2009 Harley Davidson Touring All Models Service Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Touring Series (All Models) Year: 2009 Covered Models: • FLHR Road King • FLHR Road King Shrine • FLHR Road King With Sidecar...

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类型: Motorcycle

斯库: 51121

标签: 2009 FL Models Harley Davidson Motorcycle Motorcycles Touring

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Touring Series (All Models)

Year:

Covered Models:

• FLHR Road King

• FLHR Road King Shrine

• FLHR Road King With Sidecar

• FLHRC Road King Classic

• FLHRC Road King Classic With Sidecar

• FLHT Electra Glide

• FLHT Electra Glide With Sidecar

• FLHTC Electra Glide Classic

• FLHTC Electra Glide Classic With Sidecar

• FLHTCU Ultra Classic Electra Glide

• FLHTCU Ultra Classic Electra Glide Shrine

• FLHTCU Ultra Classic Electra Glide with Sidecar

• FLHX Street Glide

• FLHX Street Glide With Sidecar

• FLTR Road Glide

• FLTR Road Glide With Sidecar

Codes

Model Codes:

• FLHR

• FLHRC

• FLHT

• FLHTC

• FLHTCU

• FLHX

• FLTR

👋 Introduction

Market Position

Positioning:

Harley-Davidson's 2009 Touring models represented a significant evolution in comfort, technology, and performance within the premium touring motorcycle segment. These bikes were designed for long-distance riding, often with substantial luggage capacity and rider/passenger comfort features.

Competitive Analysis

Competitors:

Competed directly with other large-displacement touring motorcycles from manufacturers such as Honda (Gold Wing), Indian, and sometimes BMW (K-series touring).

Key Features

Features Of Vehicles:

Large displacement V-twin engines, comfortable seating, ample storage (saddlebags, tour paks), advanced suspension for their time, cruise control, optional audio systems, and robust construction for long-distance touring.

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive service, repair, and maintenance for all 2009 Harley-Davidson Touring models.

Secondary Coverage:

Includes troubleshooting, diagnostics, specifications, and wiring diagrams.

Page Count

Estimated Page Count:

Approximately 800-1000 pages (typical for comprehensive service manuals of this era and scope).

Manual Type

Type:

Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine assembly/disassembly, cylinder head, pistons, rings, crankshaft, camshaft, valve train, lubrication system, cooling (if applicable), fuel system (carburetor/fuel injection), ignition system, starting system, charging system (alternator/generator).

Transmission Drivetrain:

Transmission overhaul, gears, clutch, primary drive, final drive, belt/chain maintenance, and adjustments.

Chassis Suspension Brakes:

Frame, front forks (including telescopic and/or air-assisted), rear shock absorbers, wheel bearings, steering head bearings, brake system (hydraulic calipers, rotors, master cylinders, bleeding procedures), parking brake.

Electrical System:

Wiring diagrams, lighting, ignition switch, battery, starter motor, charging system, instrument cluster, audio system, security system, accessory wiring.

Bodywork Fittings:

Fairings, saddlebags, tank, seat, fenders, chrome trim, controls, levers, mirrors, windshield installation/removal.

Procedures Included

Maintenance Procedures:

Scheduled maintenance intervals, oil changes (engine, transmission, primary), filter replacements, spark plug service, brake fluid flush, tire pressure checks, chain/belt adjustment.

Repair Procedures:

Complete engine rebuild, transmission repair, suspension overhaul, brake caliper rebuilding, electrical component replacement, body panel repair/replacement.

Troubleshooting:

Diagnostic flowcharts for common problems, electrical fault finding, engine performance issues.

Special Tools:

Identification and usage of specialized Harley-Davidson tools required for specific procedures.

Technical Depth

Depth:

Comprehensive. Covers everything from basic routine maintenance to complete engine and transmission rebuilds. Includes detailed technical specifications, torque values, and diagnostic procedures.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely searchable text within the PDF for efficient information retrieval.

Print Quality

Printability:

Printable, allowing users to create physical copies for workshop use.

Binding Type

Binding:

Not applicable (digital download).

Paper Type

Paper Type:

Not applicable (digital download).

⚙️ Engine Specifications

Primary Engine

Engine Family:

Twin Cam 96 (1584cc)

Engine Configuration:

Air-cooled, 45-degree V-twin

Bore X Stroke:

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

Displacement:

96 cu. in. (1584 cc)

Compression Ratio:

8.9:1

Performance

Horsepower Estimated:

Approximately 70-75 HP (at crankshaft, manufacturer claims often conservative)

Torque Estimated:

Approximately 90-95 ft-lbs (at crankshaft, typically around 3000 RPM)

Fuel System

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

Unleaded gasoline, minimum 91 octane recommended

Ignition

Ignition System:

High-performance, electronic ignition with knock control

🔧 Transmission

Standard

Type:

6-speed Cruise Drive transmission

Features

Gear Ratios:

Specific ratios for 1st through 6th gear are detailed in the manual.

Clutch Type:

Clutch, wet, multi-plate, heavy-duty

Primary Drive:

45/64 ratio, hydraulic clutch actuation

Final Drive:

Belt drive, 32/66 ratio

📐 Dimensions

Exterior

Length Overall:

Varies by model (e.g., FLHR ~93.3 in., FLHTCU ~103.1 in.)

Wheelbase:

Varies by model (e.g., FLHR ~63.5 in., FLHTCU ~65.6 in.)

Weights

Dry Weight:

Varies by model (e.g., FLHR ~703 lbs, FLHTCU ~838 lbs)

Gvwr:

Typically around 1360 lbs or higher, depending on model.

Payload Capacity:

Approximately 450-500 lbs.

Capacities

Fuel Capacity:

6.0 gallons (22.7 L)

Oil Capacity Engine:

4.0 US qt (3.8 L) with filter change

Oil Capacity Transmission:

2.8 US qt (2.6 L)

Oil Capacity Primary Chain Case:

2.7 US qt (2.5 L)

🛡️ Safety Features

Ratings

Crash Test Ratings:

Not applicable to motorcycles in the same way as automobiles. Safety is based on rider skill, active safety features, and motorcycle design.

Active Features

Braking System:

Dual-caliper front braking system, single-caliper rear. Optional ABS (Anti-lock Braking System) was available on many models.

Lighting:

Halogen headlight, LED tail/stop light, directional signals, passing lamps (on some models).

Cruise Control:

Standard on many Touring models for enhanced highway safety and fatigue reduction.

Passive Features

Frame Construction:

Steel, cradle frame designed for stability and rigidity.

Ergonomics:

Designed for rider comfort and control during long rides.

💡 Technology Features

Infotainment

Audio System:

Many Touring models came equipped with premium audio systems, often featuring AM/FM, CB radio, intercom, and passenger controls. CD players were common.

Instrumentation:

Analog tachometer and speedometer, with digital readouts for odometer, trip meters, fuel level, gear indicator, and diagnostics (on some models).

Driver Assistance

Cruise Control:

Electronically controlled cruise control.

Anti Lock Brakes:

Optional Anti-lock Braking System (ABS).

Connectivity

Accessory Ports:

12V auxiliary power outlets for charging accessories.

🔧 Maintenance

Service Intervals

Initial Service:

1,000 miles (1,600 km) - critical for engine break-in and fluid changes.

Subsequent Service:

Every 5,000 miles (8,000 km) or annually, whichever comes first. Includes oil changes, filter replacements, and inspections.

Major Service Points:

Spark plugs (around 10,000 miles), transmission and primary oil (every 5,000-10,000 miles), brake fluid flush (every 2 years), and belt inspection/tensioning.

Fluid Specifications

Engine Oil:

Harley-Davidson SYN3 (fully synthetic) or equivalent SAE 20W-50 motorcycle oil meeting Harley-Davidson specifications (e.g., H-D 360).

Transmission Oil:

Harley-Davidson Transmission Fluid (Formula +) or equivalent SAE 85W-140 gear oil.

Primary Chain Case Oil:

Harley-Davidson SYN3 or Formula +; check manual for specific model requirements.

Brake Fluid:

DOT 4 hydraulic brake fluid.

Fork Oil:

Specific weight fork oil (e.g., Harley-Davidson Type 'E' or equivalent 10W).

Known Issues

Common Wear Items:

Clutch plates, primary chain tensioner (early Twin Cam models could have automatic tensioner wear), wheel bearings, battery life, fuel tank paint issues (rare), exhaust leaks.

Electrical Gremlins:

Common in older motorcycles, can include issues with charging systems, ignition modules, or accessory wiring. The manual is essential for diagnosis.

📚 Vehicle History

Brand Heritage

Heritage:

Harley-Davidson has a long-standing history of producing iconic motorcycles, particularly in the touring segment, dating back to the early 20th century. The Touring line is a direct descendant of the Electra Glide models.

Model Evolution

Evolution Of Touring:

The 2009 models represent the evolution of Harley-Davidson's touring platform, featuring the introduction of the Twin Cam 96 engine and refinements to chassis, suspension, and styling that have defined Harley touring bikes for decades.

Production

Manufacturing Location:

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

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

Harley-Davidson Touring bikes consistently receive accolades for their comfort, touring capability, and iconic styling. While specific awards for the 2009 model year might be less documented than modern bikes, the platform has a long history of enthusiast and critical appreciation.