🏷️ Basic Information

Make:

Harley-Davidson

Model:

FLST Heritage Softail

Year:

2009

Market Designation:

Brazil Only

👋 Introduction

Target Audience:

Harley-Davidson FLST Heritage Softail owners and independent repair shops focusing on this model.

Value Proposition:

Provides comprehensive, factory-accurate information for maintenance, diagnosis, and repair, enabling owners to perform their own servicing or for shops to work efficiently.

Alternatives:

Generic aftermarket repair manuals, online forums, and dealership service departments. This manual offers official factory data.

Completeness:

Official factory documentation ensures accuracy and completeness for all service procedures.

Print Flexibility:

Allows users to print only the necessary pages, reducing paper usage and cost.

Historical Accuracy:

Directly addresses the 2009 model year, ensuring relevance for that specific production run.

📋 Manual Details

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

Printable (digital format implied)

Page Count:

Hundreds of pages (specific number not provided, but implies comprehensive)

📖 Manual Coverage

Engine:

Detailed breakdown of the Twin Cam 96 engine, including disassembly, inspection, assembly, and torque specifications.

Fuel System:

Includes procedures for fuel injection system (EFI), fuel pump, fuel tank, and fuel lines.

Ignition System:

Covers ignition module, spark plugs, and related components for proper timing and performance.

Transmission:

Comprehensive coverage of the 6-speed Cruise Drive transmission, including clutch, gearbox, and final drive.

Chassis:

Details on frame, suspension (front fork, rear shock absorbers), steering, and wheel bearings.

Brakes:

In-depth information on hydraulic brake systems, including front and rear calipers, master cylinders, brake lines, and bleeding procedures.

Electrical System:

Extensive coverage of wiring diagrams, lighting, battery, charging system (alternator, regulator), starting system, and diagnostics.

Bodywork And Fittings:

Instructions for disassembly and reassembly of body panels, fenders, fuel tank, seat, and accessories.

Routine Maintenance:

Oil changes, filter replacements, lubrication points, chain adjustment (if applicable), and fluid level checks.

Scheduled Maintenance:

Detailed intervals and procedures for major service points as recommended by Harley-Davidson.

Troubleshooting:

Systematic diagnostic procedures for identifying and resolving common and complex issues.

Engine Repair:

Complete overhaul procedures for the Twin Cam 96 engine, including piston, ring, valve, and cylinder head service.

Transmission Repair:

Disassembly, inspection, and reassembly of the 6-speed transmission, including gear inspection and bearing replacement.

Suspension Service:

Fork seal replacement, shock absorber inspection and replacement, and steering head bearing adjustment.

Brake System Service:

Brake pad replacement, caliper service, master cylinder rebuild, and brake fluid bleeding.

Electrical Diagnostics:

Troubleshooting for starting, charging, lighting, and ignition system faults using wiring diagrams.

Diagnostic Capabilities:

Includes diagnostic codes, fault finding charts, and specific testing procedures for various electrical and mechanical systems.

Rebuild Procedures:

Detailed, step-by-step instructions for complete engine and transmission rebuilds.

Torque Specifications:

Provides precise torque values for critical fasteners throughout the motorcycle.

Special Tools:

Lists and describes specialized tools required for specific repair and maintenance tasks.

📊 Manual Specifications

Digital Format:

PDF (assumed for printability, typical for this type of product)

Searchability:

Likely searchable text for efficient information retrieval.

Page Layout:

Designed for clear printing, allowing users to select and print specific sections or the entire manual.

Physical Manual Binding:

N/A (digital product, but often implies coil-bound or similar for printed versions for lay-flat usability)

Physical Manual Paper:

N/A (digital product, but factory manuals often use durable, high-quality paper)

⚙️ Engine Specifications

Engine Type:

Harley-Davidson Twin Cam 96

Configuration:

Air-cooled, 45-degree 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), pushrod actuated, two valves per cylinder

Horsepower:

Approx. 70-75 HP (at crankshaft, specific figures vary by tuning and dyno)

Torque:

Approx. 90-95 ft-lbs (at crankshaft, specific figures vary)

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

Unleaded gasoline, minimum 91 octane (RON+MON)/91 AKI

Fuel Capacity:

18.9 L (5.0 US gal)

🔧 Transmission

Transmission Type:

6-speed Cruise Drive

Clutch Type:

Clutch, wet, multi-plate, hydraulic actuation

Gear Ratios:

1st: 9.593, 2nd: 6.650, 3rd: 4.934, 4th: 3.826, 5th: 3.151, 6th: 2.435

Final Drive:

Belt drive, 32/46 ratio (32 tooth front, 46 tooth rear pulley)

Transmission Fluid:

Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant (or equivalent API GL-5 rated SAE 75W-90 synthetic gear oil)

Primary Chaincase Fluid:

Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant (or equivalent API GL-5 rated SAE 75W-90 synthetic gear oil)

📐 Dimensions

Overall Length:

2360 mm (92.7 in)

Seat Height:

660 mm (26.0 in)

Ground Clearance:

135 mm (5.3 in)

Dry Weight:

320 kg (705 lbs)

Gross Vehicle Weight Rating:

Not specified in product info, but typically around 510 kg (1125 lbs)

Front Tire:

130/90B16 67H

Rear Tire:

150/80B16 77H

Front Wheel:

16-inch wire-spoke

Rear Wheel:

16-inch wire-spoke

🛡️ Safety Features

Crash Test Results:

N/A for motorcycles as per industry standards.

Braking System:

Dual-action, front and rear hydraulic disc brakes.

Lighting:

Halogen headlight, LED tail lamp, front and rear turn signals.

Frame Construction:

Steel, tubular, cradle frame designed for stability and rider control.

Ergonomics:

Designed for comfortable rider posture and control, contributing to safe operation.

💡 Technology Features

Audio System:

Optional accessory audio systems may be available, but not standard on all models of this era. The manual would cover installation and basic troubleshooting of factory-installed accessories if present.

ABS:

Anti-lock Braking System (ABS) was an optional feature for the 2009 Softail models. The manual will detail its operation and service if equipped.

Diagnostics:

The manual provides the technical foundation for using diagnostic tools to read engine codes and monitor sensor data, essential for modern EFI systems.

🔧 Maintenance

Initial Service:

Typically at 1,000 miles (1,600 km) for break-in service, including an oil and filter change.

Routine 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 as recommended.

Primary Chaincase Fluid Change:

Every 10,000 miles (16,000 km) or as recommended.

Engine Oil:

Harley-Davidson SYN3 Full Synthetic Motorcycle Oil (SAE 20W-50) or equivalent API CI-4 rated synthetic or conventional oil.

Engine Oil Capacity:

3.5 US quarts (3.3 liters) with filter change.

Brake Fluid:

DOT 4 Hydraulic Fluid.

Cam Chain Tensioner Wear:

Early Twin Cam models (pre-2007) experienced wear on the hydraulic cam chain tensioners. While the Twin Cam 96 (2007+) uses improved tensioners, inspection is still prudent. The manual will detail inspection and replacement procedures.

Oil Leaks:

Like many motorcycles, leaks can occur from seals and gaskets. The manual provides detailed instructions for identifying and replacing leaking components.

Clutch Adjustment:

Proper clutch adjustment is crucial for smooth operation. The manual covers the procedure for adjusting the clutch cable or hydraulic clutch.

📚 Vehicle History

Founding Year:

1903

Brand Identity:

Iconic American motorcycle manufacturer known for its cruiser and touring models.

Softail Lineage:

The Softail platform, introduced in 1983, is characterized by its hidden rear shock absorbers, giving a hardtail appearance. The Heritage Softail models are known for their classic styling with modern performance.

Twin Cam Introduction:

The Twin Cam engine platform was introduced in 1999, evolving into the Twin Cam 96 in 2007 with increased displacement and performance.

Manufacturing Plant:

Typically manufactured in Milwaukee, Wisconsin, USA, and York, Pennsylvania, USA.

Model Year Changes 2009:

While specific Brazil-only changes are rare to document publicly, 2009 models generally featured the Twin Cam 96 engine, 6-speed transmission, and a range of classic styling cues. Minor updates to features or colors are common.

🏆 Awards & Recognition

Harley Davidson Legacy:

Harley-Davidson motorcycles, particularly the Softail line, are widely recognized for their iconic styling, build quality, and rider experience, often earning accolades within the motorcycle enthusiast community.

Customer Satisfaction:

Generally high, though specific ratings vary. The availability of a comprehensive service manual directly contributes to owner satisfaction by enabling reliable maintenance.

Manual Standard:

Adheres to automotive service documentation standards, providing accurate and detailed technical information.