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Harley Davidson Softail (2008) Service Manual

English Service Manual to motorcycles Harley Davidson Softail (2008).

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HARLEY DAVIDSON SOFTAIL (2008) - SERVICE MANUAL

- English Service Manual to motorcycles Harley Davidson Softail (2008).



CONTENTS:


SERVICE MANUAL:


COVER

FOREWORD

TABLE OF CONTENTS

1. MAINTENANCE
- 1.1 General
- 1.2 Maintenance Schedule
- 1.3 Fuel And Oil
- 1.4 Bulb Requirements
- 1.5 Engine Oil And Filter
- 1.6 Brakes
- 1.7 Air Cleaner And Exhaust System
- 1.8 Tires And Wheels
- 1.9 Primary Chain
- 1.10 Transmission Lubricant
- 1.11 Clutch
- 1.12 Rear Belt And Sprockets
- 1.13 Rear Belt Deflection
- 1.14 Throttle Cables
- 1.15 Bleeding Brakes
- 1.16 Brake Pads And Discs
- 1.17 Battery Maintenance
- 1.18 Suspension Adjustments
- 1.19 Spark Plugs
- 1.20 Steering Head Bearings: All But Flstsb
- 1.21 Steering Head Bearings: Flstsb
- 1.22 Rocker Bearings: Flstsb
- 1.23 Front Fork Oil
- 1.24 Cable And Chassis Lubrication
- 1.25 Headlamp Alignment
- 1.26 Critical Fasteners
- 1.27 Engine Mounts
- 1.28 Storage
- 1.29 Troubleshooting

2. CHASSIS
- 2.1 Specifications
- 2.2 Vehicle Identification Number (V.I.N.)
- 2.3 Front Wheel: All But Flstsb
- 2.4 Front Wheel: Flstsb
- 2.5 Rear Wheel
- 2.6 Sealed Wheel Bearings
- 2.7 Wheel Lacing: 16 Inch Rim
- 2.8 Wheel Lacing: 17 Inch Rim
- 2.9 Wheel Lacing: 21 Inch Rim
- 2.10 Truing Laced Wheels
- 2.11 Checking Cast Wheel Runout
- 2.12 Vehicle Alignment
- 2.13 Front Brake Master Cylinder
- 2.14 Front Brake Caliper: All But Flstsb
- 2.15 Front Brake Caliper: Flstsb
- 2.16 Rear Brake Master Cylinder
- 2.17 Rear Brake Caliper
- 2.18 Tires
- 2.19 Front Fork: Telescopic
- 2.20 Front Fork: Springer
- 2.21 Steering Head
- 2.22 Belt Guard And Debris Deflector
- 2.23 Rear Shock Absorbers
- 2.24 Rear Fork
- 2.25 Throttle Control
- 2.26 Clutch Control
- 2.27 Handlebars: All But Flstf/Flstsb/Fxcw/Fxcwc
- 2.28 Handlebars: Flstf
- 2.29 Handlebars: Flstsb
- 2.30 Handlebars: Fxcw/Fxcwc
- 2.31 Front Fender: All But Flstsb
- 2.32 Front Fender: Flstsb
- 2.33 Rear Fender: Flst/Flstc
- 2.34 Rear Fender: Flstf
- 2.35 Rear Fender: Fxst/Fxstb/Fxstc/Flstsb
- 2.36 Rear Fender: Fxcw/Fxcwc
- 2.37 Rear Fender: Flstn
- 2.38 Rear Fender Wire Conduit
- 2.39 Jiffy Stand
- 2.40 Fork Lock

- 2.41 Seat And Strap Retention Nut
- 2.42 Seat: Fxst/Fxstb
- 2.43 Seat: Fxstc
- 2.44 Seat: Fxcw/Fxcwc
- 2.45 Seat: Flstn/Flstf/Flst/Flstc
- 2.46 Seat: Flstsb
- 2.47 Luggage Rack: Flstn
- 2.48 Saddlebags: Flstc
- 2.49 Windshield: Flstc

3. ENGINE
- 3.1 Specifications
- 3.2 Service Wear Limits
- 3.3 Engine Oil Flow
- 3.4 Oil Pump Operation
- 3.5 Breather Operation
- 3.6 Oil Pressure
- 3.7 Troubleshooting
- 3.8 How To Use This Section
- 3.9 Top End Service
- 3.10 Bottom End Service
- 3.11 Stripping Motorcycle For Service
- 3.12 Assembling Motorcycle After Service
- 3.13 Removing Engine From Chassis
- 3.14 Installing Engine In Chassis
- 3.15 Top End Overhaul: Disassembly
- 3.16 Top End Overhaul: Assembly
- 3.17 Bottom End Overhaul: Disassembly
- 3.18 Bottom End Overhaul: Assembly
- 3.19 Breather Assembly
- 3.20 Rocker Arm Support Plate
- 3.21 Push Rods, Lifters And Covers
- 3.22 Cylinder Head
- 3.23 Cylinder
- 3.24 Piston
- 3.25 Cover And Cam Support Plate
- 3.26 Oil Pump
- 3.27 Crankcase
- 3.28 Flywheel And Connecting Rods
- 3.29 Counterbalancer Assembly
- 3.30 Oil Tank: All But Fxcw/C
- 3.31 Oil Tank: Fxcw/C

4. FUEL SYSTEM
- 4.1 Specifications: Fuel System
- 4.2 Electronic Fuel Injection (Efi)
- 4.3 Idle Speed
- 4.4 Air Cleaner Assembly
- 4.5 Fuel Tank
- 4.6 Throttle Position Sensor (Tps)
- 4.7 Intake Air Temperature Sensor (Iat)
- 4.8 Engine Temperature Sensor (Et)
- 4.9 Induction Module
- 4.10 Idle Air Control (Iac)
- 4.11 Manifold Absolute Pressure Sensor (Map)
- 4.12 Oxygen Sensor
- 4.13 Fuel Injectors
- 4.14 Fuel Pump And Fuel Gauge Sending Unit
- 4.15 Fuel Pressure Test
- 4.16 Exhaust System: All But Flstf/Flstn/Flstsb
- 4.17 Exhaust System: Flstf/Flstn/Flstsb
- 4.18 Intake Leak Test
- 4.19 Evaporative Emissions Control (Ca Models)

5. STARTER
- 5.1 Specifications: Starter
- 5.2 Starter
- 5.3 Starter Solenoid

6. DRIVE
- 6.1 Specifications: Drive
- 6.2 Primary Chaincase Cover
- 6.3 Drive Components
- 6.4 Primary Chaincase Housing
- 6.5 Clutch
- 6.6 Transmission Sprocket
- 6.7 Drive Belt

7. TRANSMISSION
- 7.1 Specifications: Transmission
- 7.2 Transmission
- 7.3 Shifter Linkage
- 7.4 Clutch Release Cover
- 7.5 Transmission Assembly
- 7.6 Main Drive Gear And Bearing
- 7.7 Transmission Case

8. ELECTRICAL
- 8.1 Specifications: Electrical
- 8.2 Electrical Panel
- 8.3 Electronic Control Module (Ecm)
- 8.4 Voltage Regulator
- 8.5 Front Electrical Caddy
- 8.6 Fuses
- 8.7 Relays
- 8.8 Main Fuse
- 8.9 Ignition And Light Switch
- 8.10 Battery Cables
- 8.11 Headlamp
- 8.12 Tail Lamp: All But Flstn
- 8.13 Tail Lamp: Flstn
- 8.14 Auxiliary Lamps: Flst/Flstc/Flstn
- 8.15 Turn Signals And Running Lights
- 8.16 Turn Signal And Security Module (Tsm/Tssm/Hfsm)
- 8.17 Crank Position Sensor (Ckp)
- 8.18 Ignition Coil
- 8.19 Spark Plug Cables
- 8.20 Alternator
- 8.21 Fuel Gauge
- 8.22 Instrument Console: Fxcw/C
- 8.23 Speedometer: All But Fxcw/C
- 8.24 Speedometer: Fxcw/C
- 8.25 Vehicle Speed Sensor (Vss)
- 8.26 Indicator Lamps: All But Fxcw/C
- 8.27 Indicator Lamps: Fxcw/C
- 8.28 Neutral Switch
- 8.29 Oil Pressure Switch
- 8.30 Rear Stoplight Switch
- 8.31 Horn
- 8.32 Active Exhaust
- 8.33 Main Wiring Harness
- 8.34 Handlebar Switch Assemblies
- 8.35 Right Handlebar Switch
- 8.36 Left Handlebar Switch

A. APPENDIX A CONNECTOR REPAIR
- A.1 Amp 1-Place Connectors
- A.2 Amp Multilock Connectors
- A.3 Autofuse Electrical Connectors
- A.4 Delphi Connectors
- A.5 Delphi Maxi Fuse Housing
- A.6 Deutsch Electrical Connectors
- A.7 Deutsch Standard Terminal Repair
- A.8 Deutsch Solid Barrel Mini Terminal Repair
- A.9 Deutsch Mini Terminal Repair
- A.10 Molex Connectors
- A.11 Packard 150 Metri-Pack Connectors
- A.12 Packard 280 Metri-Pack Relay And Fuse Block Connectors
- A.13 Packard 480 Metri-Pack Connectors
- A.14 Packard 630 Metri-Pack Connectors
- A.15 Packard Metri-Pack Terminals
- A.16 Packard Ecm Connector
- A.17 Packard Micro-64 Connectors
- A.18 Sealed Splice Connectors

B. APPENDIX B WIRING
- B.1 Connectors
- B.2 Wiring Diagrams

C. APPENDIX C CONVERSIONS
- C.1 Metric Conversion
- C.2 Fluid Conversions
- C.3 Torque Conversions

D. APPENDIX D GLOSSARY
- D.1 Glossary

TOOLS

TORQUE VALUES

INDEX


ELECTRICAL DIAGNOSTICS MANUAL:


COVER

FOREWORD

TABLE OF CONTENTS

1. STARTING / CHARGING
- 1.1 Starter Troubleshooting
- 1.2 Starting System Diagnosis
- 1.3 Diagnostics/Troubleshooting
- 1.4 Starter Activation Circuits
- 1.5 Testing Starter On Motorcycle
- 1.6 Testing Starter On Bench
- 1.7 Charging System
- 1.8 Battery Testing

2. INSTRUMENTS
- 2.1 Checking For Diagnostic Trouble Codes
- 2.2 Initial Diagnostic Check: Speedometer
- 2.3 Speedometer Self Diagnostics
- 2.4 Speedometer
- 2.5 Breakout Box: Speedometer
- 2.6 Fuel Gauge
- 2.7 Indicator Lamps
- 2.8 Dtc B1004, B1005
- 2.9 Dtc B1006, B1007
- 2.10 Dtc B1008
- 2.11 Dtc U1016, U1255
- 2.12 Dtc U1064, U1255
- 2.13 Dtc U1300, U1301 Or Bus Er

3. TSM/HFSM
- 3.1 Turn Signal Overview
- 3.2 Harley-Davidson Smart Security System
- 3.3 H-Dsss Actuation
- 3.4 Personal Identification Number (Pin)
- 3.5 Arming/Disarming Security System
- 3.6 Warnings And Alarms
- 3.7 Service/Emergency Functions
- 3.8 Troubleshooting
- 3.9 Checking For Diagnostic Trouble Codes
- 3.10 Initial Diagnostic Check: Tsm/Hfsm
- 3.11 Speedometer Self Diagnostics
- 3.12 Breakout Box: Tsm/Hfsm
- 3.13 Fails To Disarm (Hfsm Only)
- 3.14 Dtc B0563
- 3.15 Tsm/Hfsm: Turn Signal Errors And Dtcs
- 3.16 Dtc B1131, B1132 (Hfsm Only)
- 3.17 Dtc B1134
- 3.18 Dtc B1135
- 3.19 Dtc B1136, B1142 (Hfsm Only)
- 3.20 Dtc B1141 (Hfsm Only)
- 3.21 Dtc B1143, B1144, B1145 (Hfsm Only)
- 3.22 Dtc B1154, B1155
- 3.23 Dtc U1016, U1255
- 3.24 Dtc U1300, U1301 Or Bus Er
- 3.25 Tsm/Hfsm: Password Learn
- 3.26 Hfsm Maintenance

4. ENGINE MANAGEMENT
- 4.1 Specifications
- 4.2 Efi System
- 4.3 Efi Diagnostic Introduction
- 4.4 Checking For Diagnostic Trouble Codes: Efi
- 4.5 Initial Diagnostic Check
- 4.6 Speedometer Self Diagnostics
- 4.7 Breakout Box: Efi
- 4.8 Wiggle Test
- 4.9 Intake Leak Test
- 4.10 Engine Cranks, But Will Not Start
- 4.11 No Ecm Power
- 4.12 Starts, Then Stalls
- 4.13 Fuel System Electrical Test
- 4.14 System Relay Check
- 4.15 Fuel Pressure Test
- 4.16 Idle Air Control
- 4.17 Misfire At Idle Or Under Load
- 4.18 Combustion Absent/Intermittent
- 4.19 Dtc P0107, P0108
- 4.20 Dtc P0112, P0113
- 4.21 Dtc P0117, P0118
- 4.22 Dtc P0122, P0123
- 4.23 Dtc P0131, P0132, P0134, P0151, P0152, P0154
- 4.24 Dtc P0261, P0262, P0263, P0264
- 4.25 Dtc P0373, P0374
- 4.26 Dtc P0501, P0502
- 4.27 Dtc P0562, P0563
- 4.28 Dtc P0603, P0605
- 4.29 Dtc P0661, P0662
- 4.30 Dtc P1009, P1010
- 4.31 Dtc P1351, P1352, P1354, P1355
- 4.32 Dtc P1475, P1477, P1478
- 4.33 Dtc P1501, P1502
- 4.34 Dtc U1064, U1255
- 4.35 Dtc U1097, U1255

A. APPENDIX A CONNECTOR REPAIR
- A.1 Amp 1-Place Connectors
- A.2 Amp Multilock Connectors
- A.3 Delphi Connectors
- A.4 Deutsch 1-Place Electrical Connectors
- A.5 Deusch Electrical Connectors
- A.6 Deutsch Standard Terminals
- A.7 Deutsch Mini-Terminal Crimps
- A.8 Deutsch Solid Barrel Terminals
- A.9 Relay And Fuse Blocks
- A.10 150 Metri-Pack Connectors
- A.11 280 Metri-Pack Connectors
- A.12 480 Metri-Pack Connectors
- A.13 630 Metri-Pack Connectors
- A.14 800 Metri-Pack Connectors
- A.15 Metri-Pack Terminals
- A.16 Molex Connectors
- A.17 Packard Ecm Connector
- A.18 Packard Micro-64 Connectors
- A.19 Sealed Splice Connectors

B. APPENDIX B WIRING
- B.1 Connectors
- B.2 Wiring Diagrams

C. APPENDIX C CONVERSIONS
- C.1 Metric Conversion
- C.2 Fluid Conversions
- C.3 Torque Conversions

D. APPENDIX D GLOSSARY
- D.1 Glossary

E. APPENDIX E TSM/TSSM (JAPAN/KOREA)
- E.1 Tsm/Tssm (Japan/Korea) Overview
- E.2 Tsm/Tssm Features
- E.3 Vehicle Delivery
- E.4 Turn Signal Functions
- E.5 Bank Angle Function
- E.6 Security System Functions (Tssm Only)
- E.7 Arming/Disarming (Tssm Only)
- E.8 Diagnostic Trouble Codes (Dtc)
- E.9 Initial Diagnostic Check: Tsm/Tssm
- E.10 Speedometer Self Diagnostics
- E.11 Breakout Box: Tsm/Tssm
- E.12 Fails To Disarm (Tssm Only)
- E.13 Turn Signal Errors: B1121, B1122, B1141
- E.14 Dtc B0563
- E.15 Dtc B1131, B1132
- E.16 Dtc B1134
- E.17 Dtc B1135
- E.18 Dtc B1154, Dtc B1155
- E.19 Dtc U1016, U1255
- E.20 Dtc U1300, U1301 Or Bus Er
- E.21 Tsm/Tssm: Password Learn
- E.22 Tssm Maintenance

TOOLS

TORQUE VALUES

INDEX