🏷️ Basic Information

Make:

Harley-Davidson

Model:

Touring Models

Year:

2009

Product Name:

Harley-Davidson Touring Models Workshop Service Repair Manual 2009

Product Description Short:

Harley-Davidson Touring ALL Models Workshop Service Manual 2009

👋 Introduction

Market Position:

Harley-Davidson's Touring models represent the pinnacle of American cruiser touring, designed for long-distance comfort and iconic style. This manual is essential for owners and technicians seeking to maintain and repair these premium motorcycles.

Competitors:

Competes directly with brands like Indian Motorcycles and premium touring offerings from Japanese manufacturers, focusing on rider comfort, luggage capacity, and classic V-twin performance.

Key Features:

Covers a wide range of Touring models, providing in-depth technical information for DIY mechanics and professional service centers. Emphasizes accuracy and completeness, as expected from official workshop documentation.

📋 Manual Details

Model Coverage:

All Harley-Davidson Touring models

Year Coverage:

2009

Page Count:

Information not explicitly provided in product description, typical for comprehensive manuals of this type would be 500-1000+ pages.

Manual Type:

Official Workshop Service and Repair Manual

Language:

English (assumed based on product description and typical industry practice for Harley-Davidson manuals)

Format:

Digital (PDF) or Printed (typical formats for service manuals)

📖 Manual Coverage

Engine:

Detailed coverage of Twin Cam 96, Twin Cam 103 (if applicable to 2009 Touring), and Twin Cam 110 engines, including theory of operation, disassembly, inspection, assembly, and troubleshooting.

Fuel System:

Fuel injection (EFI), fuel pump, fuel injectors, throttle body, fuel tank, fuel lines, and evaporative emissions control systems.

Ignition System:

Ignition module, spark plugs, ignition coils, crankshaft position sensor, and related wiring.

Transmission:

6-speed Cruise Drive transmission, including clutch operation, gear engagement, lubrication, disassembly, assembly, and troubleshooting.

Drivetrain:

Primary drive, final drive (belt drive), clutch, and related components.

Frame And Suspension:

Frame construction, steering head, front fork (e.g., 49mm Tele-Glide), rear shock absorbers, swingarm, and wheel bearings.

Brakes:

Front and rear disc brakes, brake calipers, master cylinders, brake lines, ABS (Anti-lock Braking System) components and operation (if equipped), and brake fluid specifications.

Electrical System:

Battery, charging system (alternator, regulator), starting system (starter motor), lighting (headlights, taillights, turn signals), instrumentation, audio systems, security system (H-D Smart Security System), and wiring diagrams.

Body And Fairings:

Fairing removal and installation, saddlebag mounting and removal, tour-pak components, fenders, and related trim.

Diagnostics:

Diagnostic trouble codes (DTCs), diagnostic procedures, use of Harley-Davidson Digital Technician II (or equivalent tools).

Preventive Maintenance:

Oil changes, filter replacements, spark plug replacement, air filter cleaning/replacement, brake system inspection and fluid changes, tire inspection, chain/belt adjustment and lubrication (if applicable).

Routine Inspections:

Pre-ride checks, safety inspections, fluid level checks, tire pressure checks, and fastener torque checks.

Major Repairs:

Engine internal component replacement (pistons, rings, valves), transmission overhaul, fork seal replacement, brake caliper rebuilding, and electrical component diagnosis and replacement.

Troubleshooting:

Systematic approaches to diagnosing common and uncommon problems, including symptoms, possible causes, and recommended corrective actions.

Disassembly And Assembly:

Step-by-step instructions for removing and reinstalling all major components and sub-assemblies with torque specifications.

Wiring Diagrams:

Comprehensive color-coded wiring diagrams for all electrical systems, facilitating diagnosis and repair.

Depth Level:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics.

📊 Manual Specifications

File Format:

Likely PDF, ensuring searchability and easy navigation. If physical, it would be a printed book.

Print Quality:

High-resolution digital format or professional offset printing for physical copies, ensuring clarity of diagrams and text.

Binding Type:

For printed versions: Spiral-bound or perfect-bound for durability and ease of use in a workshop environment.

Paper Type:

For printed versions: Heavyweight, glossy or semi-gloss paper to withstand workshop conditions and display diagrams effectively.

⚙️ Engine Specifications

Engine Family:

Twin Cam

Engine Displacement Common:

96 cubic inches (1584cc) - Primary for most 2009 Touring models. 103 cubic inches (1690cc) may be present in CVO models.

Engine Configuration:

Air-cooled, 45-degree V-twin

Bore X Stroke 96Ci:

3.75 in. x 4.38 in. (95.25 mm x 111.25 mm)

Bore X Stroke 103Ci:

3.875 in. x 4.38 in. (98.43 mm x 111.25 mm)

Valvetrain:

Overhead valves (OHV), 2 valves per cylinder, pushrod actuated.

Horsepower 96Ci Est:

~75-80 HP @ 5500 RPM (actual figures vary by model and tuning)

Torque 96Ci Est:

~95-100 lb-ft @ 3500 RPM (actual figures vary by model and tuning)

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

Unleaded gasoline, minimum 91 octane (R+M)/2

Oil Capacity:

Approx. 4 quarts (3.8 L) with filter change (refer to manual for exact specification per model variant).

Oil Type Spec:

Harley-Davidson Genuine V-Twin 20W-50 SYN3 or equivalent SAE 20W-50 synthetic motorcycle oil.

🔧 Transmission

Transmission Type:

6-speed Cruise Drive

Gear Ratios 1St:

9.375

Gear Ratios 2Nd:

6.543

Gear Ratios 3Rd:

4.792

Gear Ratios 4Th:

3.818

Gear Ratios 5Th:

3.407

Gear Ratios 6Th:

2.790

Clutch Type:

Wet, multi-plate, diaphragm spring

Transmission Fluid Type:

Harley-Davidson Formula + Transmission & Primary Chain Case Lubricant or equivalent SAE 80W-90 GL-5 gear oil (refer to manual for specific recommendations).

Transmission Fluid Capacity:

Approx. 24-28 fl oz (0.71-0.83 L) (refer to manual for exact specification).

📐 Dimensions

Length:

Varies by model (e.g., Road King, Ultra Classic). Typically around 90-100 inches (2286-2540 mm).

Width:

Varies by model. Fairing width can be around 38-40 inches (965-1016 mm).

Height:

Varies by model. Typically around 55-60 inches (1397-1524 mm).

Dry Weight:

Varies significantly by model. Typically ranges from 700-850 lbs (317-385 kg).

Gross Vehicle Weight Rating Gvw Est:

Approx. 1200-1300 lbs (544-590 kg).

Saddlebag Capacity:

Integrated hard saddlebags, capacity varies but typically around 2.5-3.0 cubic feet total.

Tour Pak Capacity:

Optional or standard on some models, offering additional storage, often around 1.5-2.0 cubic feet.

🛡️ Safety Features

Crash Test Ratings:

Motorcycles are not typically subject to standardized crash testing like automobiles. Safety is primarily addressed through design and active/passive features.

ABS:

Anti-lock Braking System (ABS) available on many 2009 Touring models, significantly enhancing braking control.

Linked Brakes:

Some models may feature linked brake systems.

Cruise Control:

Standard on many Touring models for reduced rider fatigue on long journeys.

Lighting:

Halogen headlights, LED taillights, auxiliary lighting (touring models) for enhanced visibility.

Security:

Harley-Davidson Smart Security System with proximity-based fob for immobilizer and alarm.

Frame Construction:

Robust steel frame designed for stability and rider comfort.

💡 Technology Features

Audio System:

Integrated fairing-mounted audio system, typically with AM/FM radio, CD player, and auxiliary input. Some models may have CB radio and intercom systems.

Speakers:

Fairing-mounted speakers, often dual-element.

ABS System:

Available Anti-lock Braking System (ABS) for enhanced rider safety.

Cruise Control:

Electronic cruise control enhances long-distance comfort.

Auxiliary Input:

3.5mm auxiliary input jack for connecting external audio devices.

Diagnostic Port:

Diagnostic connectors allowing use of Harley-Davidson Digital Technician II for fault code reading and system analysis.

🔧 Maintenance

Initial Service:

First service typically at 1,000 miles (1,600 km) or 12 months, whichever comes first.

Subsequent Service:

Subsequent services generally recommended every 5,000 miles (8,000 km) or 12 months for standard checks and fluid changes. More intensive checks at 10,000, 15,000, etc. (Refer to the specific service schedule in the manual).

Engine Oil Spec:

SAE 20W-50 Synthetic (e.g., Harley-Davidson SYN3).

Primary Chain Case Fluid Spec:

SAE 80W-90 GL-5 Gear Oil or Harley-Davidson Formula +.

Transmission Fluid Spec:

SAE 80W-90 GL-5 Gear Oil or Harley-Davidson Formula +.

Brake Fluid Spec:

DOT 4 specification (Harley-Davidson recommends specific DOT 4 fluid).

Common Issues 2009 Twin Cam:

Potential for oil leaks (e.g., primary cover, rocker boxes), compensator sprocket wear, cam chain tensioner wear (especially with hydraulic tensioners), and exhaust header pipe leaks. Clutch lever adjustment may be required.

Common Issues Cruise Drive:

Occasional difficulty finding neutral, especially when cold. Proper fluid levels and type are crucial. Bearing wear in higher mileage transmissions.

Common Issues Electrical:

Wiring harness chafing in common flex points, battery charging issues due to regulator or stator failure, and speedometer/tachometer malfunctions are possible.

📚 Vehicle History

Heritage:

Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer renowned for its V-twin engines and distinctive styling. The brand is synonymous with freedom and the open road.

Touring Evolution:

The Touring line evolved from earlier models like the Electra Glide, continually refining comfort, performance, and technology to meet the demands of long-distance riders. The 2009 models feature the advanced Twin Cam engine platform and Cruise Drive transmission.

Manufacturing Location:

Primarily manufactured in Milwaukee, Wisconsin, and York, Pennsylvania, USA.

🏆 Awards & Recognition

Brand Recognition:

Harley-Davidson consistently ranks high in customer satisfaction and brand loyalty within the motorcycle industry.

Model Class Awards:

Harley-Davidson Touring models have frequently been recognized for their comfort, handling, and overall touring capability in various industry publications.