover with new gasket. d. Apply a small dab of Loctite Medium Strength

Threadlocker 243 (blue) to threads of soc k et scre ws .

Install screws and alternately tighten to 90-120 in-

lbs (10.2-13.6 Nm).

INSTALLATION

TOOL NAMEPART NUMBER

HOSE CLAMP PLIERSHD-97087-65B

NOTE

If mounting bracket is already installed, proceed to next step.

1. Install mounting bracket as follows: a. With the "TOP" stamp facing upw ard, install mounting

bracket onto studs on lower frame crossmember.

b. Install front electrical caddy and voltage regulator.

See VOLTAGE REGULATOR in the Touring Models Service Manual.

2. Slide new clamp onto oil cooler side of return hose, which can be identified by the paint stamp reading COOLER BOTT OM.With the script facing upward, install hose onto bottom fitting of oil cooler. Crimp clamp using HOSE CLAMP PLIERS (Part No. HD-97087-65B).

3. Slide new clamp onto oil cooler side of supply hose, which can be identified by the paint stamp reading COOLER TOP.With the script facing upward, install hose onto top fitting of oil cooler. Crimp clamp.

NOTE If the paint stamps are not present, the long hose is the return and the short hose is the supply. Install both hoses, so that the 90° bend goes to the oil cooler adapter.

4. Slide threaded studs at bottom of oil cooler through holes

in mounting bracket. Install flat washers and flange nuts on studs. Alternately tighten flange nuts to 70-100 in- lbs (7.9-11.3 Nm).

5. Slide new clamp onto free end of return hose (stamped

COOLER BOTTOM). Install hose on upper fitting of oil cooler adapter. Crimp clamp using HOSE CLAMP PLIERS (Part No. HD-97087-65B).

6. Slide new clamp onto free end of supply hose (stamped COOLER TOP). Install hose on lower fitting of oil cooler adapter. Crimp clamp.

7. Check engine oil level. See ENGINE OIL AND FILTER in the Touring Models Service Manual.

OIL COOLER ADAPTER AND THERMOST A T REPLACEMENT

TOOL NAMEPART NUMBER

HOSE CLAMP PLIERSHD-97087-65B

Removal

NOTE

A faulty thermostat requires replacement of the oil cooler adapter.

1. Place a suitable drain pan beneath the oil cooler and oil filter.

2. Using a side cutters, cut and remove clamps on oil cooler adapter side of supply and return hoses. Pull hoses from fittings.

3. Remove the engine oil filter. See ENGINE OIL AND FILTER in the Touring Models Service Manual.

4. Using internal hex, remove the oil filter adapter. Remove the oil cooler adapter and gasket. See Figure 3-2.

Installation

NOTE

Skip first step if hose fittings are already installed.

1. Install hose fittings as follows: a. Install hose fittings until finger tight.

b. Using wrench on flats, rotate hose fittings an addi-

tional 2-3 turns.

2. Position oil cooler adapter flange against oil filter mount. Index tabs on flange engage a recess on each side of the oil filter mount oil outlet hole. See Figure 3-3.

3. Apply Loctite High Temperature/Medium Strength Threadlocker 246 to threads of oil filter adapter.With the internal hex on the outboard side, thread oil filter adapter into oil filter mount. Holding the oil cooler adapter to prevent rotation, tighten oil filter adapter to 18-22 ft-lbs (24.4-

29.8 Nm).

4. Slide new clamp onto free end of return hose (stamped COOLER BOTTOM). Install hose on upper fitting of oil cooler adapter. Crimp clamp using HOSE CLAMP PLIERS (Part No. HD-97087-65B).

5. Slide new clamp onto free end of supply hose (stamped COOLER TOP). Install hose on lower fitting of oil cooler adapter. Crimp clamp.

6. Install new oil filter and check engine oil level. See ENGINE OIL AND FILTER in the Touring Models Service Manual.

7. Start engine and inspect oil cooler/adapter fittings and hoses for leaks.

3-4 2008 FLT Police Service: Engine

Page 41

sm04713

1. Index tabs

2. Adhesive gasket

3. Socket screw (2)

4. Inspection cover Figure 3-3. Oil Cooler Adapter

2008 FLT Police Service: Engine 3-5

Page 42

NOTES

3-6 2008 FLT Police Service: Engine

Page 43

SUBJECT............................................................................................................................PAGE NO.

4.1 FUEL SYSTEM..........................................................................................................................4-1

FUEL SYSTEM

Page 44

NOTES

Page 45

NO UNIQUE CONTENT

Any information not presented in this supplement can be found in the Touring Models Service Manual.

4.1FUEL SYSTEM

2008 FLT Police Service: Fuel System 4-1

Page 46

NOTES

4-2 2008 FLT Police Service: Fuel System

Page 47

SUBJECT............................................................................................................................PAGE NO.

5.1 ELECTRIC STARTER................................................................................................................5-1

ELECTRIC STARTER

Page 48

NOTES

Page 49

NO UNIQUE CONTENT

Any information not presented in this supplement can be found in the Touring Models Service Manual.

5.1ELECTRIC STARTER

2008 FLT Police Service: Electric Starter 5-1

Page 50

NOTES

5-2 2008 FLT Police Service: Electric Starter

Page 51

SUBJECT............................................................................................................................PAGE NO.

6.1 DRIVE........................................................................................................................................6-1

DRIVE

Page 52

NOTES

Page 53

NO UNIQUE CONTENT

Any information not presented in this supplement can be found in the Touring Models Service Manual.

6.1DRIVE

2008 FLT Police Service: Drive 6-1

Page 54

NOTES

6-2 2008 FLT Police Service: Drive

Page 55

SUBJECT............................................................................................................................PAGE NO.

7.1 TRANSMISSION.......................................................................................................................7-1

TRANSMISSION

Page 56

NOTES

Page 57

NO UNIQUE CONTENT

Any information not presented in this supplement can be found in the Touring Models Service Manual.

7.1TRANSMISSION

2008 FLT Police Service: Transmission 7-1

Page 58

NOTES

7-2 2008 FLT Police Service: Transmission

Page 59

SUBJECT............................................................................................................................PAGE NO.

8.1 BULB CHART............................................................................................................................8-1

8.2 SYSTEM FUSES AND RELAYS...............................................................................................8-3

8.3 REAR MARKER LIGHTS..........................................................................................................8-5

8.4 HANDLEBAR SWITCHES.........................................................................................................8-6

8.5 AUTOMATIC COMPRESSION RELEASE...............................................................................8-10

ELECTRICAL

Page 60

NOTES

Page 61

GENERAL

8.1BULB CHART

The table below gives the bulb requirements for FLHTP and FLHP/E police model motorcycles.

Table 8-1. Bulb Chart FLHTP, FLHP/E

LAMP DESCRIPTION

(ALL LAMPS 12V)

Head Lamp

Tail/Stop Lamp

Turn Signal Lamp

Rear Fender Tip Lamp

Pursuit Lamp

Instrument Panel Lamps-FLHTP Indicator Module (with LEDs)

Oil Pressure Indicator** Neutral Indicator** Turn Signal Indicator**

Gauge Lamps-FLHTP

Tachometer**

Fuel Gauge

Instrument/Gauge Lamps-FLHP/E Indicator Module (with LEDs)

Oil Pressure Indicator** Neutral Indicator** Turn Signal Indicator**

NUMBER OF BULBS

(REQUIRED)

(AMPERAGE)

The rear strobe is a source of high voltage and must be off at least 10 minutes before servicing. Inadequate safety precautions may result in death or serious injury . (00097a)

WATTAGECURRENT DRAW

605.00HIgh Beam

242.10Stop Lamp

HARLEY-DAVIDSON

PART NUMBER

68329-03554.581Low Beam

68167-8860.591Tail Lamp

68168-8927/72.25 / 0.592Front / Running

68572-64B272.252Rear

53439-793.70.332Rear Fender Tip Bulb

68727-64A302.51Left (Red)

68728-64Right (Blue) 67598-8820N/ARear Strobe, if provided

68859-07N/A0.05N/AHigh Beam Indicator**

N/AN/AN/AN/ASpeedometer**

67445-003.40.241Voltmeter

N/AN/AN/AN/AEngine**

68642-961.10.081Pursuit (fairing)

68113-99BN/A0.05N/AHigh Beam Indicator**

2008 FLT Police Service: Electrical 8-1

Page 62

Table 8-1. Bulb Chart FLHTP, FLHP/E

LAMP DESCRIPTION

(ALL LAMPS 12V)

Speedometer** Odometer** Engine** Pursuit** ** LED illuminated. LEDs are not repairable. Assembly must be replaced if LED fails.

NUMBER OF BULBS

(REQUIRED)

(AMPERAGE)

WATTAGECURRENT DRAW

HARLEY-DAVIDSON

PART NUMBER

N/AN/AN/AN/AFuel Gauge**

8-2 2008 FLT Police Service: Electrical

Page 63

SYSTEM FUSES

ed01646

109

11 12 13 14

ed01653

8.2SYSTEM FUSES AND RELAYS

Removal

1. Verify that the Ignition/Light Key Switch is turned to the OFF position.

2. Remove left side saddlebag.

3. See Figure 8-1. Remove wing nut style bolt to release bottom of siren amplifier mounting bracket from clamp on saddlebag guard. Rotate brac ket upward to gain complete access to side cover area. Loosen top bolt, if necessary.

4. Gently pull side cover from frame downtubes (no tools required). Ex ercise caution to a void scratching side cover on amplifier mounting bracket.

5. Raise the fuse block cover.

NOTE The fuse block cov er has a fuse puller attachment that may be used to remove fuses.

6. Remove fuse from fuse block and inspect the element.

7. See Figure 8-2 to identify fuse location. Replace fuse if

element is burned or broken. Automotive type ATO fuses are used.

Always use replacement fuses that are of the correct type and amperage rating. Use of incorrect fuses can result in damage to electrical systems. (00222a)

Figure 8-1. Siren Amplifier Mounting Bracket

2. 16.9.Accessory (15A) Headlamp (15A)EFI system relay

Radio/Siren (15A)

5. 19.Radio memory (if equipped) (15A)

6. 21.13.Battery (15A) MAXIFUSE (40A)Ignition (15A)

Figure 8-2. Left Side Electrical Caddy

10.3. 17.Starter relayP&A (15A) Lighting (15A)

max)

12. 20.Instruments (15A) Spare (30A)

14.7. Engine control (15A)ECM power (15A)

15.8.1. Brake light relayFuel pump (15A)Brakes/Pursuit (15A)

18.11.4. Spare (15A)P&A ignition (if equipped) (2A ABS (if equipped) (30A)

2008 FLT Police Service: Electrical 8-3

Page 64

Installation

1. Install fuse in fuse block. For correct type and amperage rating, refer to Figure 8-2.

2. Install cover on fuse block.

3. Align barbed studs in side cover with grommets in frame downtubes and push firmly into place (no tools required).

4. Rotate siren amplifier mounting bracket downw ard. Install wing nut style bolt to secure bracket to clamp on saddlebag guard.Tighten top bolt, if loosened.

5. Install left side saddlebag.

8-4 2008 FLT Police Service: Electrical

Page 65

8.3REAR MARKER LIGHTS

ed01647

MARKER LIGHTS REPLACEMENT

1. On inboard side of rear marker lights bracket, gently pull electrical connector from prongs on marker light.

2. Rotate marker light in a counterclockwise direction and remove from hole in rear marker lights bracket.

3. Place new marker light into hole in rear marker lights bracket and rotate in a clockwise direction to install.

4. On inboard side of rear marker lights bracket, gently push electrical connector onto prongs on marker light.

REMOVAL

1. Disconnect rear marker lights harness connector [12], 3place Multilock, inboard of left upper frame tube.

2. Carefully cut cable strap to release rear marker lights (and pole lamp) conduit from left side of bottom support tube.

3. On inboard side of license plate bracket, note that catches on rear marker lights bracket engage oblong holes in license plate bracket. Using tip of flat blade screwdriver, gently push top catch down and then bottom catch up to release from oblong hole. Repeat step to release other side of rear marker lights bracket.

4. Remove rear marker lights assembly from motorcycle.

INSTALLATION

1. Gently pull both electrical connectors from prongs to detach rear marker lights harness.

2. On inboard side of left upper frame tube, mate pin and socket housings of rear marker lights harness connector [12], 3-place Multilock.

3. Route free end of rear marker lights conduit rearward following inboard side of bottom support tube.When conduit reaches air reservoir, loop left side rear marker light conduit to outboard side, while routing right side rear marker light conduit between top of bottom support tube and bottom of air reservoir bracket to right side of motorcycle.

4. Engage catches on each side of rear marker lights bracket into oblong holes in license plate bracket.

5. On inboard side of rear marker lights bracket, gently push electrical connectors onto prongs on marker lights.

6. Install new cable strap to secure rear marker lights (and pole lamp) conduit to left side of bottom support tube. Cut any excess cable strap material.

1. Rear marker light (2)

2. Rear marker lights bracket

3. Rear marker lights harness

4. License plate bracket

5. Bottom support tube Figure 8-3. Rear Marker Lights Assembly

2008 FLT Police Service: Electrical 8-5

Page 66

HORN AND SIREN YELP SWITCH

ed01654

ed01655

NOTE

Install new cable strap to secure rear marker lights (and pole lamp) conduit to left side of bottom support tube. Cut any excess cable strap material.

Removal

1. Gain access to the inside of the switch housing. See HANDLEBAR SWITCH ASSEMBLIES in the Touring Models Service Manual.

2. From inside the switch housing, carefully cut cable strap to free conduit from the turn signal switch bracket.

3. Remove the Phillips screw (with lockwasher) to release the turn signal switch bracket. Remove the switch assembly from the housing.

4. Remove the two T8 TORX screws and the Phillips screw (with lockwasher) to release the lower bracket. Carefully lift out the bracket so as not to disturb the spring-loaded ramp on the inboard side of the housing.

5. Carefully remove the keycap disengaging slot from hook on ramp.

6. While holding down the ramp, pull both s witches from the housing.

7. Cut the wires from the old switches as follows: a. Yellow/Black wire: 1-1/4 in. (32 mm)

b. Orange/White wires: 1-7/8 in. (48 mm) c. Brown/Black wire: 1-1/2 in. (38 mm)

8.4HANDLEBAR SWITCHES

1. Engine start switch

2. Front stoplight switch

3. Engine stop switch: Off/Run

4. Pole and pursuit lamp switc h: Off/A uxiliary/Pursuit

5. Turn-right signal switch

Figure 8-4. Right Handlebar Switch Housing

NOTE

Replacement Horn/Siren Yelp Switch wires are cut to length and partially stripped (Yellow/Black wire: 3-3/4 in. (95 mm); Orange/White wires: 3-1/2 in. (89 mm); Brown/Black wire: 33/8 in. (86 mm).

8. Connect wires of new switch. See HANDLEBAR SWITCH ASSEMBLIES in the Touring Models Service Manual.

NOTE

If the ramp and spring mechanism becomes loose, install as follows:

• Using the blade of a small screwdriver, compress spring and place in wider portion of channel at bottom of ramp.

• V erify that spring is evenly compressed and is not coc k ed or skewed. Push spring so that it bottoms in channel.

• With tab side of ramp facing inboard and hook end on switch side of casting, install ramp so that narrow channels engage pins cast into housing.

8-6 2008 FLT Police Service: Electrical

1. Clutch/starter interlock switch

2. Siren switch: On/Off

3. Light switch: high and low beams

4. Turn-left signal switch

5. Horn/siren yelp switch Figure 8-5. Left Handlebar Switch Housing

Installation

1. Install the switches in the housing with contacts facing tabs on ramp. F or best results, install one s witch at a time. Ribs cast in lower housing hold switches in position.

The Horn switch with the Yellow/Black lead (pivot point towards rider) is installed at the bottom, while the Siren Yelp switch with the Brown/Black lead (pivot point tow ards the front) is at the top. Route switch wires in channel on the outboard side of the ribbed area.

Page 67

2. Install the keycap engaging slot with hook on ramp.

3. Install lower bracket sliding pin through keycap and engaging hole in lower casting.

4. Slide T8 T ORX screws through holes in lo wer brack et and switches and thread into lower casting until snug.

5. Install Phillips screw (with lockwasher), to secure lower bracket to threaded boss in housing.Verify operation of Horn and Siren Yelp switches to ensure that both are spring returned.

6. Install clutch interlock switch in bore of lower switch housing, if loose.

7. Insert tapered end of new 7-inch cable strap into round hole in turn signal switch bracket and then feed back through using the adjacent hole. Reserve the oblong hole for the bracket screw.

NOTE Be sure that all splices are positioned above the turn signal switch bracket.

8. Place the turn signal switch assembly into the housing

aligning the oblong hole in the bracket with the lower bracket weld nut. Be sure that bracket is fully seated.T abs on each side are captured in slots cast into switch housing.

9. Install Phillips screw (with lockwasher) to secure bracket

inside housing.

If routed incorrectly, wires can be pinched by casting or handlebar resulting in switch failure. (00542b)

10. Loop switch wires so that spliced lengths are positioned

directly over bracket screw.

11. Capturing conduit about 1/4 inch (6 mm) from end,

securely tighten cable strap to draw conduit to bracket. Remove any excess cable strap material.

12. On opposite side, install second 7-inch cable strap cap-

turing conduit and wire splices. Securely tighten cable strap to draw splices to conduit. Remov e any excess cab le strap material.

13. Route wire bundle to upper switch housing below and then

forward of the main wire harness positioning conduit in channel next to angular arm of bracket. Secure bundle to arm placing new cable strap 1/4 inch (6 mm) from end of conduit. Cut an y excess cable str ap material. If necessary, bend angular arm of bracket downward to firmly secure clutch interlock switch in installed position.

14. See HANDLEBAR SWITCHES in the Touring Models

Service Manual.

CLUTCH INTERLOCK SWITCH

NOTE All Police models have a clutch interlock switch that prevents

the motorcycle from starting (even in NEUTRAL) if the clutch lever is not pulled in.

Removal

1. See HANDLEBAR SWITCH ASSEMBLIES in the Touring

Models Service Manual.

2. From inside the switch housing, carefully cut cable strap to free conduit from the turn signal switch bracket.

3. Remove the Phillips screw (with lockwasher) to release the turn signal switch bracket. Remove the switch assembly from the housing.

4. Remove the clutch interlock switch from the housing.

5. Cut wires 1/4 in. (6 mm) from old switch. Discard switch assembly.

NOTE Replacement clutch interlock switch wires are cut to length. Looking at rear side, left side switch wire is 2-1/4 in. (57 mm), and right side is 2-3/4 in. (70 mm) and partially stripped.

6. Connect wires of new switch. See HANDLEBAR SWITCH

ASSEMBLIES in the Touring Models Service Manual.

Installation

1. Install clutch interlock switch in bore of lower switch

housing.

2. Insert tapered end of new 7-inch cable strap into round

hole in turn signal switch bracket and then feed back through using the adjacent hole. Reserve the oblong hole for the bracket screw.

NOTE Be sure that all splices are positioned above the turn signal switch bracket.

3. Place the turn signal switch assembly into the housing

aligning the oblong hole in the bracket with the lower bracket weld nut. Be sure that bracket is fully seated.T abs on each side are captured in slots cast into switch housing.

4. Install Phillips screw (with lockwasher) to secure bracket

inside housing. If routed incorrectly, wires may be pinched by casting or handlebar resulting in switch failure.

If routed incorrectly, wires can be pinched by casting or handlebar resulting in switch failure. (00542b)

5. Loop switch wires so that spliced lengths are positioned

directly over bracket screw.

6. Capturing conduit about 1/4 in. (6 mm) from end, securely

tighten cable strap to draw conduit to bracket. Remove any excess cable strap material.

7. On opposite side, install second 7-inch cable strap cap-

turing conduit and wire splices. Securely tighten cable strap to draw splices to conduit. Remov e any excess cab le strap material.

8. Route wire bundle to upper switch housing below and then

forward of the main wire harness positioning conduit in channel next to angular arm of bracket. Secure bundle to arm placing new cable strap 1/4 in. (6 mm) from end of conduit. Cut an y excess cable str ap material. If necessary, bend angular arm of bracket downward to firmly secure clutch interlock switch in installed position.

9. See HANDLEBAR SWITCH ASSEMBLIES in the Touring

Models Service Manual.

2008 FLT Police Service: Electrical 8-7

Page 68

ed01649

Figure 8-6. Lower Switch Housing

PURSUIT AND AUXILIARY SWITCH

NOTE

Pursuit lamps are operational on domestic motorcycles only.

Removal

1. See HANDLEBAR SWITCH ASSEMBLIES in the Touring Models Service Manual.

2. From inside the switch housing, carefully cut cable strap to free conduit from the turn signal switch bracket.

3. Remove the Phillips screw (with lockwasher) to release the turn signal switch bracket. Remove the switch assembly from the housing.

4. Remove the two T8 TORX screws and the Phillips screw (with lockwasher) to release the lower bracket. Remove the bracket from the housing.

5. Pull both switches from the housing.

6. Cut the wires from the old switches as follows: a. Gray/Black wire: 1-1/2 in. (38 mm)

b. Orange/Violet wires: 1-7/8 in. (48 mm) c. Green/Red wire: 1-1/4 in. (32 mm)

NOTE

Replacement pursuit/auxiliary switch wires are cut to length and partially stripped (Gray/Black wire: 2 in. (51 mm); Orange/Violet wires: 1-7/8 in. (48 mm); Green/Red wire: 13/4 in. (45 mm).

7. Connect wires of new switch. See HANDLEBAR SWITCH ASSEMBLIES in the Touring Models Service Manual.

8. Move keycap to the OFF position. Install the switches in the housing with contacts facing the recessed area on the ramp. Ribs cast in lower housing hold s witches in position.

The Auxiliary switch with the Gray/Black lead is installed at the bottom, while the Pursuit switch with the Green/Red lead is at the top. Route switch wires into corner space outside of the ribbed area.

NOTE If the keycap and ramp mechanism requires replacement, install as follows:

• Slide ramp upward to remove from keycap shaft.

• Remove keycap from switch housing.

• Install spring into hole on inboard side of new keycap.

Position ball on end of spring. Use a small amount of grease to hold ball in place.

• Install keycap so that ball engages detent in switch

housing.

• Slide ramp over keycap shaft so that tongues on ramp

engage grooves in keycap shaft.

Installation

1. Install lower bracket with the weld nut side down.

2. Slide the T8 TORX scre ws through holes in lo wer br ac k et

and switches and thread into lower casting until snug.

3. Install Phillips screw (with lockwasher), to secure lower

bracket to threaded boss in housing.Work Auxiliary and Pursuit switches to ensure smooth operation.

4. See Figure 8-7. Insert tapered end of new 7-inch cable

strap into round hole in turn signal switch bracket and then feed back through using the adjacent hole. Reser ve the oblong hole for the bracket screw.

NOTE Be sure that all splices are positioned above the turn signal switch bracket.

5. Place the turn signal switch assembly into the housing

aligning the oblong hole in the bracket with the lower bracket weld nut. Be sure that bracket is fully seated.T abs on each side are captured in slots cast into switch housing.

6. Install Phillips screw (with lockwasher) to secure turn signal

switch bracket inside housing.

If routed incorrectly, wires can be pinched by casting or handlebar resulting in switch failure. (00542b)

7. Loop switch wires so that spliced lengths are positioned

directly over bracket screw.

8. Capturing conduit about 1/4 in. (6 mm) from end, securely

tighten cable strap to draw conduit to bracket. Remove any excess cable strap material.

9. On opposite side, install second 7-inch cable strap cap-

turing conduit and wire splices. Securely tighten cable strap to draw splices to conduit. Remov e any excess cab le strap material.

10. Route wire bundle to upper switch housing in channel next

to angular arm of bracket. Secure bundle to arm placing new cable strap 1/4 in. (6 mm) from end of conduit. Cut any excess cable strap material. If necessary, bend

8-8 2008 FLT Police Service: Electrical

Page 69

angular arm of bracket downward to firmly secure Front

ed01650

Stoplight Switch in installed position.

11. See HANDLEBAR SWITCH ASSEMBLIES in the T ouring Models Service Manual.

1. 7" cable strap

2. Bracket

3. Right turn signal switch

Figure 8-7. Hole Location Cable Strap Switch Bracket

2008 FLT Police Service: Electrical 8-9

Page 70

GENERAL

ed01623

ed01624

ed01625

See Figure 8-8. The Automatic Compression Release (ACR) is opened and closed by the ECM to assist starting.

See Figure 8-9.When open, compressed gases are released through the exhaust port.

REMOVAL

TOOL NAMEPART NUMBER

ACR SOLENOID SOCKETHD-48498

1. While preparing motorcycle for service, separate the ACR rear [203R] and front [203F] connectors from the main wiring harness.

2. Remove the rocker cover and the rocker box. See STRIPPING MOTORCYCLE FOR SERVICE and TOP END OVERHAUL in the Service Manual for procedures.

3. See Figure 8-13. Use ACR SOLENOID SOCKET (Part No. HD-48498) to remov e the ACR from the cylinder head.

8.5AUTOMATIC COMPRESSION RELEASE

Figure 8-10. ACR in Head

INSTALLATION

TOOL NAMEPART NUMBER

ACR SOLENOID SOCKETHD-48498

Figure 8-8. ACR Valve in Combustion Chamber

1. V erify that the copper seal washer is in place on the ACR.

2. See Figure 8-11. Identify a location around the threads of the ACR approximately 1/3 of the way up from the end.

3. See Figure 8-12. Apply three equally spaced dots of LOCTITE 246 THREADLOCKER MEDIUM STRENGTH/HIGH TEMPERATURE (blue) on threads.

4. To prevent cross threading, install and finger tighten.

5. See Figure 8-13. Using ACR SOLENOID SOCKET (Part No. HD-48498), tighten to 11-15 ft-lbs (14.9-20.3 Nm).

6. Before installing the rocker box on each cylinder head, route the wire harness toward the inside of the cylinder V.

7. With rocker box es installed and the engine in the chassis , mate the ACR connectors [203R] and [203F] to the corresponding socket housings on the main wiring harness.

Figure 8-9. ACR Exhaust Port Release

8-10 2008 FLT Police Service: Electrical

Page 71

ed01626

ed01627

ed01628

Figure 8-11. Bottom Third

Figure 8-12.Three Dots of Loctite 246 Medium

Strength/High Temperature

Figure 8-13. ACR Solenoid Socket (HD-48498) and ACR

COMPRESSION TEST

TOOL NAMEPART NUMBER

CYLINDER COMPRESSION GAUGEHD-33223-1

A compression test can determine the source of cylinder leakage. Use CYLINDER COMPRESSION GAUGE (Part No. HD-33223-1) with a screw-in type adapter.

NOTE

The Twin Cam 103 Engine uses a 12 mm adapter with the compression gauge.

1. Operate engine to normal operating temperature.

2. Disconnect spark plug wires.

3. Clean around plug base and remove front cylinder spark plug.

4. Install compression tester to front cylinder per gauge instructions.

NOTE The test results will vary depending on whether the ACR is connected or not. Refer to Table 8-2 for specifications.

5. Shift transmission to neutral. Crank engine continuously

through 5 to 7 compression strokes.

6. Record gauge readings at the end of the first and last

compression strokes (highest readings).

7. Replace front spark plug and repeat test on rear cylinder.

8. Refer to Table 8-2. Readings should be within specified

range. If readings are higher than normal, suspect a compression release that is not functioning correctly. If readings are low, inject approximately 1/2 oz. (15 ml) engine oil into each cylinder and repeat the compression tests on both cylinders.

NOTE Readings that are considerably higher after injecting the oil indicate worn piston rings.

2008 FLT Police Service: Electrical 8-11

Page 72

Table 8-2. Compression Specifications

Y/GN

V/GY

[78A] [78B]

ACR

[119B]

[203FB]

[203RB]

1 2 1 2

K 87

T 87A

E 30

SU85

2 1

em00235

PSIACR STATUS

kN/m

896-1,173130-170Connected

1,379-1,517200-220Disconnected

DIAGNOSTICS

TOOL NAMEPART NUMBER

TEST CONNECTOR KITHD-41404-B BREAK-OUT BOXHD-48637

Diagnostic Tips

Refer to flow charts that follow for troubleshooting.

Diagnostic Notes

NOTE

The step numbers below correlate with the circled numbers in the flow chart.

1. Use TEST CONNECTOR KIT (P art No. HD-41404-B) with gray terminal probes and patch cords.

2. Connect BREAK-OUT BOX (P art No. HD-48637) to ECM.

3. If V/GY wire is shorted to ground, the ACRs will remain on for a time that exceeds the design parameters and the ACR solenoids will fail.

Figure 8-14. ACR Circuit

Table 8-3. Connectors/Fuse in ACR Circuit

LOCATIONTYPEDESCRIPTIONNUMBER

Under seat73-place DelphiECM[78] Between cylinders2-place Amp (Tyco)ACR[203F] Between cylinders2-place Amp (Tyco)ACR[203R] ESPFI fuse blockLugsSystem relay[119]

8-12 2008 FLT Police Service: Electrical

Page 73

ACR Diagnostics (Part 1 of 2)

Is battery voltage 12.6

VDC or higher?

Charge battery.

Perform starter current draw test while cranking

engine at room temperature. Remove system

relay and repeat starter current draw test.

Is current draw 20-40 Amps greater with

system relay removed?

YES

During the first 2 seconds after turning the

key on (while relay is energized) or while

cranking, measure voltage at terminal “1” on

connector [203FB] (front) or [203RB] (rear).

Is battery voltage present?

Locate and repair open on Y/GN

wire between terminal “1” on

connector [203FB] (front) or

[203RB] (rear) and system relay.

Review symptoms.

Issue is not ACR related.

Measure continuity between

terminal “2” on connector [203FB]

(front) or [203RB] (rear) and

breakout box terminal “19”.

Is continuity present?

Locate and repair open on V/GY wire

between terminal “2” on connector

[203FB] (front) or [203RB] (rear) and

ECM connector [78B] terminal “19”.

Disconnect breakout box from ECM

leaving harness connected to breakout

box. Measure continuity between terminal

“19” on breakout box and ground.

Is continuity present?

Disconnect connector [203FB] (front)

and [203RB] (rear) one at a time.

Is continuity to ground still resent?

Replace grounded

ACR.

Locate and repair short to ground on

V/GY wire between terminal “2” on

connector [203FB] (front) or [203RB]

(rear) and ECM connector [78B}

terminal “19” and replace both ACRs.

YES

fc01777_en

Go to

ACR Diagnostics

(Part 2 of 2).

STOP

7077

7078

7077

7076

2008 FLT Police Service: Electrical 8-13

Page 74

ACR Diagnostics (Part 2 of 2)

Continued from ACR Diagnostics

(Part 1 of 2).

Measure voltage at breakout box terminal “19”

with breakout box disconnected from ECM.

Is voltage present?

Measure resistance between

terminal “1” and “2” on connector

[203FA](front) or [203RA].

Is continuity present?

Reconnect breakout box and ECM; and

ACRs to the engine wiring harness. Measure

voltage at terminal “19” during cranking.

Is voltage 0.1-8.0 VDC and fluctuating while

engine cranks?

Perform compression test (only one spark plug can

be removed at a time or ACR will be disabled).

Refer to COMPRESSION TEST.

Is compression 130 - 170 PSI (896- 1,173 kN/m2 0

with ACR connected and 200-220 PSI (1379-1517

kN/m2) with ACR disconnected?

Review symptoms. Issue

is not ACR related.

Replace ACR on cylinder

that is non-functional.

Locate and repair short to voltage

on V/GY wire between terminal

“2” on connector [203FB] (front)

or [203RB] (rear) and ECM

connector [78B] terminal “19”.

Replace defective

ACR solenoid.

Replace ECM

YES NO

YES

fc01778_en

7079

7077

7080

7077

8-14 2008 FLT Police Service: Electrical

Page 75

SUBJECT............................................................................................................................PAGE NO.

A.1 CONNECTORS........................................................................................................................A-1

A.2 INDEX TO WIRING DIAGRAMS...............................................................................................A-7

APPENDIX A WIRING

Page 76

NOTES

Page 77

[31L]

[167]

[207]

[176]

[31R]

[108]

[21]

[39]

[69]

[24]

[70]

[33]

[32]

[22]

[15]

[2]

[1]

ed01651

A.1CONNECTORS

CONNECTORS

Figure A-1. Inner Fairing

Table A-1. FLHTP Wire Harness Connectors

16-place Molex (black)Main to interconnect harness[1]

2008 FLT Police Service: Appendix A Wiring A-1

LOCATIONTYPEDESCRIPTIONNO.

Inner fairing - right storage box support bracket

Inner fairing - right fairing support brace12-place Molex (gray)Main to interconnect harness[2] Upper frame cross member (under seat)4-place DeutschAccessory[4]

Page 78

Table A-1. FLHTP Wire Harness Connectors

16-place Molex (black)Interconnect to right handlebar switches[22]

12-place DeutschTSM/HFSM[30]

4-place MultilockLeft front turn signal/pursuit lamp[31L]

2-place Multilock (black)Front fender tip lamp jumper harness[32]

3-place PackardIgnition/light key switch[33]

2-place DeutschCKP sensor[79]

LOCATIONTYPEDESCRIPTIONNO.

Under left side cover2-place PackardMAXIFUSE[5] Top of rear fender (under seat)8-place MultilockRear fender lights harness[7] Inboard of left upper frame tube3-place MultilockRear marker lights harness[12] Behind fuel tank (under seat)4-place MultilockFuel tank harness[13] Inner fairing - front of right fairing bracket4-place PackardMain to interconnect harness[15] Circuit board under tail lamp assembly2-place MultilockLeft rear turn signal[18] Circuit board under tail lamp assembly2-place MultilockRight rear turn signal[19] Inner fairing - above storage box10-place MultilockIndicator lights[21] Inner fairing - fork stem nut lock plate (left

side) Inner fairing - left fairing support brace12-place Molex (gray)Interconnect to left handlebar switches[24] Cavity in crossmember at rear of battery

box (under seat) Inner fairing - outboard of left fairing

bracket Inner fairing - right fairing support brace4-place MultilockRight front turn signal/pursuit lamp[31R] Inner fairing - below upper fork bracket

(left side) Inner fairing - under storage box (front of

ignition switch housing) Inner fairing (back of headlamp)Headlamp ConnectorHeadlamp[38] Inner fairing (back of speedometer)12-place Packard (black)Speedometer[39] Circuit board under tail lamp assembly3-place MultilockRear fender tip lamp[45] Bottom of voltage regulator (left side)3-place LyallStator[46] Top rail of engine guard (right side)2-place DeutschSiren/PA speaker[57] Under luggage rack (left side)2-place DeutschRear pole lamp[59] Under left side coverPackardFuse block[64] Top of transmission case (under Starter)3-place DelphiVSS[65] Inner fairing - front of speedometerRelay connectorPursuit flasher (domestic only)[69] Inner fairing - left fairing support brace12-place Deutsch (black)Siren amplifier harness[70] Top rail of saddlebag guard (left side)18-place PackardSiren amplifier[72] Bottom of voltage regulator (right side)2-place LyallVoltage regulator[77] Under right side cover73-place PackardECM[78] Electrical caddy at bottom of lower frame

A-2 2008 FLT Police Service: Appendix A Wiring

Page 79

Table A-1. FLHTP Wire Harness Connectors

12-place MultilockFairing cap switches[105]

Relay connectorIgnition keyswitch relay[126]

3-place Molex (black)Jiffy Stand Sensor[133]

2-place Amp (Tyco)O2 sensor front exhaust header[138]

2-place Amp (Tyco)Front wheel speed sensor[167]

6-place DeutschMain to interconnect harness[176]

5-place Amp (Tyco)Active exhaust actuator[179]

LOCATIONTYPEDESCRIPTIONNO.

Inner fairing - above upper fork bracket (right side)

Inner fairing (back of tachometer)12-place Packard (gray)Tachometer[108] Inner fairing (back of voltmeter)Spade connectorVoltmeter lamp[110] Inner fairing (back of voltmeter)Spade connectorVoltmeter[111] Inner fairing (back of fuel gauge)Spade connectorFuel gauge lamp[116] Inner fairing (back of fuel gauge)Spade connectorFuel gauge[117] Fuse block (under right side cover)Fuse terminalsEFI fuses[119] Bottom of rear frame downtube (right side)Spade terminalsRear brake light switch[121] Between cylinders (left side)Spade terminalsHorn[122] Fuse block (under left side cover)Relay connectorStarter relay[123] Fuse block (under left side cover)Relay connectorBrake light relay[124] Cavity in crossmember at rear of battery

box (under seat) Top of starterSpade terminalsStarter solenoid[128] Upper frame cross member (under seat)Ring terminalsHarness grounds[129] Top of transmission (right side)Post terminalsNeutral switch[131] Inner fairing (left side)Spade terminalsCigarette lighter[132] HDI: Electrical caddie at bottom of lower

frame crossmember. (Not used on Domestic)

Fuse block (under right side cover)Relay connectorEFI system relay[135] Under chrome starter cover2-place Amp (Tyco)O2 sensor rear exhaust header[137] Back of cross brace between front frame

downtubes (left side) Front right crankcase4-place DelphiOil pressure sender[139] Top of canopy (under console)4-place PackardFuel level sender and fuel pump[141] Inner fairing - right fairing support brace6-place DeutschMain to interconnect harness[156] Upper frame cross member (under seat)1-place PackardB+[160] Under right side cover20-place MolexABS module[166] Inner fairing - below upper fork bracket

(left side) Under right side cover2-place Amp (Tyco)Rear wheel speed sensor[168] Inner fairing - outboard of right fairing

bracket Back of air cleaner backplate2-place Amp (Tyco)Active intake solenoid[178] Domestic (not used): under right side

cover HDI: under right side cover (behind electrical bracket)

Under right side cover4-place DeutschABS diode pack[201] Between cylinders2-place Amp (Tyco)ACR solenoid[203F] Between cylinders2-place Amp (Tyco)ACR solenoid[203R] Inner fairing, right support bracket6-place MolexTwist Grip sensor[204] Inner fairing - front of right fairing bracket3-place Molex (black)Stealth (disable lighting circuit)[207] Throttle body6-place MolexThrottle Control Actuator[211]

2008 FLT Police Service: Appendix A Wiring A-3

Page 80

[67]

[24]

[73]

[22]

[31]

[20]

[32]

[177]

[167]

[207]

ed01652

Figure A-2. Headlamp Nacelle (FLHP/E)

Table A-2. FLHP/E Wire Harness Connectors

12-place MolexRight handlebar switches[22]

12-place MolexLeft handlebar switches[24]

12-place DeutschTSM/HFSM[30]

6-place MultilockFront turn signals[31]

LOCATIONTYPEDESCRIPTIONNO.

Upper frame cross member (under seat)4-place DeutschAccessory[4] Under left side cover2-place PackardMAXIFUSE[5] Top of rear Fender (under seat)8-place MultilockRear fender lights harness[7] Circuit board under tail lamp assembly2-place MultilockLeft rear turn signal[18] Circuit board under tail lamp assembly2-place MultilockRight rear turn signal[19] Inside headlamp nacelle6-place DeutschTachometer harness[20] Under console8-place DeutschIndicator lamps[21] Inside headlamp nacelle - fork stem nut

lock plate (right side) Inside headlamp nacelle - fork stem nut

lock plate (left side) Cavity in crossmember at rear of battery

box (under seat) Inside headlamp nacelle - fork stem nut

lock plate (left side) Inside headlamp nacelle2-place Multilock (black)Front fender tip lamp jumper harness[32] Under console3-place PackardIgnition/light key switch[33] Inside headlamp nacelleHeadlamp connectorHeadlamp[38] Back of speedometer (under console)12-place PackardSpeedometer[39]

A-4 2008 FLT Police Service: Appendix A Wiring

Page 81

Table A-2. FLHP/E Wire Harness Connectors

2-place DeutschCKP sensor[79]

Relay connectorIgnition keyswitch relay[126]

3-place Molex (black)Jiffy Stand Sensor[133]

2-place Amp (Tyco)O2 sensor front exhaust header[138]

LOCATIONTYPEDESCRIPTIONNO.

Circuit board under tail lamp assembly3-place MultilockRear fender tip lamp[45] Bottom of voltage regulator (left side)3-place LyallStator[46] Top rail of engine guard (right side)2-place DeutschSiren/PA speaker[57] Under luggage rack (left side)2-place DeutschRear pole lamp[59] Under left side coverPackardFuse block[64] Top of transmission case (under Starter)3-place DelphiVSS[65] Inside headlamp nacelle4-place AmpAccessory switch[67] Inside headlamp nacelleRelay connectorPursuit flasher (domestic only)[69] Top rail of saddlebag guard (left side)18-place PackardSiren amplifier[72] Inside headlamp nacelle2-place Multilock (white)Pursuit lamps[73] Bottom of voltage regulator (right side)2-place LyallVoltage regulator[77] Under right side cover73-place PackardECM[78] Electrical caddy at bottom of lower frame

crossmember Top of induction module3-place PackardMAP sensor[80] Below fuel tank (left side)4-place DelphiIgnition coil[83] Below fuel tank (left side)2-place DelphiFront injector[84] Below fuel tank (left side)2-place DelphiRear injector[85] Below fuel tank (right side)4-place DelphiIAC[87] Below fuel tank (right side)3-place DelphiTP sensor[88] Below fuel tank (right side)2-place DelphiIAT sensor[89] Back of Front Cylinder (left side)2-place DelphiET sensor[90] Under right side cover4-place DeutschData link[91] Circuit board under tail lamp assembly4-place MultilockTail lamp[93] Circuit board under tail lamp assembly6-place MultilockRear fender lights harness to circuit board[94] Back of tachometer12-place Packard (gray)Tachometer[108] Below fuel tank (left side)4-place MultilockFuel gauge[117] Fuse block (under right side cover)Fuse terminalsEFI fuses[119] Front Right CrankcasePost terminalOil pressure switch[120] Bottom of rear frame downtube (right side)Spade terminalsRear brake light switch[121] Between cylinders (left side)Spade terminalsHorn[122] Fuse Block (under left side cover)Relay connectorStarter relay[123] Fuse Block (under left side cover)Relay connectorBrake light relay[124] Cavity in crossmember at rear of battery

frame crossmember. (Not used on Domestic)

Fuse block (under right side cover)Relay connectorEFI system relay[135] Under chrome starter cover2-place Amp (Tyco)O2 sensor rear exhaust header[137] Back of cross brace between front frame

downtubes (left side) Top of canopy (under console)4-place PackardFuel level sender and fuel pump[141]

2008 FLT Police Service: Appendix A Wiring A-5

Page 82

Table A-2. FLHP/E Wire Harness Connectors

5-place Amp (Tyco)Active exhaust actuator[179]

LOCATIONTYPEDESCRIPTIONNO.

Under front fender tip lamp bracket2-place Multilock (black)Front fender tip lamp (DOM)[143] Upper frame cross member (under seat)1-place PackardB+[160] Under right side cover20-place MolexABS module[166] Inside headlamp nacelle (left side)2-place Amp (Tyco)Front wheel speed sensor[167] Under right side cover2-place Amp (Tyco)Rear wheel speed sensor[168] Inboard of left upper frame tube3-place MultilockRear marker lights harness[173] Under left side cover (beneath harness)4-place DeutschMain to main harness[176] Back of air cleaner backplate2-place Amp (Tyco)Active intake solenoid[178] Domestic (not used): under right side

cover HDI: under right side cover (behind electrical bracket)

Inside headlamp nacelle (left side)2-place DeutschMain to main harness[177] Under right side cover4-place DeutschABS diode pack[201] Between cylinders2-place Amp (Tyco)ACR solenoid[203F] Between cylinders2-place Amp (Tyco)ACR solenoid[203R] Inside Headlamp Nacelle6-place MolexTwist Grip sensor[204] Inside headlamp nacelle3-place MolexStealth (disable lighting circuit)[207] Throttle body6-place MolexThrottle Control Actuator[211] Under the seat4-place PackardIgnition switch interconnect[222]

A-6 2008 FLT Police Service: Appendix A Wiring

Page 83

WIRING DIAGRAM INFORMATION

910

1 2

GN/Y

1 2 4

[21A] [21B]

ed01269

Wire Color Codes

Wire traces on wiring diagrams are labeled with alpha codes. Refer to Table A-3.

For Solid Color Wires: See Figure A-3. The alpha code identifies wire color (3).

For Striped Wires:The code is written with a slash (/) between the solid color code and the stripe code (4). For example, a trace labeled GN / Y is a green wire with a yellow stripe.

Wiring Diagram Symbols

See Figure A-3. On wiring diagrams and in service/repair instructions, connectors are identified by a number in brack ets (1). The letter (2) inside the brackets identifies whether the housing is a socket or pin housing.

A=Pin: The letter A after a connector number and the pin symbol (6) identifies a pin housing.

B=Socket: The letter B after a connector number and the socket symbol (5) identifies a socket housing.

Other symbols found on the wiring diagrams include the symbol for a diode (7), a symbol for a wire-to-wire connection (8), a symbol that verifies that no connection (9) between two wire traces exists and a symbol identifying two wires that are twisted together (10).

A.2INDEX TO WIRING DIAGRAMS

1. Connector number

2. Terminal code (A=pin, B=socket)

3. Solid wire color

4. Striped wire color

5. Socket symbol

6. Pin symbol

7. Diode

8. Connection

9. No connection

10. Twisted pair

Figure A-3. Connector/Wiring Diagram Symbols (typical)

Table A-3.Wire Color Codes

WIRE COLORALPHA CODE

BlueBE

BlackBK BrownBN GreenGN

GreyGY

Light GreenLGN

OrangeO

PinkPK

RedR

TanTN VioletV WhiteW

YellowY

2008 FLT Police Service: Appendix A Wiring A-7

Page 84

WIRING DIAGRAMS

Wiring Diagram List

Fender Tip Lamps

Cap Switches and HFSM Antenna

and Strobe Harness

T ail Lamp , Pursuit Lamps, Directional Lamps, Accessory/Spot Switch, Speedometer , Tachometer and HFSM Antenna

LOCATIONDIAGRAM

Figure A-42008 FLHTP, DOMESTIC and INTERNATIONAL Models, Main Harness without ABS (1 of 2) Figure A-52008 FLHTP, DOMESTIC and INTERNATIONAL Models, Main Harness with ABS (1 of 2) Figure A-62008 FLHTP, DOMESTIC and INTERNATIONAL Models, Main Harness (2 of 2) Figure A-72008 FLHTP, DOMESTIC and INTERNATIONAL Models, Interconnect Harness Figure A-82008 FLHTP, DOMESTIC and INTERNATIONAL Models, Pursuit Lamps, Directional Lamps, Tail Lamp and

Figure A-92008 FLHTP, DOMESTIC and INTERNATIONAL Models, Starting and Charging

Figure A-102008 FLHTP, DOMESTIC and INTERNATIONAL Models, Handlebar Switches, Indicator Lamps, Fairing

Figure A-112008 FLHTP, DOMESTIC and INTERNATIONAL Models, Anti-Lock Brake System (ABS) Siren Amplifier

Figure A-122008 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models, Main Harness without ABS (1 of 2) Figure A-132008 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models, Main Harness with ABS (1 of 2) Figure A-142008 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models, Main Harness (2 of 2) Figure A-152008 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models, Starting and Charging Figure A-162008 FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models, Handlebar Switches, Indicator Lamps,

Figure A-172008 FLHTP, FLHP and FLHPE, DOMESTIC and INTERNATIONAL Models, Optional Strobe System

A-8 2008 FLT Police Service: Appendix A Wiring

Page 85

B A

Turn Signal/

Turn Signal Security

Module

To Main Harness Page 2

Fairing

Harness

Fairing

Harness

Fairing

Harness

[15B]

[2B]

[1B]

Front GND

Stud

(Dirty)

Rear GND

Stud

(Clean)

Fuel Pump

Assembly Intank

[141A]

[13B]

[13A]

A B C D

1 2 334

Power

Signal

Ground

Optional Security

Siren

Start

Solenoid

[142A]

[142B]

[128B]

1 2 3 1 2 3

BK/GN

BN/GY

LGN/BN

1 2 4

Fuel

Pump

[GND1]

[GND2]

[GND1A]

BK/GN

[139B]

Oil

Pressure

Sender

[30A] [30B]

(GY)

Battery 1 1

Ignition 2 2

Serial Data

3 3

Neutral Switch

4 4

Left Turn Feed

5 5

Right Turn Feed

6 6

Right Turn SW Input

7 7

Left Turn SW Input

8 8

Start Relay Control

9 9

Clutch Switch

10 10

Alarm Signal

11 11

Ground

12 12

GY TN BN

W/V

O/W O/R

R/O

Y/W

O/V

W/V

LGN/BN

LGN/V

BN/GY

BK/GN

BE/GY

BK/GN

BN/GN

BN/GY

BN/GN

TN/GN

LGN/V

LGN/R

W/BN

GN/O

R/BE

W/BK

Y/BK

BK/R

GN/Y

W/BN

O/GY

Y/W

BK/GN

O/GY

R/BE

O/BE

BK/R

Y/GN

W/BK

To Rear LightingTour-Pak

Accessory Connector

Rear

Stop Light

Switch

Neutral

Switch

Horn

[7A]

[12B]

(BK)

[4A]

[122]

1 2 31

112

2 3 3 2 14 5 6 7

BKBNBE

O/W

R/Y

O/R

R/Y

Y/BK

R/BE

Main Power

at Starter

40 Amp

MAXIFUSE

Voltage

Regulator

Ignition

SwitchB+

Connector

[BATT]

[5B] [77B]

[160B]

[33B]

A B

1 2 3

1 2

R/GY

R/BK

[126B]

Lighting

Relay

Police Stealth

[207A]

[207B]

[126A]

87(5)

30(3)

85(2)

86(1)

87A(4)

R/BK

Amber cap removed when stealth switch

option is used

1 3

Start Relay

System Relay

Brake Relay

Cruise/Brake - 15A1B 1A

Accessory - 15A1D 1C

Battery - 15A2D 2C

Radio Memory - 15A2B 2A

ECM Power - 15A2F 2E

Fuel Pump - 15A4B 4A

P & A - 15A1B 1A

INSTRS - 15A1D 1C

Ignition - 15A1F 1E

Engine CNTRL - 15A1H 1G

Headlamp - 15A2D 2C

Lights - 15A Spare - 15A

Spare - 30A

(ABS Only)

2F 2E

4B 4A

3H 3G

4H 4G

P & A - 15A

Radio Power/

Siren - 15A

3H 4G 4H 3G

30 87 86 85

3 5 1 2

3D 4C 4D 3C

30 87 86 85

3 5 1 2

2B 3A 3B 2A

30 87 86 85

3 5 1 2

O/V

O/R

R/O

O/W

O/V

R/Y

O O

TN/GN

BE/GY

BE/GY BE/GY

BN/GY

LGN/R

O/GY

W/BK GN/O

Y/GN

BK/R

R/GY

O/BE

R/GY

R/BE

R/BK

15A

1 2 3 4

15A

B D F H

C E G J

A C E G J

15A 15A

15A

30A

15A

85 31579-04

12VOC

87 86

85 31579-04

12VOC

87 86

[33A]

[12A]

[121]

[131]

[139A]

[15A]

[2A]

(GY)

[1A]

(BK)

15A

1 2 3 4

30A

85 31579-04

12VOC

87 86

[141B]

et00067

Figure A-4. 2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Main Harness without ABS (1 of 2)

Page 86

Figure A-4.Figure A-4.

2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Main

Harness without ABS (1 of 2)

2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Main

Harness without ABS (1 of 2)

Page 87

B A

Turn Signal/

Turn Signal Security

Module

To Main Harness Page 2

To ABS

Fairing

Harness

Fairing

Harness

Fairing

Harness

[15B]

[2B]

[1B]

Front GND

Stud

(Dirty)

Rear GND

Stud

(Clean)

Fuel Pump

Assembly Intank

[141A]

[141B]

[13B]

[13A]

A B C D

1 2 334

Power

Signal

Ground

Optional Security

Siren

Start

Solenoid

[142A]

[142B]

[128B]

1 2 3 1 2 3

BK/GN

BN/GY

LGN/BN

1 2 4

Fuel

Pump

[GND1]

[GND2]

[GND1A]

BK/GN

[139B]

Oil

Pressure

Sender

[30A] [30B]

Battery 1 1

Ignition 2 2

Serial Data

3 3

Neutral Switch

4 4

Left Turn Feed

5 5

Right Turn Feed

6 6

Right Turn SW Input

7 7

Left Turn SW Input

8 8

Start Relay Control

9 9

Clutch Switch

10 10

Alarm Signal

11 11

Ground

12 12

TN BN

BK BK

W/V

O/W

O/R

R/O

Y/W

O/V

W/V

R/V

LGN/BN

LGN/V

BN/GY

PK/BN

LGN/V

BK/GN

BE/GY

BK/GN

BK/GN BK/GN

BN/GN

BN/GY

BN/GN

PK/BN

TN/GN

LGN/V

LGN/R

W/BN

GN/O

R/BE

W/BK

Y/BK

BK/R

GN/Y

W/BN

R/BN

R/BE

O/GY

Y/W

BK/GN

O/GY

R/BN

O/BE

BK/R

Y/GN

W/BK

To Rear LightingTour-PakAccessory

Connector

Rear

Stop Light

Switch

Neutral

Switch

Horn

[7A]

[12B]

(BK)

[4A]

[122]

1 2 31

112

2 3 3 2 14 5 6 7

BKBNBE

O/W

R/Y

O/R

R/Y

Y/BK

Main Power

at Starter

40 Amp

MAXIFUSE

Voltage

Regulator

Ignition Switch

B+

Connector

[BATT]

[5B] [77B]

[160B]

[33B]

A B

1 2 3

1 2

R/GY

R/BK

[126B]

Lighting

Relay

Police Stealth

[207A]

[207B]

87(5)

30(3)

85(2)

86(1)

87A(4)

R/BK

Amber cap removed when stealth switch

option is used

1 3

Start Relay

System Relay

Brake Relay

Spare 30A

Spare 15A

Cruise/Brake - 15A1B 1A

Accessory - 15A1D 1C

Battery - 15A2D 2C

Radio Memory - 15A2B 2A

ECM Power - 15A2F 2E

Fuel Pump - 15A4B 4A

P & A - 15A1B 1A

INSTRS - 15A1D 1C

Ignition - 15A1F 1E

Engine CNTRL - 15A1H 1G

Headlamp - 15A2D 2C

Lights - 15A2F 2E

4B 4A

3H 3G

4H 4G

P & A - 15A

Radio Power/

Siren - 15A

3H 4G 4H 3G

30 87 86 85

3 5 1 2

3D 4C 4D 3C

30 87 86 85

3 5 1 2

2B 3A 3B 2A

30 87 86 85

3 5 1 2

O/V

O/R

R/O

O/W

O/V

R/Y

R/V

O O

TN/GN

BE/GY

BE/GY BE/GY

BN/GY

LGN/R

O/GY

W/BK GN/O

Y/GN

BK/R

R/GY

O/BE

R/GY

R/BE

R/BK

ABS - 30 A

15A 15A

15A

1 2 3 4

15A

B D F H

C E G J

A C E G J

15A 15A

15A

30A 30A

15A

85 31579-04

12VOC

87 86

85 31579-04

12VOC

87 86

85 31579-04

12VOC

87 86

[33A]

[12A]

[121]

[131]

[15A]

[139A]

[2A]

(GY)

[1A]

(BK)

et00068

Figure A-5. 2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Main Harness with ABS (1 of 2)

Page 88

Figure A-5.Figure A-5.

2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Main

Harness with ABS (1 of 2)

2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Main

Harness with ABS (1 of 2)

Page 89

[78A] [78B]

[91A]

[90A]

[90B]

[179B] [95B] [138B] [137B] [65B] [133B] [203FB] [203RB]

[204B]

[204A]

[83A]

[83B]

[85A]

[85B]

[84A]

[84B]

[80A]

[80B]

[211A]

[211B]

[79A]

[79B]

From Main Harness Page 1

(GY)

ECM

21 23

24 25

28 29 30

36 37 38 39 40

49 50 51 52

53 54

59 61

62 63 64

66 68

Exhaust Actuator

Rear Injector

TMAP Sensor Input

Brake Switch

Front Injector

Twist Grip High

Twist Grip Low

Ion Sense

Throttle Pos. Sensor 2

Throttle Pos Sensor 1

Exhaust Feedback Twist Grip Sensor 2 VehicleSpeed Input

Crank Position Sensor (-)

Rear O2Sensor (Unheated)

Twisted

Pair

Intake Air Temperature

5V Sensor Power 1

Engine Temperature

12 V Power

Rear Coil

Front Coil

Jiffy Stand Sensor

Twist Grip Sensor 1

5V Sensor Ground 1 5V Sensor Ground 2

Crank Position Sensor (+)

VehicleSpeed Ground

Front O2Sensor (Unheated)

5V Sensor Power 2

Serial Data

Ground

22Cruise/Set/Coast 22

1 2 3 4

A B

A B A B A B A B

C D

A B C D

1 2 3 4 5 6

Purge Solenoid 20

19ACR 19

23 24 25

27System Relay Enable 27

29 30

33 34Cruise Resume/Accelerate 34 35Cruise Enable 35

69 71

12V Battery 71

12V Run/Stop Switch 72

5 B A 1 2 1 2 1 2 3 1 2 34 3 2 1

Data Link Connector

Engine Temp

Sensor

Twist Grip

Sensor

Ignition Coil

Crank Pos.

Sensor

1 2 1 2

A B A B

Power

Ion Sense

Coil Rear

Coil Front

Rear

Injector

Front

Injector

TMAP

Sensor

1 2 3 4 1 2 3 4

Throttle Control

Actuator

6 5 4 3 2 1 6 5 4 3 2 1

Active

Exhaust

(HDI Only)

Purge

Solenoid

Jiffy Stand

Sensor

(HDI Only)

1 2

Rear ACR

1 2

Front

ACR

Vehicle

Speed

Sensor

Front

O2Sensor

Rear

O2Sensor

V/O

V/W

V/Y

R/W

V/W

W/Y

R/W

V/O

W/Y

V/Y

BK/PK

GY/BE

GN/GY

LGN/Y

GN/BN

LGN/V

LGN/R

PK/GN

GN/BN

BK/GN

BE/BK

PK/GN

BE/GN

BK/GY

BK/GN

BE/GY

GN/GY

R/BE

R/GN BN/V

PK/Y

Y/BE

BK/W

W/BK

PK/O

V/BE

GY/Y

PK/O

BK/W

W/GN

BN/O

BK/Y

Y/GN

+BK

GY/Y

BK/O

PK/Y

BK/W

Y/GN

Y/BE

Y/GN

BN/V

BN/O

BN/R

BK/O

BK/W

BE/O

BN/O

W/BE

W/GN

BN/O Y/GN

BE/O

BK/Y

BN/R

V/BE

GN/O

LGN/V

BK/GN

BE/GN

BK/GY

LGN/Y

BK/GY

BK/PK

BE/BK

BK/GN

LGN/V

R/BE GN/O

W/BE R/GN

Y/GN

LGN/R

BE/GY

W/BK

Yellow Tubing

Black Tubing

V/GY

et00097

Figure A-6. 2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Main Harness (2 of 2)

Page 90

Figure A-6.Figure A-6.

2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Main

Harness (2 of 2)

2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Main

Harness (2 of 2)

Page 91

1 2 3 4 5 6 7 8 9

L1 L2 B L1 L2 B

4 3 2 1 4 3 2 1

1 52 7 11

1 2 4 5 6 7

9 8

1 2

11271 62 53 4 211 36 4

1 2 4 5 6 7

86 9

1 52 7 1186 9

O/W

O/R

O/W

Y/W

O/R

W/V

O/V

Y/W

O/W

Y/W

O/V

W/V

GY/BK

GN/BK

GY/BK

GY/BN

BN/GY

GN/BK

BK/GN

LGN/V

TN/BK

PK/BK

R/BE

Y/PK

GY/V

Y/BK

GN/R

BK/R

Y/BK

O/BE

W/BN

W/BK

R/BE

BK/R

GN/R

GN/Y

W/BK W/BN

Fuel

[111A] [111B]

[110A] [110B]

[116A] [116B]

[117A] [117B]

[22B]

[24B]

[70A]

[21A]

[32A]

[15A]

[1A]

[2A]

Cigar

Lighter

Main

Harness

Speedometer

Tachometer

[39B] [39A]

[108B] [108A]

RH Front

Turn Signal

LH Front

Turn Signal

Odometer

Reset

Switch

(BK)

(GY)

(BK)

[31LA]

[31RA]

Rpm x 100

Voltmeter

[21B]

To Indicator

Lamps

[70B]

To Siren Amplifier

Harness

Front Fender

Tip Lamp

[32B]

(BK)

Right Hand

Controls

[22A]

(BK)

Left Hand

Controls

[24A]

(GY)

[154A]

[15B]

(BK)

Main

Harness

[2B]

(GY)

Main

Harness

[1B]

(BK)

[132B] [132A]

Pursuit Flasher

Headlamp

Hi_Beam

Lo_Beam

GND

[38A]

[38B]

[69B] [69A]

Ground

To Upper

Triple Clamp

GND 3

HDI Only

[29B]

et00088

Figure A-7. 2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Interconnect Harness

Page 92

Figure A-7.Figure A-7.

2008 FLHTP, DOMESTIC and INTERNATIONAL Models,

Interconnect Harness

2008 FLHTP, DOMESTIC and INTERNATIONAL Models,

Interconnect Harness

Page 93

[32B]

Fender Tip Lamp

(DOM Only)

Right Rear Directional Lamp

Left Rear Direction Lamp

TailLamp

Fender Tip Lamp (DOM Only)

From

Fairing

Harness

Right

Directional

and DOM

Running Lamp

Left

Directional

and DOM

Running Lamp

From

Fairing

Harness

From Main

Harness

Rear Lighting

[31RB]

License PlateLamp (HDI Only)

[7B]

Brake Light

Running Light (DOM )

Running Light (HDI)

[19B]

[19A]

[93B]

[94B]

[94A]

[93A]

[18A]

[45A]

[18B]

[45B]

[143B]

[143A]

68772-06

4 3 2 1

1 2 3 4 5 6 7 8

3456

1 2 3

4 3 2 1

123456

1 2

1 2 3

1 2

Right

Pursuit

Lamp (Blue)

FLHTP

Left

Pursuit

Lamp (Red)

FLHTP

[31LB]

From

Fairing

Harness

4 3 2 1

[73RB]

[73LB]

BE BN

BKBKBE

O/W

R/Y

V/BN

O/W

BKBNBE

O/W

R/Y

GY/BK

BE/W

O/W

R/Y

BE/W

[31RA]

[31LA]

[32A]

[7A]

et00071

Figure A-8. 2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Pursuit Lamps, Directional Lamps,Tail Lamp and Fender Tip Lamps

Page 94

Figure A-8.Figure A-8.

2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Pursuit

Lamps, Directional Lamps,Tail Lamp and Fender Tip Lamps

2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Pursuit

Lamps, Directional Lamps,Tail Lamp and Fender Tip Lamps

Page 95

[128B]

[128A]

[2B]

[33B]

[1B]

Starter

Battery

3 6

1 2 3

1 2 3 4

10 12

1 2 3 4

10 12

[30A]

[78A] [78B]

[208A] [208B]

[209B] [209A]

[30B]

TSM/TSSM/HFSM

Battery

Ignition

Serial Data

Left

GND 1

Right

GND 2

40 A

MAXIFUSE

[1A]

[2A]

(Black)

(Gray)

[24A]

(Gray)

[24B]

Ignition Switch

Lighting

Relay

IGNITION SWITCH LEGEND

SWITCH

POSITION

"X" INDICATES CONTINUITY

BETWEEN LEAD WIRES

IN POSITION INDICATED

RED

RED/ GRAY

RED/

BLACK

LOCK X

OFF X IGN X X X ACC X X

Red Band

[64B]

1F 1E

2C2D

Ignition - 15A

Battery - 15A

3 6

Clutch

Lockout

Switch

Left Hand Controls

[22A]

(Black)

[22B]

Engine Off/Run Switch

Starter Switch

Right Hand Controls

ECM

Serial Data 697269

12V Run/Stop Switch Power

Starting System

[126B]

[126A]

86(1)

85(2)

30(3)

87A(4)

87(5)

3H 4G 4H 3G

3 5 1 2

Start Relay

30 87 86 85

[5B]

Neutral Switch

1 2 3 4

1 2

3 4

HFSM

Receive Antenna

Xmit Antenna A Xmit Antenna B

Unused

Start Relay Control

Clutch Switch

Ground

[21B]

(BK)

LH GND Stud (Dirty)

GND 1A

[131]

Neutral

Neutral Switch

5 5 6

[21A]

Powertrain

Grounds

40 A

MAXIFUSE

[77B]

Starter

Battery

B A

Charging System

Left Dirty

GND

[77A]

Stator

DC AC

[46A] [46B]

Red Band

[5B]

Turn Signal/

Turn Signal

Security

Module

Hands Free

Security

Module

B A

GY TN

BN/GY

TN/GN

BK/GN

LGN/V

BK/R

W/BK

GY GY

BK/R BK/R

W/BK W/BK

BK BK

BK/GN

TN/GN

BN/GY

BK/R

BK/R BK/R

BK/R

R/GY

R/BK

R/GY

BK/R

W/BK

BK/R

R/BK

[33A]

Y/BK

O/Y

et00070

Figure A-9. 2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Starting and Charging

Page 96

Figure A-9.Figure A-9.

2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Starting

and Charging

2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Starting

and Charging

Page 97

FLHTP Only

To Fairing Harness

[22B] (BK)

[24B] (GY)

[22A]

[24A]

ACC

[105A]

[105B]

To Fairing

Harness

1 2 3 4 5 6 7 8 9

Right Hand Controls

1 2 3 4 5 6 7 8

9 10 11 12

10 11 12

Clutch Lockout Switch

Siren Off/Run Switch

Headlamp Hi/Lo Switch Left Directional Switch

Left Hand Controls

Horn/Siren Switch

Move Y/BK wire to terminal 11 when using Whelen Siren Amplifier & 'Air Horn' function

Off/Aux Pursuit Switch Right Directional Switch

Engine Off/ Run Switch Starter Switch

Stoplamp Switch

Right Turn

Oil Pressure

Neutral

High Beam

Left Turn

[21B]

Indicator

Lamps

(BK)

1 2 3 4 5 6 7 8 9 10

From Fairing

Harness

[21A]

212

Antenna ’A’ Antenna ’B’

Hands Free Antenna

[209B] [209A]

[30A]

Receive Antenna

Transmit Antenna A Transmit Antenna B

Battery

Ignition

Serial Data Neutral Switch Left Turn Feed

Right Turn Feed

Right Turn Switch Input

Left Turn Switch Input

Start Relay Control

Clutch Switch

Alarm Signal

Ground

[208A] [208B]

Hands Free Security

Module (HFSM)

For Turn Signal & Security

Module (TSM/TSSM)

O/Y

Y/BK

O/R

GN/Y

O/W

W/V

O/V

GY/BK

PK/BK TN/BK

R/BE

W/BK W/BN

GN/R

BK/R

Y/BK

et00089

Figure A-10. 2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Handlebar Switches, Indicator Lamps, Fairing Cap Switches and HFSM Antenna

Page 98

Figure A-10.Figure A-10.

2008 FLHTP, DOMESTIC and INTERNATIONAL Models,

Handlebar Switches, Indicator Lamps, F airing Cap Switches and

HFSM Antenna

2008 FLHTP, DOMESTIC and INTERNATIONAL Models,

Handlebar Switches, Indicator Lamps, F airing Cap Switches and

HFSM Antenna

Page 99

R/V

PK/BK

PK/BK TN/BK

BE/PK

BK/BE

PK/BN

BE/BN LGN/V

TN/BK

GY/R GY/R

R/PK

Y/PK

O/BE

W/PK

R/PK

W/PK

GN/R GN/R

W/BN

BK/V

BE/BN

BE/V

R/BN

R/BE

LGN/V

R/BN

BE/V

R/BE R/BE R/BN

Y/PK

O/BE

1B 2A 2B 2C 2E 3B

3C 3A 2D 1E 3F

2F 1F 1D 1A 1C

12 11

4 3 2 1

1 2 3 4 5 6

4 3 2 1

1 2 3 4 5 6

1 2

Ref: Siren wires

are not polarity

sensitive

Siren/PA Speaker

FLHTP-FRG

Siren Amplifier Harness

interconnect

harness

Microphone

Jack

[68]

[57A]

[229B]

[230B]

[72A]

[72B] [72B]

[72B]

[59B]

[57B]

[70B]

To optional

pole lamp

Siren

Amplifier

To optional

dealer installed

strobe power

supply

To optional

dealer installed

strobe lights

FLHTP-FRG Strobe Harness

A B A B

ABS Control Module

[166A]

[166B]

[167B] [167A]

[168B]

[201B] [201A]

[168A]

To main harness

page 1

Rear Wheel

Speed Sensor

Front Wheel

Speed Sensor

ABS

Diode

Pack

1 3

7 8

9 10 11

17 18 19 20

1 3

7 8

9 10 11

17 18 19 20

ECU/Solenoid ground

ECU/Solenoid power

Rear brake input

Rear wheel speed (-)

Rear wheel speed (+)

Front wheel speed (+)

Front wheel speed (-)

Serial data

Motor ground

Front brake input

Ignition wake-up

Motor power

[70A]

et00013

Figure A-11. 2008 FLHTP, DOMESTIC and INTERNATIONAL Models, Anti-Lock Brake System (ABS) Siren Amplifier and Strobe Harness

Page 100

Figure A-11.Figure A-11.

2008 FLHTP, DOMESTIC and INTERNA TIONAL Models, Anti-Lock

Brake System (ABS) Siren Amplifier and Strobe Harness

2008 FLHTP, DOMESTIC and INTERNA TIONAL Models, Anti-Lock

Brake System (ABS) Siren Amplifier and Strobe Harness

Harley Davidson FLT Police 2008 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

TABLE OF CONTENTS

MAINTENANCE

1.1SCHEDULED MAINTENANCE

GENERAL

CHASSIS

2.1SPECIFICATIONS: CHASSIS

GENERAL

2.2VEHICLE IDENTIFICATION NUMBER (V.I.N.)

GENERAL

2.3TIRES

GENERAL

GENERAL

2.4SEAT

SEAT REMOVAL

SEAT INSTALLATION

AIR SPRING REPLACEMENT

REMOVAL

2.5AIR SEAT RESERVOIR

INSTALLATION

LOCKSET

2.6SADDLEBAGS

HINGES

REMOVAL

2.7TACHOMETER BRACKET: FLHP/E

INSTALLATION

ENGINE

3.1SPECIFICATIONS: ENGINE

GENERAL

MANUFACTURING TOLERANCES

3.2SERVICE WEAR LIMITS

GENERAL

OPERATION

3.3OIL COOLER

REMOVAL

CLEANING AND INSPECTION

INSTALLATION

OIL COOLER ADAPTER AND THERMOST A T REPLACEMENT

FUEL SYSTEM

NO UNIQUE CONTENT

4.1FUEL SYSTEM

ELECTRIC STARTER

NO UNIQUE CONTENT

5.1ELECTRIC STARTER

DRIVE

NO UNIQUE CONTENT

6.1DRIVE

TRANSMISSION

NO UNIQUE CONTENT

7.1TRANSMISSION

ELECTRICAL

GENERAL

8.1BULB CHART

SYSTEM FUSES

8.2SYSTEM FUSES AND RELAYS

8.3REAR MARKER LIGHTS

MARKER LIGHTS REPLACEMENT

REMOVAL

INSTALLATION

HORN AND SIREN YELP SWITCH

8.4HANDLEBAR SWITCHES

CLUTCH INTERLOCK SWITCH

PURSUIT AND AUXILIARY SWITCH

GENERAL

REMOVAL

8.5AUTOMATIC COMPRESSION RELEASE

INSTALLATION

COMPRESSION TEST

DIAGNOSTICS

A.1CONNECTORS

CONNECTORS

WIRING DIAGRAM INFORMATION

A.2INDEX TO WIRING DIAGRAMS

WIRING DIAGRAMS