🏷️ Basic Information

Make:

Harley-Davidson

Model:

Touring

Year:

2009

Product Type:

Workshop Service Manual / Repair Manual

Manual Code Approximation:

Likely related to Harley-Davidson's internal service manual numbering system for the specific model year and platform.

👋 Introduction

Market Segment:

Luxury touring motorcycles, catering to riders who prioritize comfort, long-distance capability, and iconic American styling.

Key Competitors 2009:

Honda Gold Wing, Indian Chief, Victory Vision Tour, BMW K1600GTL (though GTL arrived later, its predecessors were competitors).

Touring Platform Strengths:

Robust Twin Cam engines, comfortable ergonomics, ample luggage capacity, and a wide range of customization options.

Target Audience:

Professional motorcycle technicians, experienced DIY mechanics, and Harley-Davidson owners seeking in-depth knowledge for maintenance and repair.

📋 Manual Details

Coverage Scope:

Comprehensive coverage for all Harley-Davidson Touring models manufactured in 2009.

Estimated Page Count:

Approximately 800-1200 pages (typical for comprehensive Harley-Davidson workshop manuals).

Manual Type:

Workshop Service Manual / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Service:

Detailed procedures for Twin Cam 96 and Twin Cam 103 engines, including disassembly, inspection, assembly, timing, fuel injection, ignition, lubrication, cooling (air-cooled), and emissions.

Transmission Service:

Coverage for 6-speed Cruise Drive transmission, including internal and external components, clutch operation, and shift mechanisms.

Chassis And Suspension:

Front fork (e.g., FLHR, FLHT, FLHX, FLTR models), rear suspension (shock absorbers, swingarm), wheel bearings, steering head, and frame inspections.

Braking System:

Hydraulic brake system service, including master cylinders, calipers, brake lines, rotors, pads, ABS (if applicable), and bleeding procedures.

Electrical System:

Comprehensive wiring diagrams, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), battery, ignition system, lighting, instrumentation, and accessory circuits.

Fuel System:

Fuel injection system (EFI) diagnostics, fuel pump, injectors, throttle body, and fuel tank servicing.

Body And Fairings:

Installation and removal of fairings, saddlebags, tour-paks, fenders, seats, and other body components.

Diagnostics And Troubleshooting:

Step-by-step troubleshooting guides for common issues, diagnostic trouble codes (DTCs), and use of diagnostic tools.

Routine Maintenance:

Oil changes, filter replacements, spark plug checks/replacement, air filter servicing, primary chain lubrication, and brake fluid flushes.

Component Replacement:

Detailed instructions for replacing specific components such as wheel bearings, brake pads, clutch plates, starter motor, battery, ignition coils, and fuel injectors.

Engine Rebuild:

Complete engine overhaul procedures, including cylinder head removal/installation, piston and ring replacement, crankshaft inspection, and gasket replacement.

Transmission Rebuild:

Disassembly and reassembly of the 6-speed transmission, including gearset servicing and clutch adjustment.

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams, multimeter testing, and component testing procedures.

Suspension Tuning:

Procedures for adjusting front fork oil levels and rear shock preload (if applicable to specific models).

Diagnostic Tool Usage:

Guidance on using Harley-Davidson's Digital Technician or equivalent diagnostic tools.

Depth Of Information:

Highly detailed, covering everything from basic maintenance to complete engine and transmission overhauls, including specifications and tolerances for professional repair.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Print Quality:

High resolution, optimized for clear viewing and printing of diagrams and text.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Text Searchability:

Searchable text content for quick access to specific information.

⚙️ Engine Specifications

Engine Type:

Air-cooled, Twin Cam V-twin

Engine Displacement:

Typically 96 cubic inches (1584cc) and 103 cubic inches (1690cc) for CVO models or specific packages.

Bore X Stroke 96Ci:

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

Bore X Stroke 103Ci:

3.875 in. x 4.38 in. (98.4 mm x 111.25 mm)

Compression Ratio 96Ci:

9.0:1

Compression Ratio 103Ci:

9.7:1 (typical for 103ci)

Horsepower 96Ci:

Approximately 70-75 HP (est.)

Torque 96Ci:

Approximately 90-95 lb-ft @ 3500 RPM (est.)

Horsepower 103Ci:

Approximately 80-85 HP (est.)

Torque 103Ci:

Approximately 100-105 lb-ft @ 3500 RPM (est.)

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

Unleaded gasoline, 91 octane (R+M)/2 or higher recommended.

🔧 Transmission

Transmission Type:

6-speed Cruise Drive constant mesh, helical gears

Clutch Type:

Clutched primary drive, wet multi-plate

Primary Drive:

Duplex chain

Final Drive:

Belt drive

Gear Ratios 6 Speed:

1st: 9.593, 2nd: 6.650, 3rd: 4.943, 4th: 3.827, 5th: 3.158, 6th: 2.790

Transmission Fluid Type:

Harley-Davidson Syn3 Transmission & Primary Fluid or equivalent (e.g., SAE 75W-90 Synthetic Gear Lubricant).

📐 Dimensions

Wheelbase:

63.5 inches (1613 mm) for most models (e.g., FLHT, FLHX, FLHR); 64.4 inches (1635 mm) for FLTR (Road Glide).

Dry Weight:

Approximately 800-850 lbs (363-386 kg) depending on model.

Gvwr:

Typically around 1360 lbs (617 kg).

🛡️ Safety Features

Safety Certification:

Manufactured to meet or exceed all applicable federal motor vehicle safety standards (FMVSS) for motorcycles.

Braking System:

Integrated braking system with dual disc front, single disc rear. Optional ABS (Anti-lock Braking System) available on many models.

Lighting:

Halogen headlight, auxiliary passing lamps (on some models), LED tail/brake lights, turn signals.

Frame Construction:

Steel frame and swingarm construction for stability and durability.

💡 Technology Features

Audio System:

Integrated infotainment systems with AM/FM radio, CD player (optional), CB/intercom (optional), and auxiliary input. Often featured Boom! Box audio systems on higher trims.

Cruise Control:

Electronic cruise control standard on most Touring models.

ABS:

Anti-lock Braking System (ABS) was an option and became more prevalent through the model year.

Diagnostic Port:

Vehicle Communication Module (VCM) port for diagnostics and software updates.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 miles (8,000 km) or 12 months for engine oil and filter. Primary/transmission fluid every 10,000 miles (16,000 km) or 24 months.

Spark Plug Interval:

Inspect every 5,000 miles (8,000 km), replace as needed or at major service intervals (e.g., 20,000 miles).

Belt Tension Check:

Check belt tension and condition every 5,000 miles (8,000 km).

Engine Oil:

Harley-Davidson V-Twin 20W-50 (preferred) or equivalent API CG-4 or higher rated motorcycle oil. Capacity: ~4 quarts (3.8L).

Primary Chain Case Fluid:

Harley-Davidson Syn3 Transmission & Primary Fluid or SAE 75W-90 Synthetic Gear Lubricant. Capacity: ~1 quart (0.95L).

Brake Fluid:

DOT 4 Hydraulic Brake Fluid.

Fork Oil:

Harley-Davidson Formula + or equivalent fork oil (viscosity varies by model and preference).

Common Wear Items:

Clutch plates, front fork seals, wheel bearings, starter solenoid, and exhaust system gaskets can be wear items.

Potential Electrical Concerns:

Older charging systems (regulator/rectifier) can be a point of failure, though less common on Twin Cam than earlier models. Loose electrical connections.

Engine Vibration Management:

Proper balancing and engine mount condition are crucial for managing vibration. Manual covers engine mount inspection.

📚 Vehicle History

Brand Legacy:

Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines, distinctive styling, and rider community.

Touring Platform Development:

The Touring platform evolved from earlier dresser motorcycles, with the introduction of the Twin Cam engine in 1999 marking a significant technological advancement. The 2009 models benefited from ongoing refinements in chassis, suspension, and powertrain.

Manufacturing Location:

Primary manufacturing in York, Pennsylvania, and Milwaukee, Wisconsin, USA.

🏆 Awards & Recognition

Market Reputation:

Harley-Davidson Touring models consistently recognized for their comfort, rider experience, and resale value within the cruiser and touring motorcycle segments.

Owner Satisfaction:

Generally high owner satisfaction ratings for comfort, style, and the overall Harley-Davidson experience.