Positioning:
Harley-Davidson's 2009 Touring models represented a significant evolution in comfort, technology, and performance within the premium touring motorcycle segment. These bikes were designed for long-distance riding, often with substantial luggage capacity and rider/passenger comfort features.
Competitors:
Competed directly with other large-displacement touring motorcycles from manufacturers such as Honda (Gold Wing), Indian, and sometimes BMW (K-series touring).
Features Of Vehicles:
Large displacement V-twin engines, comfortable seating, ample storage (saddlebags, tour paks), advanced suspension for their time, cruise control, optional audio systems, and robust construction for long-distance touring.
Primary Coverage:
Comprehensive service, repair, and maintenance for all 2009 Harley-Davidson Touring models.
Secondary Coverage:
Includes troubleshooting, diagnostics, specifications, and wiring diagrams.
Estimated Page Count:
Approximately 800-1000 pages (typical for comprehensive service manuals of this era and scope).
Type:
Service Manual / Workshop Manual
Engine Systems:
Engine assembly/disassembly, cylinder head, pistons, rings, crankshaft, camshaft, valve train, lubrication system, cooling (if applicable), fuel system (carburetor/fuel injection), ignition system, starting system, charging system (alternator/generator).
Transmission Drivetrain:
Transmission overhaul, gears, clutch, primary drive, final drive, belt/chain maintenance, and adjustments.
Chassis Suspension Brakes:
Frame, front forks (including telescopic and/or air-assisted), rear shock absorbers, wheel bearings, steering head bearings, brake system (hydraulic calipers, rotors, master cylinders, bleeding procedures), parking brake.
Electrical System:
Wiring diagrams, lighting, ignition switch, battery, starter motor, charging system, instrument cluster, audio system, security system, accessory wiring.
Bodywork Fittings:
Fairings, saddlebags, tank, seat, fenders, chrome trim, controls, levers, mirrors, windshield installation/removal.
Maintenance Procedures:
Scheduled maintenance intervals, oil changes (engine, transmission, primary), filter replacements, spark plug service, brake fluid flush, tire pressure checks, chain/belt adjustment.
Repair Procedures:
Complete engine rebuild, transmission repair, suspension overhaul, brake caliper rebuilding, electrical component replacement, body panel repair/replacement.
Troubleshooting:
Diagnostic flowcharts for common problems, electrical fault finding, engine performance issues.
Special Tools:
Identification and usage of specialized Harley-Davidson tools required for specific procedures.
Depth:
Comprehensive. Covers everything from basic routine maintenance to complete engine and transmission rebuilds. Includes detailed technical specifications, torque values, and diagnostic procedures.
Engine Family:
Twin Cam 96 (1584cc)
Engine Configuration:
Air-cooled, 45-degree V-twin
Bore X Stroke:
3.75 in. x 4.38 in. (95.25 mm x 111.25 mm)
Displacement:
96 cu. in. (1584 cc)
Horsepower Estimated:
Approximately 70-75 HP (at crankshaft, manufacturer claims often conservative)
Torque Estimated:
Approximately 90-95 ft-lbs (at crankshaft, typically around 3000 RPM)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane recommended
Ignition System:
High-performance, electronic ignition with knock control
Type:
6-speed Cruise Drive transmission
Gear Ratios:
Specific ratios for 1st through 6th gear are detailed in the manual.
Clutch Type:
Clutch, wet, multi-plate, heavy-duty
Primary Drive:
45/64 ratio, hydraulic clutch actuation
Final Drive:
Belt drive, 32/66 ratio
Length Overall:
Varies by model (e.g., FLHR ~93.3 in., FLHTCU ~103.1 in.)
Wheelbase:
Varies by model (e.g., FLHR ~63.5 in., FLHTCU ~65.6 in.)
Dry Weight:
Varies by model (e.g., FLHR ~703 lbs, FLHTCU ~838 lbs)
Gvwr:
Typically around 1360 lbs or higher, depending on model.
Payload Capacity:
Approximately 450-500 lbs.
Fuel Capacity:
6.0 gallons (22.7 L)
Oil Capacity Engine:
4.0 US qt (3.8 L) with filter change
Oil Capacity Transmission:
2.8 US qt (2.6 L)
Oil Capacity Primary Chain Case:
2.7 US qt (2.5 L)
Crash Test Ratings:
Not applicable to motorcycles in the same way as automobiles. Safety is based on rider skill, active safety features, and motorcycle design.
Braking System:
Dual-caliper front braking system, single-caliper rear. Optional ABS (Anti-lock Braking System) was available on many models.
Lighting:
Halogen headlight, LED tail/stop light, directional signals, passing lamps (on some models).
Cruise Control:
Standard on many Touring models for enhanced highway safety and fatigue reduction.
Frame Construction:
Steel, cradle frame designed for stability and rigidity.
Ergonomics:
Designed for rider comfort and control during long rides.
Audio System:
Many Touring models came equipped with premium audio systems, often featuring AM/FM, CB radio, intercom, and passenger controls. CD players were common.
Instrumentation:
Analog tachometer and speedometer, with digital readouts for odometer, trip meters, fuel level, gear indicator, and diagnostics (on some models).
Cruise Control:
Electronically controlled cruise control.
Anti Lock Brakes:
Optional Anti-lock Braking System (ABS).
Accessory Ports:
12V auxiliary power outlets for charging accessories.
Initial Service:
1,000 miles (1,600 km) - critical for engine break-in and fluid changes.
Subsequent Service:
Every 5,000 miles (8,000 km) or annually, whichever comes first. Includes oil changes, filter replacements, and inspections.
Major Service Points:
Spark plugs (around 10,000 miles), transmission and primary oil (every 5,000-10,000 miles), brake fluid flush (every 2 years), and belt inspection/tensioning.
Engine Oil:
Harley-Davidson SYN3 (fully synthetic) or equivalent SAE 20W-50 motorcycle oil meeting Harley-Davidson specifications (e.g., H-D 360).
Transmission Oil:
Harley-Davidson Transmission Fluid (Formula +) or equivalent SAE 85W-140 gear oil.
Primary Chain Case Oil:
Harley-Davidson SYN3 or Formula +; check manual for specific model requirements.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Fork Oil:
Specific weight fork oil (e.g., Harley-Davidson Type 'E' or equivalent 10W).
Common Wear Items:
Clutch plates, primary chain tensioner (early Twin Cam models could have automatic tensioner wear), wheel bearings, battery life, fuel tank paint issues (rare), exhaust leaks.
Electrical Gremlins:
Common in older motorcycles, can include issues with charging systems, ignition modules, or accessory wiring. The manual is essential for diagnosis.
Heritage:
Harley-Davidson has a long-standing history of producing iconic motorcycles, particularly in the touring segment, dating back to the early 20th century. The Touring line is a direct descendant of the Electra Glide models.
Evolution Of Touring:
The 2009 models represent the evolution of Harley-Davidson's touring platform, featuring the introduction of the Twin Cam 96 engine and refinements to chassis, suspension, and styling that have defined Harley touring bikes for decades.
Manufacturing Location:
United States (primarily York, Pennsylvania, and Milwaukee, Wisconsin).
