🏷️ Basic Information

Make:

Harley-Davidson

Model:

FLHR Road King

Year:

2009

Chassis Code:

FLHR

Engine Code:

TWIN CAM 96

👋 Introduction

Segment:

Cruiser Touring

Target Audience:

Harley-Davidson owners seeking to perform their own maintenance and repairs, independent motorcycle repair shops.

Competitors:

Indian Chief, Victory Kingpin

Vehicle Appeal:

Iconic styling, comfortable touring capability, V-twin rumble, customizable platform.

Manual Value:

Provides essential technical data and procedures for maintaining and repairing the Harley-Davidson FLHR Road King, saving time and money on dealership service.

📋 Manual Details

Primary Coverage:

Repair, Maintenance, Troubleshooting, Diagnostics, Electrical System, Engine, Transmission, Drivetrain, Chassis, Suspension, Brakes, Fuel System, Ignition System, Cooling System, Exhaust System, Bodywork, Wiring Diagrams

Total Pages:

702

Type:

Workshop Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Twin Cam 96 V-Twin Engine, Engine Disassembly/Reassembly, Cylinder Head, Piston, Connecting Rod, Crankshaft, Camshaft, Valvetrain, Lubrication System, Oil Pump, Oil Cooler, Oil Filter

Transmission:

6-Speed Cruise Drive Transmission, Transmission Disassembly/Reassembly, Clutch, Primary Drive, Gearbox Components, Shifting Mechanism

Drivetrain:

Belt Drive System, Rear Pulley, Drive Belt Inspection and Replacement, Wheel Bearings

Brakes:

Front and Rear Hydraulic Brake Systems, Brake Caliper Overhaul, Master Cylinders, Brake Lines, Brake Pads, Brake Discs, ABS System (if equipped)

Suspension:

Front Fork (Telescopic), Rear Shock Absorbers, Suspension Adjustment, Fork Seal Replacement, Shock Absorber Replacement

Electrical:

Complete Electrical System Schematics, Battery, Charging System (Alternator/Regulator), Ignition System (Sparks Plugs, Coils), Starting System (Starter Motor), Lighting (Headlight, Taillight, Signals), Horn, Instrumentation, Gauges, Security System (H-D Smart Security System), Diagnostic Codes, EFI System (Fuel Injection)

Fuel System:

Fuel Tank, Fuel Pump, Fuel Filter, Fuel Injectors, Throttle Body, Idle Air Control (IAC) Motor

Bodywork:

Fairing, Saddlebags, Fenders, Seat, Handlebars, Controls, Paint and Finish Repair, Body Panel Removal/Installation

Maintenance:

Oil Changes, Filter Replacements, Spark Plug Replacement, Air Filter Cleaning/Replacement, Tire Pressure Checks, Chain/Belt Adjustment, Brake Fluid Flush, Battery Maintenance, General Inspection

Troubleshooting:

Systematic Diagnostic Procedures for Common and Uncommon Issues, Fault Code Interpretation, Symptom-Based Troubleshooting Guides

Repair:

Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation for all major systems.

Diagnostics:

Detailed procedures for using diagnostic tools (e.g., HD-VCI, diagnostic scan tools), interpreting diagnostic data, and performing system tests.

Depth:

Comprehensive coverage from basic routine maintenance to complete engine and transmission overhauls, including detailed specifications, torque values, and tolerances.

📊 Manual Specifications

File Type:

PDF

Searchable Text:

Likely Searchable (dependent on scan quality)

Resolution:

Typically high for digital manuals, ensuring clarity of diagrams and text.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ 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

Valvetrain:

Pushrod actuated, overhead valves, 2 valves per cylinder

Horsepower:

Approx. 70 HP (at rear wheel, typical)

Torque:

Approx. 85 ft-lbs (at rear wheel, typical)

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

Unleaded gasoline, minimum 91 octane

Oil Type:

Harley-Davidson SYN3 (Full Synthetic) or SAE 20W50 Motorcycle Oil

Oil Capacity:

3.7 U.S. quarts (3.5 liters) with filter change

Ignition System:

High-performance electronic ignition

Spark Plugs:

Harley-Davidson recommended (e.g., NGK DCPR8E)

🔧 Transmission

Transmission Type:

6-speed Cruise Drive

Optional Transmission:

N/A

Gear Ratios:

1st: 9.311, 2nd: 6.438, 3rd: 4.795, 4th: 3.824, 5th: 3.207, 6th: 2.750

Primary Drive:

Patented diaphragm spring clutch, 34 tooth. Primary chain drive to transmission, 32 tooth. (Ratio 1.07:1)

Final Drive:

Enclosed Belt Drive, 32 tooth. Rear pulley, 70 tooth. (Ratio 2.1875:1)

Transmission Oil:

Harley-Davidson Transmission Lubricant (Formula +) or equivalent SAE 80W-90 Hypoid Gear Lubricant

Transmission Oil Capacity:

2.6 U.S. quarts (2.4 liters)

📐 Dimensions

Length:

93.1 in (2365 mm)

Wheelbase:

63.5 in (1615 mm)

Seat Height Laden:

26.5 in (673 mm)

Ground Clearance:

5.1 in (130 mm)

Handlebars Rise:

1.8 in (46 mm)

Handlebars Pullback:

3.1 in (79 mm)

Dry Weight:

720 lbs (326.6 kg)

Wet Weight:

752 lbs (341.1 kg)

Gross Vehicle Weight Rating Gvwr:

1280 lbs (580 kg)

Saddlebag Capacity:

Approx. 2.2 cubic feet total

Front Tire:

Dunlop D402F MH90-21 56H

Rear Tire:

Dunlop D401 HW 150/80B16 71H

Front Wheel:

16-inch chrome aluminum spoke wheel

Rear Wheel:

16-inch chrome aluminum spoke wheel

🛡️ Safety Features

Crash Safety:

Motorcycle safety is primarily rider responsibility. Focus on active safety features and proper maintenance.

Brakes:

Dual-Disc Front Brakes, Single-Disc Rear Brake. Optional ABS (Anti-lock Braking System) available.

Lighting:

Large Halogen Headlight, Rear Taillight, Front and Rear Turn Signals.

Frame Construction:

Steel frame and swingarm for rigidity and stability.

Ergonomics:

Forward-mounted foot controls, comfortable rider triangle, windscreen for wind deflection.

💡 Technology Features

Audio System:

Standard AM/FM radio with CB/Intercom capability and Weatherband. Often equipped with fairing speakers and handlebar-mounted controls.

Display:

Analog gauges with a small LCD display for odometer, trip meter, and gear indication.

ABS:

Optional Anti-lock Braking System (ABS) available on some configurations.

Cruise Control:

Electronic cruise control is a standard feature on the FLHR Road King model.

Diagnostic Interface:

Vehicle Communication Interface (VCI) port for use with Harley-Davidson diagnostic software.

🔧 Maintenance

Engine Oil Change:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first.

Transmission Oil Change:

Every 10,000 miles (16,000 km) or 12 months.

Primary Chain Case Oil Change:

Every 10,000 miles (16,000 km) or 12 months.

Spark Plug Replacement:

Every 10,000 miles (16,000 km).

Air Filter Cleaning:

Inspect every 5,000 miles (8,000 km), clean or replace as needed.

Brake Fluid Flush:

Every 2 years, regardless of mileage.

Engine Oil:

Harley-Davidson SYN3 (Full Synthetic) or SAE 20W50 Motorcycle Oil

Transmission Oil:

Harley-Davidson Transmission Lubricant (Formula +) or SAE 80W-90 Hypoid Gear Lubricant

Primary Chain Case Oil:

Harley-Davidson Primary Chain Case Lubricant (Formula +) or SAE 80W-90 Hypoid Gear Lubricant

Brake Fluid:

DOT 4 (for ABS models, check manual for specific recommendations)

Common Problems:

Cam chain tensioner wear (early Twin Cam models, addressed by later designs), primary compensator issues, potential fuel injector issues, regulator/stator failures are known to occur on many Harley models. The 2009 models are generally robust but benefit from regular preventative maintenance.

📚 Vehicle History

Heritage:

Harley-Davidson has a long-standing reputation for building iconic American motorcycles, synonymous with freedom and the open road.

Road King Lineage:

The Road King line has been a staple of Harley-Davidson's touring lineup since the early 1990s, evolving to incorporate modern technology while retaining classic styling.

Manufacturing Location:

York, Pennsylvania, USA and Milwaukee, Wisconsin, USA (assembly)

🏆 Awards & Recognition

Market Reputation:

The Harley-Davidson Road King is consistently recognized as a benchmark in the cruiser touring segment for its blend of classic style and long-distance comfort.

Consumer Satisfaction:

Generally high consumer satisfaction, often cited for its rider experience and build quality.

Manual Certification:

N/A (Third-party publication of workshop manual)