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Harley Davidson FLHTCU Ultra Classic Electra Glide Complete Workshop Service Repair Manual 2009

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHTCU Ultra Classic Electra Glide Model Designation: Ultra Classic Electra Glide Year: 2009 Codes Vehicle Chassis Code: FLHTCU Engine Code Family: Twin Cam...
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Harley Davidson FLHTCU Ultra Classic Electra Glide Complete Workshop Service Repair Manual 2009
🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FLHTCU Ultra Classic Electra Glide
Model Designation:
Ultra Classic Electra Glide
Year:
2009
Codes
Vehicle Chassis Code:
FLHTCU
Engine Code Family:
Twin Cam 103
👋 Introduction
Market Position
Vehicle Class:
Full-dress Touring Motorcycle
Target Audience:
Long-distance riders, touring enthusiasts, and those seeking maximum comfort and amenities.
Competitive Analysis
Key Competitors:
Honda Gold Wing, Indian Roadmaster, BMW K1600GTL.
Usp Features:
Iconic Harley-Davidson V-twin rumble, extensive touring features (fairing, saddlebags, tour-pak), comfortable rider and passenger ergonomics, extensive customization options.
Key Features
Model Highlights:
Flagship touring model, integrated luggage, advanced infotainment, rider comfort features, powerful V-twin engine.
Manual Purpose
Manual Value Proposition:
Empowers owners and technicians to perform all necessary maintenance and repairs, ensuring the longevity and optimal performance of the 2009 FLHTCU Ultra Classic Electra Glide.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Service, Repair, and Maintenance
Diagnostic Coverage:
Troubleshooting and Diagnostic Procedures
Electrical Coverage:
Wiring Diagrams and Electrical System Diagnosis
Engine Overhaul:
Complete Engine Rebuild Procedures
Transmission Overhaul:
Complete Transmission Rebuild Procedures
Chassis And Suspension:
Frame, Forks, Swingarm, and Suspension Components
Braking System:
Brake System Inspection, Repair, and Fluid Service
Fuel System:
Fuel Injection, Carburetor (if applicable), and Fuel Tank Service
Bodywork And Trim:
Fairings, Saddlebags, Tour-Pak, and Body Panels
Comfort And Convenience:
Seating, Audio System, Cruise Control, and Climate Control
Page Count
Estimated Page Count:
Approximately 800-1000 pages (typical for a complete workshop manual)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine disassembly, assembly, internal components, cooling, lubrication, and exhaust systems.
Transmission Systems:
Gearbox, clutch, primary drive, secondary drive (belt drive), and shift mechanisms.
Electrical Systems:
Battery, charging system, ignition system, lighting, instrumentation, audio, security, and accessory wiring.
Chassis Systems:
Frame, front forks, steering head, rear suspension, swingarm, wheels, and tires.
Braking Systems:
Front and rear brakes (hydraulic disc), ABS (if equipped), brake fluid types, and bleeding procedures.
Fuel And Emission Systems:
Fuel delivery, fuel injection (EFI), throttle body, fuel pump, injectors, and emission control systems.
Body And Fairings:
Fairings, windshield, saddlebags, tour-pak, seat, and all trim components.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug service, tire pressure checks, chain/belt adjustment.
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues.
Component Replacement:
Detailed instructions for replacing all major and minor components.
Rebuild Procedures:
Complete engine and transmission rebuilds with torque specifications and clearances.
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams and diagnostic codes.
Suspension Adjustment:
Fork adjustments, rear shock settings, and related component service.
Brake System Service:
Brake pad replacement, caliper service, and brake bleeding procedures.
Technical Depth
Depth Level:
Comprehensive, covering everything from basic maintenance to full engine and transmission overhauls.
Diagnostic Tools:
Information on using diagnostic tools like the Harley-Davidson Digital Technician (H-D-DT) or equivalent.
Torque Specifications:
Detailed torque values for all fasteners and critical components.
Clearances And Tolerances:
Engine internal clearances, bearing tolerances, and critical assembly measurements.
Wiring Diagrams:
Full-color, detailed wiring diagrams for all electrical systems.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text for quick access to information.
Printability:
Printable pages for on-site workshop use.
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, Twin Cam 103 V-twin
Displacement:
1690 cc (103 cubic inches)
Bore X Stroke:
3.875 in x 4.380 in (98.4 mm x 111.3 mm)
Compression Ratio:
9.2:1
Performance
Horsepower Peak:
Approx. 78 HP @ 5000 RPM (Manufacturer estimates vary; actual may differ)
Torque Peak:
Approx. 101 lb-ft @ 3500 RPM (Manufacturer estimates vary; actual may differ)
Fuel System
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Fuel Tank Capacity:
6.0 US gallons (22.7 L)
Lubrication System
Oil Type Specification:
Harley-Davidson Genuine Formula + Transmission Drive & Primary Chaincase Lubricant or equivalent.
Oil Capacity Engine:
4.0 US quarts (3.8 L)
🔧 Transmission
Standard
Transmission Type:
6-speed Cruise Drive
Primary Drive:
Multi-plate clutch, wet
Secondary Drive:
Belt drive, 24 mm width
Features
Gear Ratios:
1st: 9.593, 2nd: 6.650, 3rd: 4.938, 4th: 3.810, 5th: 3.150, 6th: 2.790
Transmission Fluid Specification:
Harley-Davidson Genuine Formula + Transmission Drive & Primary Chaincase Lubricant or equivalent.
Transmission Fluid Capacity:
1.0 US quart (0.95 L)
📐 Dimensions
Exterior
Length:
103.5 in (2629 mm)
Width:
38.0 in (965 mm)
Height:
54.0 in (1372 mm)
Wheelbase:
63.5 in (1613 mm)
Ground Clearance:
5.1 in (130 mm)
Weights
Dry Weight:
838 lbs (380 kg)
Weight In Running Order:
N/A (typically around 870-880 lbs with fluids)
Gvwr:
1360 lbs (617 kg)
Cargo
Saddlebag Capacity:
Approx. 2.2 cu ft per saddlebag
Tour Pak Capacity:
Approx. 2.7 cu ft
🛡️ Safety Features
Ratings
Crash Test Ratings:
Motorcycles are generally not subject to the same standardized crash test ratings as passenger cars; safety is primarily evaluated through design and active safety features.
Active Features
Braking System:
Dual front disc brakes, single rear disc brake. Integrated Linked Braking System (ILBS) and optional ABS (Anti-lock Braking System) available for enhanced control.
Lighting:
Halogen headlight, auxiliary passing lamps, LED tour-pak brake/tail light, front and rear turn signals.
Passive Features
Frame Construction:
Steel, rigid frame and swingarm for stability.
Ride Stability:
Low center of gravity and long wheelbase contribute to stability.
Security System:
Factory-installed H-D Smart Security System with immobilizer.
💡 Technology Features
Infotainment
Audio System:
Harley-Davidson Advanced Audio System with AM/FM, CD player, CB radio, intercom, and weather band.
Display:
Multi-function display for audio, navigation (optional), and vehicle information.
Driver Assistance
Cruise Control:
Electronic cruise control standard.
ABS:
Optional Anti-lock Braking System (ABS) available for enhanced braking safety.
Connectivity
Communication System:
CB radio and intercom system for rider-passenger and rider-rider communication.
Comfort Features
Climate Control:
Fairing lowers with vents for adjustable airflow, passenger backrest with armrests.
🔧 Maintenance
Service Intervals
Initial Service:
Typically at 1,000 miles (1,600 km) for initial break-in service (oil change, filter, inspection).
Regular Oil Change:
Every 5,000 miles (8,000 km) or annually, whichever comes first.
Transmission Fluid Change:
Every 10,000 miles (16,000 km) or annually.
Primary Chaincase Lubricant Change:
Every 10,000 miles (16,000 km) or annually.
Spark Plug Replacement:
Refer to manual, typically around 15,000-20,000 miles (24,000-32,000 km).
Brake Fluid Flush:
Every 2 years, regardless of mileage.
Belt Tension Check:
Every 10,000 miles (16,000 km).
Fluid Specifications
Engine Oil Viscosity:
20W-50 Harley-Davidson Genuine V-Twin Synthetic or equivalent.
Transmission Fluid Type:
Harley-Davidson Genuine Formula + Transmission Drive & Primary Chaincase Lubricant or equivalent.
Primary Chaincase Fluid Type:
Harley-Davidson Genuine Formula + Transmission Drive & Primary Chaincase Lubricant or equivalent.
Brake Fluid Type:
DOT 4 (for models with ABS) or DOT 5.1 (for non-ABS, check manual specific to ABS presence). Consult manual for precise specification.
Known Issues
Common Wear Items:
Clutch plates, brake pads, wheel bearings, fork seals, belt tensioner, and starter brushes.
Potential Engine Issues:
Cam chain tensioner wear (early Twin Cams), potential oil leaks, exhaust header pipe leaks at the cylinder head.
Electrical Gremlins:
Loose connections, faulty switches, and battery charging issues can occur; thorough electrical diagnosis is key.
📚 Vehicle History
Brand Heritage
Brand Origin:
Harley-Davidson Motor Company, founded in Milwaukee, Wisconsin, USA in 1903.
Heritage Focus:
Renowned for V-twin engines, classic styling, and a strong rider community.
Model Evolution
Electra Glide Origins:
The Electra Glide line dates back to the 1960s, evolving into the quintessential American touring motorcycle.
Ultra Classic Development:
The 'Ultra Classic' designation signifies the pinnacle of touring luxury and features within the Electra Glide family, adding amenities like the Tour-Pak and improved fairings.
Twin Cam Introduction:
The Twin Cam engine family was introduced in 1999, with significant updates and displacements like the 103 cubic inch (1690cc) becoming prominent in later years.
Production
Manufacturing Location:
York, Pennsylvania, USA, and Milwaukee, Wisconsin, USA
Model Year Introduction:
The FLHTCU Ultra Classic Electra Glide has been a staple for decades, with the 2009 model representing an iteration within the Twin Cam era.
🏆 Awards & Recognition
Recognitions
Model Awards:
While specific awards for the 2009 model are less commonly documented than modern bikes, the Ultra Classic Electra Glide platform has historically been recognized for its touring capabilities and comfort by various motorcycle publications and rider polls.
Ratings
Rider Satisfaction:
Consistently high rider satisfaction for comfort and long-distance capability.
Certifications
Emissions Compliance:
Meets EPA and CARB emissions standards for its model year.
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