Manual Coverage
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Systems Covered
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Engine Mechanical:
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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.
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Fuel System:
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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.
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Transmission:
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6-speed Cruise Drive transmission service, including clutch operation, gear inspection, shifting mechanism, and final drive (belt drive) maintenance.
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Electrical System:
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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.
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Brakes:
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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.
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Suspension:
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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.
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Body And Frame:
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Frame inspection, fairing removal and installation, saddlebag service, fuel tank mounting, seat service, and general chassis component inspection.
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Diagnostics:
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Extensive diagnostic procedures for common and uncommon issues, fault code interpretation, component testing, and troubleshooting flowcharts specific to the 2009 touring platform.
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Procedures Included
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Routine Maintenance:
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Oil changes (engine, transmission, primary drive), filter replacements, air filter cleaning/replacement, spark plug service, lubrication points, and tire pressure checks.
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Engine Repair:
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Top-end rebuilds (cylinder heads, pistons), bottom-end overhauls (crankshaft, connecting rods), cam bearing replacement, and timing procedures.
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Transmission Repair:
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Clutch assembly replacement, gear set service, bearing replacement, and seal repairs.
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Electrical Diagnostics:
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Troubleshooting electrical faults using schematics, testing individual components (sensors, actuators, switches), and diagnosing system malfunctions with specific fault codes.
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Brake Service:
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Brake pad replacement, rotor inspection and replacement, brake line bleeding (including ABS systems), and master cylinder seal replacement.
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Suspension Overhaul:
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Front fork seal replacement, oil change, spring inspection, and rear shock absorber adjustment and replacement.
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Bodywork Repair:
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Fairing repair and painting, saddlebag latch and hinge service, and mounting hardware replacement.
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Troubleshooting Guides:
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Systematic troubleshooting flowcharts for various performance and operational issues.
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Technical Depth
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Depth Level:
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Comprehensive, from basic routine maintenance and troubleshooting to complete engine and transmission rebuilds. Covers all aspects of vehicle repair and maintenance.
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Diagnostic Capabilities:
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Includes specific diagnostic tools, procedures, and interpretations for Harley-Davidson's EFI systems (e.g., Delphi). Detailed electrical schematics with component identification.
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Repair Procedures:
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Step-by-step instructions with clear diagrams and torque specifications for all repair operations.
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Special Tools:
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Lists and descriptions of required Harley-Davidson factory-specialty tools and their usage for specific procedures.
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Maintenance
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Service Intervals
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Initial Service:
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Typically at 1,000 miles (1,600 km) - includes oil change, primary chain case inspection, and general inspection.
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Regular Service:
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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.
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Major Service:
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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).
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Fluid Specifications
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Engine Oil:
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Harley-Davidson SYN3 Full Synthetic Motorcycle Oil (20W50) or equivalent SAE 20W50 API CI-4 Plus or higher rated engine oil.
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Transmission Fluid:
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Harley-Davidson Formula+ Transmission and Primary Chain Case Lubricant or SAE 80W90 Hypoid gear oil (API GL-4).
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Primary Chain Case Lubricant:
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Harley-Davidson Formula+ Transmission and Primary Chain Case Lubricant or SAE 80W90 Hypoid gear oil (API GL-4).
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Brake Fluid:
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DOT 4, Harley-Davidson Heavy Duty Brake Fluid.
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Coolant:
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N/A (Air-cooled engines)
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Known Issues
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Common Wear Items:
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Clutch wear, brake pad wear, battery life, tire wear, fork seal leaks, exhaust gasket leaks, potential voltage regulator issues.
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Electrical Gremlins:
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Can sometimes occur with complex wiring harnesses, hence the importance of the electrical diagnostic manual for troubleshooting.
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Engine Vibration:
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Characteristic of V-twin engines, but excessive vibration can indicate mounting or internal balance issues.
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