🏷️ Basic Information

Make:

Harley-Davidson

Model:

Touring

Model Year:

2009

Product Type:

Service Repair Manual

Product Code Indicator:

Harley-Davidson Touring Repair Manual 2009

👋 Introduction

Target Audience:

Harley-Davidson owners, independent motorcycle repair shops, DIY enthusiasts

Value Proposition:

Provides authorized factory repair procedures and specifications, enabling accurate and efficient maintenance and repair, saving costs compared to dealership service.

Alternatives:

Haynes, Clymer manuals (often less detailed than factory service manuals), unofficial online forums.

Diagrams:

Step-by-step diagrams for complex procedures

Completeness:

Covers re-wiring to engine rebuilding, indicating a high level of detail.

Electrical Schematics:

Essential for diagnosing and repairing electrical issues.

📋 Manual Details

Engine Coverage:

All 2009 Harley-Davidson Touring model engines (e.g., Twin Cam 96, Twin Cam 103 variations if applicable)

Transmission Coverage:

All 2009 Harley-Davidson Touring model transmissions (e.g., Cruise Drive 6-speed)

Chassis Coverage:

Frame, suspension (front and rear), wheels, brakes, steering

Electrical Coverage:

Wiring diagrams, ignition system, lighting, charging system, starter, battery, fuel injection, body control modules

Bodywork Coverage:

Fairings, saddlebags, tour-pak, body panels, seat

Estimated Page Count:

Extensive, typically 700+ pages for a comprehensive manual

Type:

Factory Authorized Service Repair Manual

Language:

English

Format:

Instant Download (Digital - likely PDF)

📖 Manual Coverage

Engine Mechanical:

Engine disassembly, assembly, component testing, overhaul (e.g., cylinder head, pistons, crankshaft, camshafts)

Fuel System:

Fuel injection system (EFI) components, fuel pump, injectors, sensors, fuel tank

Cooling System:

Air cooling system (typically, though some models might have oil cooling components)

Ignition System:

Spark plugs, ignition coils, electronic control module (ECM) ignition functions

Exhaust System:

Exhaust pipes, mufflers, catalytic converters (if applicable), sensor locations

Transmission Mechanical:

Transmission disassembly, assembly, gear inspection, shift mechanism

Clutch System:

Clutch assembly, primary drive, clutch operation, adjustments

Brakes:

Hydraulic brake system, master cylinders, calipers, brake pads, rotors, bleeding procedures, ABS (if equipped)

Suspension:

Front fork (e.g., telescopic forks), rear shock absorbers, swingarm, bearings

Steering:

Handlebars, steering head bearings, fork components

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams, component testing

Lighting System:

Headlights, taillights, turn signals, auxiliary lighting

Charging System:

Stator, voltage regulator/rectifier, battery maintenance and testing

Starting System:

Starter motor, starter solenoid, battery connections

Accessories:

Audio systems, cruise control (if applicable), lighting upgrades

Basic Maintenance:

Oil changes, filter replacements, spark plug replacement, chain/belt adjustments, tire pressure checks

Intermediate Repair:

Brake pad replacement, fork seal replacement, clutch cable adjustment, wheel bearing service

Advanced Repair:

Engine rebuilds, transmission overhauls, complete electrical system diagnosis and repair, suspension component replacement

Troubleshooting:

Step-by-step diagnostic procedures for common and complex issues

Wiring Diagrams:

Detailed electrical schematics for all circuits

Torque Specifications:

Precise torque values for all fasteners

Special Tools:

Identification and usage of Harley-Davidson specific tools

Depth:

Comprehensive, covering all aspects from routine maintenance to full engine and transmission rebuilds, including detailed electrical troubleshooting.

📊 Manual Specifications

Format:

PDF (Portable Document Format)

Searchable:

Yes (typically text-searchable PDF)

Printability:

Printable (allows users to print specific sections or the entire manual)

Image Resolution:

High resolution for clear diagrams and images

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Family:

Twin Cam

Displacement Options:

Commonly 96 cubic inches (1584cc) for 2009 Touring models, with potential for 103 cubic inch variants in CVO or specific models. (Manual will cover specific engines for the year).

Configuration:

V-Twin, 45-degree, air-cooled

Valve Train:

Overhead valve (OHV), 2 valves per cylinder

Bore X Stroke:

Typically 3.75 in x 4.38 in (95.25 mm x 111.25 mm) for Twin Cam 96.

Horsepower Est Tq:

While exact figures vary by model, the Twin Cam 96 typically produced around 90-100 ft-lbs of torque at approximately 3000-3500 RPM, and approximately 70-75 HP.

Injection Type:

Electronic Sequential Port Fuel Injection (ESPFI) - Harley-Davidson's Delphi-based system.

Fuel Type:

Unleaded gasoline, minimum 91 octane recommended

Fuel Pump:

In-tank electric fuel pump

🔧 Transmission

Type:

Cruise Drive 6-Speed Manual

Gear Ratios:

Specific ratios will be detailed in the manual, but generally include: 1st: 9.273, 2nd: 6.053, 3rd: 4.289, 4th: 3.420, 5th: 2.875, 6th: 2.473

Clutch Type:

Wet, multi-plate, diaphragm spring

Transmission Options:

Typically only the 6-speed manual was standard for most 2009 Touring models.

Features:

Integrated transmission and primary drive case design

📐 Dimensions

Wheelbase:

Typically around 63.5 inches (1613 mm) for standard Touring models.

Length:

Varies by model (e.g., Street Glide, Road King, Ultra Classic), generally around 95-100 inches (2413-2540 mm).

Dry Weight:

Varies by model, typically between 750-900 lbs (340-408 kg).

Gvwr:

Not typically specified for motorcycles in the same way as cars, but payload capacity is a consideration.

🛡️ Safety Features

Crash Test Ratings:

Motorcycles are not typically rated by agencies like NHTSA in the same manner as automobiles.

ABS:

Anti-lock Braking System (ABS) was an optional or standard feature on many 2009 Touring models.

Cruise Control:

Electronic cruise control available on many Touring models.

Lighting:

Halogen headlights, LED taillights, incandescent turn signals (typical for 2009).

Braking System:

Dual disc front, single disc rear hydraulic brakes.

💡 Technology Features

Audio System:

Many 2009 Touring models featured advanced (for the time) infotainment systems with AM/FM radio, CD player, CB radio, intercom, and CB functions, often with handlebar-mounted controls.

Display:

Integrated fairing or dash-mounted display for audio and vehicle information.

Cruise Control:

Electronic cruise control was a significant technology feature for long-distance touring.

Internal Diagnostics:

On-board diagnostics (OBD) for engine management and fault codes, accessible via diagnostic tools.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 miles (8,000 km) or annually, whichever comes first.

Primary Chain Tensioner:

Inspection at 10,000 miles (16,000 km), replacement recommended around 20,000-30,000 miles (32,000-48,000 km) due to potential failure.

Spark Plugs:

Typically recommended for replacement every 10,000 miles (16,000 km).

Engine Oil:

Harley-Davidson 20W-50 SYN3 (synthetic) or equivalent high-quality motorcycle-specific 20W-50 oil.

Transmission Fluid:

Formula + Transmission & Primary Chaincase Lubricant (or equivalent Harley-Davidson approved gear oil).

Primary Chaincase Fluid:

Formula + Transmission & Primary Chaincase Lubricant (same as transmission fluid).

Brake Fluid:

DOT 4 (for hydraulic brake systems)

Primary Chain Tensioner:

Known to wear out prematurely, potentially causing noise and engine damage if not addressed. Upgrade to hydraulic tensioners is common.

Cam Chain Tensioners:

The hydraulic cam chain tensioners in the Twin Cam (especially earlier versions) are also prone to wear. 2009 is often considered towards the later end of this issue, but still worth checking.

Alternator Rotor:

Rarely, the alternator rotor magnets can break loose, causing charging issues.

📚 Vehicle History

Brand Foundation:

Harley-Davidson Motor Company founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and long-distance touring capabilities.

Touring Lineage:

The Touring line has evolved from early large touring motorcycles, becoming synonymous with the Harley-Davidson brand and its emphasis on comfort, luggage capacity, and rider experience for long journeys.

Twin Cam Introduction:

The Twin Cam engine platform was introduced in 1999 and became the primary engine for Harley-Davidson's big twin models, including the Touring line, by 2000. The 2009 models represent a mature iteration of this platform.

Manufacturing Location:

Primarily manufactured in the United States.

🏆 Awards & Recognition

Brand Recognition:

Harley-Davidson consistently ranks high in brand loyalty and customer satisfaction among motorcycle owners. The Touring platform is celebrated for its comfort and capability for long-distance travel.

Owner Satisfaction:

High owner satisfaction generally attributed to the riding experience, customization, and community.