🏷️ Basic Information

Make:

Harley-Davidson

Year:

2009

Product Name:

2009 Harley Davidson Touring Models Service and Repair Manual

Model Codes Covered:

FLHT, FLHTC, FLHTCU, FLTR, FLHX, FLHR, FLHRC

👋 Introduction

Market Position:

Harley-Davidson's Touring models in 2009 represented the pinnacle of American cruiser comfort and long-distance riding capability, targeting riders seeking iconic style, a premium experience, and extensive customization potential.

Competitive Landscape:

Competed directly with other major touring motorcycles from brands like Honda (Gold Wing), Indian, and to a lesser extent, BMW and other large-displacement cruisers offering similar long-haul comfort and features.

Touring Features:

Large fairings for rider protection, comfortable seating for rider and passenger, ample storage (saddlebags, tour-paks), cruise control, advanced infotainment systems (on some models), air-adjustable rear suspension.

Manual Value Proposition:

This manual is an indispensable resource for owners and technicians, providing the precise procedures and specifications needed to maintain, diagnose, and repair 2009 Harley-Davidson Touring motorcycles, ensuring optimal performance and longevity.

📋 Manual Details

Models Covered:

2009 Harley-Davidson FLHT Electra Glide, FLHTC Electra Glide Classic, FLHTCU Ultra Classic Electra Glide, FLTR Road Glide, FLHX Street Glide, FLHR Road King, FLHRC Road King Classic

Page Count:

N/A (Typical for comprehensive service manuals of this era, often 600-900+ pages)

Manual Type:

Service and Repair Manual

Language:

English

Format:

Printed Book (Common for this era, PDF versions may also exist)

📖 Manual Coverage

Engine Systems:

Twin Cam 96 (1584cc) V-Twin engine, fuel injection (EFI), ignition system, exhaust system, lubrication system, cooling system (oil cooling), engine disassembly and reassembly, performance tuning.

Transmission And Drivetrain:

6-speed Cruise Drive transmission, primary drive, clutch operation and adjustment, final drive (belt drive), gearbox disassembly and reassembly, shift mechanism.

Chassis And Suspension:

Frame, front fork (telescopic), rear suspension (air-adjustable shocks), swingarm, steering assembly, wheel bearings, wheel and tire service.

Braking System:

Front and rear disc brakes, hydraulic system, brake calipers, master cylinders, brake fluid specifications, ABS (Anti-lock Braking System) for applicable models.

Electrical System:

Battery, charging system (alternator, regulator), starting system (starter motor), lighting systems (headlight, taillight, turn signals), ignition system (ECU, sensors), instrumentation, wiring diagrams, fuses and relays, audio systems, cruise control.

Bodywork And Trim:

Fairings, saddlebags, tour-paks, seat, fuel tank, fenders, chrome components, cosmetic repair and detailing, body panel removal and installation.

Maintenance Procedures:

Routine checks, oil changes, filter replacements (oil, air), spark plug replacement, battery maintenance, tire pressure checks, brake pad inspection and replacement, belt tension adjustment, suspension adjustments.

Diagnostic Procedures:

Troubleshooting guide for common issues, diagnostic trouble codes (DTCs), use of diagnostic tools (e.g., Harley-Davidson Digital Technician Lite).

Repair Procedures:

Detailed step-by-step instructions for disassembly, repair, and reassembly of all major components and systems, including engine rebuilds, transmission overhauls, electrical component replacement, suspension servicing.

Special Tool Requirements:

Identification of specialized Harley-Davidson tools required for specific procedures (e.g., clutch holding tools, bearing pullers, torque wrenches calibrated for specific specs).

Wiring Diagrams:

Detailed electrical system wiring diagrams for all major circuits, aiding in troubleshooting and repair of lighting, ignition, charging, and accessory systems.

Torque Specifications:

Comprehensive list of all critical torque specifications for fasteners throughout the motorcycle, essential for proper assembly and safety.

Depth Of Coverage:

Comprehensive coverage from basic owner maintenance to full engine and transmission rebuilds, including detailed torque specifications, clearances, and assembly sequences.

Diagnostic Codes:

Explanation of diagnostic trouble codes (DTCs) and procedures for retrieving them using the vehicle's onboard diagnostics.

📊 Manual Specifications

File Format:

N/A (Assuming print format for this product)

Print Quality:

High-quality printing on durable paper for workshop use, clear diagrams and illustrations.

Binding Type:

Professional binding (e.g., perfect bound or spiral bound) to withstand frequent use in a workshop environment.

Paper Type:

Durable, grease-resistant paper to ensure longevity in a mechanical setting.

⚙️ Engine Specifications

Engine Type:

Air-cooled, Twin Cam 96 V-Twin

Displacement:

1584 cc (96 cubic inches)

Bore X Stroke:

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

Compression Ratio:

9.2:1

Valve Train:

Overhead valves (OHV) with two valves per cylinder, pushrod actuated.

Horsepower:

Approx. 70-75 HP (at crank, depending on specific tuning and exhaust)

Torque:

Approx. 90-95 lb-ft (at crank, depending on specific tuning and exhaust)

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

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

Ignition Type:

High-performance, capacitor discharge (CDI) electronic ignition with knock control.

Cooling Method:

Air-cooled with supplemental oil cooling.

Oil Type:

Harley-Davidson recommends Harley-Davidson 20W-50 Synthetic or Harley-Davidson 360 Motor Oil SAE 20W-50.

Oil Capacity:

Approx. 4.0 US qt. (3.8 L) with filter change.

🔧 Transmission

Transmission Type:

6-speed Cruise Drive manual transmission

Gear Ratios:

1st: 9.59, 2nd: 6.65, 3rd: 4.95, 4th: 3.72, 5th: 3.24, 6th: 2.79

Primary Drive:

Multi-plate wet clutch, chain drive to transmission.

Final Drive:

Carbon fiber reinforced belt drive, 32/66 ratio.

Transmission Oil Type:

Harley-Davidson Formula + Transmission and Primary Chaincase Lubricant (or equivalent meeting HD spec).

Transmission Oil Capacity:

Approx. 2.8 US qt. (2.6 L)

📐 Dimensions

Length:

Varies by model, typically 98.1 to 101.2 inches (2492 to 2570 mm)

Width:

Varies by model, typically 37.0 to 38.0 inches (939 to 965 mm)

Height:

Varies by model, typically 53.0 to 60.0 inches (1346 to 1524 mm)

Wheelbase:

Varies by model, typically 63.5 to 64.5 inches (1613 to 1638 mm)

Dry Weight:

Varies by model, typically 780 to 860 lbs (354 to 390 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 1360 lbs (617 kg) (check specific model)

Saddlebag Capacity:

Approx. 2.2 cu ft total (70.9 liters) for standard hard saddlebags.

Tour Pak Capacity:

Varies by model, but adds significant luggage capacity.

🛡️ Safety Features

Crash Test Ratings:

Motorcycles are not typically subject to the same government crash test ratings as automobiles. Safety is assessed through design features and independent reviews.

ABS:

Available as an option on many 2009 Touring models, providing enhanced braking control.

Cruise Control:

Standard on many Touring models, aiding rider fatigue reduction on long journeys.

Lighting:

Halogen headlight, LED taillight and brake light, auxiliary passing lamps (on some models) for increased visibility.

Braking System Design:

Dual front disc brakes and single rear disc brake for robust stopping power.

💡 Technology Features

Audio System:

Many Touring models featured advanced infotainment systems with AM/FM radio, CD player, CB radio, intercom, and weather band capabilities. Later models integrated MP3/iPod connectivity.

Display:

Integrated dashboard displays with analog gauges and LCD readouts for fuel level, gear selection, clock, etc. Some models had larger screen displays for infotainment.

Cruise Control:

Electronic cruise control system for maintaining set speeds.

Communication Features:

CB radio and intercom systems on many models facilitate communication between rider and passenger, and with other riders on rallies.

🔧 Maintenance

Initial Service:

First service typically at 1,000 miles (1,600 km) - includes engine oil change, primary chaincase oil change, chassis lubrication, and general inspection.

Regular Service:

Subsequent services typically every 5,000 miles (8,000 km) or annually, whichever comes first. Includes engine oil and filter change, inspection of various components.

Belt Drive Inspection:

Inspect drive belt tension and condition every 5,000 miles (8,000 km).

Engine Oil Viscosity:

20W-50 Synthetic or Mineral

Brake Fluid Type:

DOT 4 (refer to manual for specific Harley-Davidson specification).

Primary Chaincase Lubricant:

Harley-Davidson Formula + Transmission and Primary Chaincase Lubricant

Common Wear Items:

Clutch wear, suspension seals, wheel bearings, brake pads due to heavy touring use.

Engine Considerations:

While generally robust, some Twin Cam 96 engines may experience cam chain tensioner wear over time (later models featured hydraulic tensioners that addressed this). Proper oil maintenance is crucial.

Electrical Considerations:

Battery health is paramount; regular charging and good connections are important. Harley-Davidson specific diagnostic tools are often necessary for electrical system troubleshooting.

📚 Vehicle History

Heritage:

Harley-Davidson, founded in 1903, has a long and storied history in motorcycling, particularly known for its V-twin engines, iconic styling, and the 'Hog' culture.

Touring Lineage:

The Touring line, including models like the Electra Glide and Road King, evolved from early large touring motorcycles, consistently refining comfort, performance, and features for long-distance travel.

Twin Cam Introduction:

The Twin Cam engine family was introduced in 1999, with the Twin Cam 96 becoming standard on most Harley-Davidson models by the mid-2000s, including the 2009 Touring range.

Manufacturing Location:

United States (primarily York, Pennsylvania, and Milwaukee, Wisconsin).

🏆 Awards & Recognition

Market Perception:

Harley-Davidson Touring models are consistently recognized for their iconic styling, comfort, and ownership experience. They are often considered benchmark motorcycles in the touring segment.

Owner Satisfaction:

Harley-Davidson typically ranks highly in owner satisfaction surveys for its touring motorcycles, reflecting brand loyalty and the emotional connection owners have with the brand.