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2009 Harley-Davidson Touring Models Service Repair Manual + Electrical Diagnostical Manual FLHR FLHT (Free Preview Highly Detailed FSM Total 1493 Pages Searchable Indexed PDF) Download

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Basic Information Identification Make: Harley-Davidson Model: Touring Year: 2009 Sub Models Covered: FLHR (Road King), FLHT (Electra Glide Standard), FLHTC (Electra Glide Classic), FLHTCU (Electra Glide Ultra Classic), FLHTCU I...
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2009 Harley-Davidson Touring Models Service Repair Manual + Electrical Diagnostical Manual FLHR FLHT (Free Preview Highly Detailed FSM Total 1493 Pages Searchable Indexed PDF) Download
Basic Information
Identification
Make: Harley-Davidson
Model: Touring
Year: 2009
Sub Models Covered: FLHR (Road King), FLHT (Electra Glide Standard), FLHTC (Electra Glide Classic), FLHTCU (Electra Glide Ultra Classic), FLHTCU I (Electra Glide Ultra Classic - Fuel Injection), FLHTCU/I, FLHTP (Road King Police), FLHTPP, FLHRC (Road King Classic), FLHTCRS, FLHTCS (Electra Glide Classic - Fuel Injection), FLHTCUTG (Tri Glide Ultra Classic - for 2009, though not explicitly listed in product name, common for touring manuals to include trike variants)
Codes
Vin Code: 4HD1
Introduction
Market Position
Segment: Premium Grand American Touring Motorcycles
Target Audience: Long-distance riders, touring enthusiasts, and owners who prefer to perform their own maintenance and repairs.
Competitive Analysis
Competitors: Honda Gold Wing, Indian Roadmaster, BMW K1600GTL
Differentiation: Iconic V-twin engine character, extensive customization options, strong dealer network, and a devoted rider community.
Key Features
Vehicle Platform: Harley-Davidson's FL platform, known for its comfortable ride, large fairings, and ample luggage capacity.
Manual Advantage: Provides factory-level detail essential for maintaining and repairing these complex machines, ensuring longevity and optimal performance.
Manual Details
Coverage Areas
Manual Type: Official Full Workshop Service and Repair Manual + Electrical Diagnostical Manual
Language: English
Format: Searchable Indexed PDF
Total Pages: 1493
Preview Status: Highly Detailed Free Preview Available
Manual Coverage
Systems Covered
Engine Mechanical: Disassembly, inspection, repair, and reassembly of Twin Cam 96 (1584cc) and Twin Cam 103 (1690cc) engines (depending on specific touring model variant), including cylinders, pistons, crankshaft, connecting rods, camshafts, and valve train.
Fuel System: Fuel injection (EFI) system diagnostics and repair, including throttle body, fuel injectors, fuel pump, fuel pressure regulator, and fuel lines. Carbureted models (less common for 2009 touring, but potentially for some variants) will have carburetor service.
Transmission: 6-speed Cruise Drive transmission service, including clutch operation, gear inspection, shifting mechanism, and final drive (belt drive) maintenance.
Electrical System: Comprehensive coverage of the entire electrical system, including battery, charging system (alternator, regulator), ignition system, lighting, starter motor, fuses, relays, and all accessory circuits. Detailed wiring diagrams for all models and configurations.
Brakes: Hydraulic brake system service, including front and rear brake calipers, master cylinders, brake lines, brake fluid flush and bleed procedures, and ABS (Anti-lock Braking System) diagnostics if equipped.
Suspension: Front fork (e.g., telescopic, Springer if applicable for specific FL models) overhaul and maintenance, rear shock absorber service and replacement, and suspension adjustment procedures.
Body And Frame: Frame inspection, fairing removal and installation, saddlebag service, fuel tank mounting, seat service, and general chassis component inspection.
Diagnostics: Extensive diagnostic procedures for common and uncommon issues, fault code interpretation, component testing, and troubleshooting flowcharts specific to the 2009 touring platform.
Procedures Included
Routine Maintenance: Oil changes (engine, transmission, primary drive), filter replacements, air filter cleaning/replacement, spark plug service, lubrication points, and tire pressure checks.
Engine Repair: Top-end rebuilds (cylinder heads, pistons), bottom-end overhauls (crankshaft, connecting rods), cam bearing replacement, and timing procedures.
Transmission Repair: Clutch assembly replacement, gear set service, bearing replacement, and seal repairs.
Electrical Diagnostics: Troubleshooting electrical faults using schematics, testing individual components (sensors, actuators, switches), and diagnosing system malfunctions with specific fault codes.
Brake Service: Brake pad replacement, rotor inspection and replacement, brake line bleeding (including ABS systems), and master cylinder seal replacement.
Suspension Overhaul: Front fork seal replacement, oil change, spring inspection, and rear shock absorber adjustment and replacement.
Bodywork Repair: Fairing repair and painting, saddlebag latch and hinge service, and mounting hardware replacement.
Troubleshooting Guides: Systematic troubleshooting flowcharts for various performance and operational issues.
Technical Depth
Depth Level: Comprehensive, from basic routine maintenance and troubleshooting to complete engine and transmission rebuilds. Covers all aspects of vehicle repair and maintenance.
Diagnostic Capabilities: Includes specific diagnostic tools, procedures, and interpretations for Harley-Davidson's EFI systems (e.g., Delphi). Detailed electrical schematics with component identification.
Repair Procedures: Step-by-step instructions with clear diagrams and torque specifications for all repair operations.
Special Tools: Lists and descriptions of required Harley-Davidson factory-specialty tools and their usage for specific procedures.
Manual Specifications
File Format
File Type: PDF
Searchability: Searchable text content
Indexing: Indexed for quick navigation
Print Quality
Resolution: High-resolution scans (assumed for 'highly detailed' description)
Readability: Excellent for on-screen viewing and printing
Binding Type
Physical Format: N/A (Digital Download)
Paper Type
Physical Format: N/A (Digital Download)
Engine Specifications
Primary Engine
Engine Type: Air-cooled, Twin Cam 96 V-twin (1584cc) or Twin Cam 103 V-twin (1690cc), Pushrod actuated overhead valves with hydraulic lifters.
Bore X Stroke: Twin Cam 96: 3.75 in. x 4.38 in. (95.25 mm x 111.25 mm); Twin Cam 103: 3.875 in. x 4.38 in. (98.4 mm x 111.25 mm)
Compression Ratio: Twin Cam 96: 9.2:1; Twin Cam 103: 9.0:1 (typical for 2009 touring models)
Performance
Horsepower: Approx. 70-75 HP (Varies slightly by model and tuning)
Torque: Approx. 92-96 ft-lbs @ 3,000 RPM (Twin Cam 96), Approx. 98-101 ft-lbs @ 3,500 RPM (Twin Cam 103) (Varies slightly by model and tuning)
Fuel System
Fuel Delivery: Electronic Sequential Port Fuel Injection (ESPFI) with closed-loop system.
Fuel Type: Unleaded Premium Gasoline, 91 octane or higher recommended.
Transmission
Standard
Type: 6-speed Cruise Drive
Optional
Type: N/A for 2009 Touring
Features
Clutch: Hydraulic assist, multi-plate wet clutch.
Final Drive: Belt Drive
Fluid Type: Harley-Davidson Formula+ Transmission and Primary Chain Case Lubricant (or equivalent API GL-4, SAE 80W90 gear oil for transmission/primary).
Dimensions
Exterior
Length: Approx. 98.4 in. (2499 mm) (Varies by model, e.g., FLHTCU)
Wheelbase: Approx. 63.5 in. (1613 mm) (Varies by model)
Seat Height: Approx. 28.2 in. (716 mm) (Unladen, Varies by model)
Weights
Dry Weight: Approx. 700-800 lbs (317-363 kg) (Varies significantly by model, e.g., FLHTCU)
Gross Vehicle Weight Rating Gvwr: Approx. 1360 lbs (617 kg)
Cargo
Saddlebag Capacity: Approx. 2.3 cu ft (0.065 m³) total (Varies)
Tour-Pak Capacity: Optional on many models, adds significant cargo volume.
Safety Features
Ratings
Crash Test Data: Motorcycles are not typically subjected to standardized crash testing like automobiles. Safety relies on design, rider skill, and adherence to traffic laws.
Active Features
ABS: Optional on many 2009 Touring models (e.g., RPO code 565). The manual will cover its operation and diagnostics.
Cruise Control: Standard on most 2009 Touring models, electronically controlled.
Passive Features
Lighting: Halogen headlight, auxiliary passing lamps (on some models), LED tail/brake lights, turn signals.
Chassis Stability: Well-balanced chassis designed for highway stability and rider comfort.
Technology Features
Infotainment
Audio System: Integrated AM/FM/WB radio, CD player (optional on some models), CB/Intercom (on Ultra models), and auxiliary input for MP3 players.
Display: Large LCD display for radio, clock, and diagnostics. Older style analog gauges for speedometer and tachometer.
Driver Assistance
ABS: Available Anti-lock Braking System, as detailed in the safety section.
Cruise Control: Electronic cruise control for reduced rider fatigue on long journeys.
Connectivity
Interfaces: Auxiliary input for audio devices.
Diagnostics Port: On-board diagnostics (OBD-II style connector, often referred to as the 'J1850' or 'CAN bus' diagnostic port for modern Harley-Davidsons) for scan tools.
Maintenance
Service Intervals
Initial Service: Typically at 1,000 miles (1,600 km) - includes oil change, primary chain case inspection, and general inspection.
Regular Service: Every 5,000 miles (8,000 km) or annually, whichever comes first. Includes oil change, filter replacement, inspection of brakes, tires, clutch, and all mechanical/electrical components.
Major Service: Specific intervals for spark plug replacement (e.g., 10,000 miles), brake fluid flush (e.g., 2 years), transmission/primary fluid change (e.g., 10,000-20,000 miles depending on use).
Fluid Specifications
Engine Oil: Harley-Davidson SYN3 Full Synthetic Motorcycle Oil (20W50) or equivalent SAE 20W50 API CI-4 Plus or higher rated engine oil.
Transmission Fluid: Harley-Davidson Formula+ Transmission and Primary Chain Case Lubricant or SAE 80W90 Hypoid gear oil (API GL-4).
Primary Chain Case Lubricant: Harley-Davidson Formula+ Transmission and Primary Chain Case Lubricant or SAE 80W90 Hypoid gear oil (API GL-4).
Brake Fluid: DOT 4, Harley-Davidson Heavy Duty Brake Fluid.
Coolant: N/A (Air-cooled engines)
Known Issues
Common Wear Items: Clutch wear, brake pad wear, battery life, tire wear, fork seal leaks, exhaust gasket leaks, potential voltage regulator issues.
Electrical Gremlins: Can sometimes occur with complex wiring harnesses, hence the importance of the electrical diagnostic manual for troubleshooting.
Engine Vibration: Characteristic of V-twin engines, but excessive vibration can indicate mounting or internal balance issues.
Vehicle History
Brand Heritage
Legacy: Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and distinctive styling.
Model Evolution
Touring Lineage: The Touring line has evolved from the early Electra Glide models of the 1960s, progressively incorporating fuel injection, advanced suspension, larger fairings, and amenities for long-distance travel.
Twin Cam Introduction: The Twin Cam engine platform was introduced in 1999, and by 2009, it had become the standard for all Harley-Davidson Big Twin models, including the Touring line.
Production
Manufacturing Location: United States (Various Harley-Davidson assembly plants)
Awards & Recognition
Recognitions
Model Awards: While specific awards for the 2009 model year are not typically highlighted in service manuals, Harley-Davidson Touring models consistently receive accolades for their comfort, capability, and iconic status in motorcycle publications and rider surveys.
Ratings
Owner Satisfaction: Harley-Davidson generally ranks high in owner satisfaction surveys, particularly for its touring models, due to brand loyalty and perceived quality.
Certifications
Emissions Compliance: All models comply with prevailing US EPA and California Air Resources Board (CARB) emissions standards for their respective model year.
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