Harley Davidson Touring 2009 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: Harley-Davidson Model: Touring Year: 2009 Platform: Harley-Davidson Touring Codes Model Codes: FLHR, FLHTC, FLHTCU, FLHTK, FLHX, FLHTCUTG 👋 Introduction Market Position Segment: Premium Grand Touring Motorcycles Competitive Analysis Competitors: Indian Motorcycles, Honda Gold Wing, BMW R 1200 RT, Yamaha Star Venture Key Features Touring Platform: Designed for long-distance comfort and luggage capacity, iconic V-twin engine, comfortable riding position 📋 Manual Details Coverage Areas General Coverage: All Models, All Engines, All Trims Page Count Estimated Page Count: Approximately 1000+ Manual Type Type: Workshop Repair and Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine And Powertrain: Engine assembly, disassembly, diagnosis, tuning, fuel system (EFI), ignition system, exhaust system, transmission, clutch, final drive Chassis And Suspension: Frame, front suspension (forks), rear suspension (shocks), wheels, tires, steering system, brakes (front and rear, ABS) Electrical And Electronics: Wiring diagrams, battery, charging system (alternator, regulator), starting system (starter motor), lighting, gauges, instrument cluster, audio system, security system, ABS control module, electronic fuel injection (EFI) controller Body And Trim: Fairings, saddlebags, tour-pak, seat, fenders, fuel tank, controls, levers, mirrors Procedures Included Maintenance: Scheduled maintenance, fluid changes (oil, brake fluid, transmission fluid, primary lubricant), filter replacements, lubrication, inspections Repair: Engine rebuild, transmission overhaul, brake caliper replacement, fork seal replacement, electrical component diagnosis and replacement, bodywork repair Troubleshooting: Diagnostic flowcharts for common issues, electrical system fault finding, engine performance problems, starting issues, braking system faults Diagnostics: Detailed diagnostic procedures for EFI, ignition, charging system, ABS, and other electronic systems using diagnostic codes (DTCs) and testing methods. Assembly Disassembly: Step-by-step instructions for component removal and installation, including torque specifications for all fasteners. Technical Depth Depth: Comprehensive from basic checks to full engine and transmission rebuilds, including detailed diagnostic procedures and specifications Specific Procedures: Valve adjustment, piston ring replacement, cylinder honing, crankshaft inspection, steering head bearing adjustment, wheel bearing replacement, brake bleeding, clutch adjustment. 📊 Manual Specifications File Format Quality: High-resolution PDF, searchable text, printable pages Searchability: Full text search capability for quick information retrieval Print Quality Fidelity: Designed for clear reproduction of diagrams and text Binding Type N/A: N/A (Digital PDF) Paper Type N/A: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled Twin Cam 96 V-Twin (for most models) Displacement: 96 cubic inches (1584cc) Bore X Stroke: 3.75 in. x 4.38 in. (95.25 mm x 111.25 mm) Compression Ratio: 8.2:1 Performance Horsepower: Approximately 78 HP @ 5500 RPM (estimated, varies by model/tune) Torque: Approximately 92 ft-lb (125 Nm) @ 3500 RPM (estimated, varies by model/tune) Fuel System Fuel Delivery: Electronic Sequential Port Fuel Injection (ESPFI) Fuel Type: Unleaded gasoline, 91 octane (R+M)/2 or higher recommended Lubrication Oil Type: Harley-Davidson SYN3 Synthetic SAE 20W50 or equivalent V-Twin motorcycle oil Cooling System: Air-cooled 🔧 Transmission Standard Type: 6-speed Cruise Drive Manual Optional Availability: N/A for this model year (standard 6-speed manual) Features Clutch Type: Clutch, multi-plate wet Final Drive: Belt Drive Fluid Specifications Transmission Oil Type: Harley-Davidson Formula+ Transmission & Primary Chain Case Lubricant (or equivalent SAE 50 motorcycle oil) Fluid Capacities Transmission Oil Capacity: Approx. 24 US fl oz (0.71 L) Primary Lubricant Capacity: Approx. 3 US pints (1.42 L) 📐 Dimensions Exterior Length: Varies by model (e.g., FLHTCU approx. 103.7 in / 2634 mm) Wheelbase: Varies by model (e.g., FLHTCU approx. 63.5 in / 1613 mm) Ground Clearance: Varies by model (e.g., approx. 5.1 in / 130 mm) Weights Dry Weight: Varies by model (e.g., FLHTCU approx. 838 lbs / 380 kg) Gross Vehicle Weight Rating: Varies by model (e.g., approx. 1360 lbs / 617 kg) Fuel Capacity: 6 US gallons (22.7 L) Cargo Saddlebag Capacity: Integrated, lockable Tour Pak Capacity: Integrated, lockable (on applicable models) 🛡️ Safety Features Ratings N/A: Motorcycles typically do not receive NHTSA or IIHS ratings. Active Features Brakes: Optional Anti-lock Braking System (ABS) available on many models Lighting: Halogen headlight, LED taillight and brake lights, turn signals Passive Features Chassis Stability: Low center of gravity, robust frame construction Security: Harley-Davidson Smart Security System with proximity-based, hands-free fob 💡 Technology Features Infotainment Audio System: Integrated Boom! Box infotainment system with AM/FM/Weather band, CB radio (on applicable models), optional CD player, auxiliary input. Display: Multi-function LCD screen with analog gauges Driver Assistance Cruise Control: Electronic Cruise Control Connectivity Device Integration: Auxiliary input for MP3 players/smartphones 🔧 Maintenance Service Intervals First Service: 1,000 miles (1,600 km) or 6 months Subsequent Service: Every 5,000 miles (8,000 km) or 12 months, whichever comes first Fluid Specifications Engine Oil Type: Harley-Davidson SYN3 Synthetic SAE 20W50 or equivalent Brake Fluid Type: DOT 4 for front and rear brake systems Clutch Fluid Type: DOT 4 for hydraulic clutch systems Fluid Capacities Engine Oil Capacity: Approx. 4 US quarts (3.8 L) Known Issues Common Concerns 2009 Touring: Cam chain tensioner wear (especially earlier Twin Cam engines), potential for starter...
Engine rebuild, transmission overhaul, brake caliper replacement, fork seal replacement, electrical component diagnosis and replacement, bodywork repair
Troubleshooting:
Diagnostic flowcharts for common issues, electrical system fault finding, engine performance problems, starting issues, braking system faults
Diagnostics:
Detailed diagnostic procedures for EFI, ignition, charging system, ABS, and other electronic systems using diagnostic codes (DTCs) and testing methods.
Assembly Disassembly:
Step-by-step instructions for component removal and installation, including torque specifications for all fasteners.
Technical Depth
Depth:
Comprehensive from basic checks to full engine and transmission rebuilds, including detailed diagnostic procedures and specifications
Specific Procedures:
Valve adjustment, piston ring replacement, cylinder honing, crankshaft inspection, steering head bearing adjustment, wheel bearing replacement, brake bleeding, clutch adjustment.
Varies by model/configuration, consult manual for specific part number.
📚 Vehicle History
Brand Heritage
Legacy:
Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer known for its V-twin engines and distinctive styling.
Model Evolution
Touring Lineage:
The Touring platform has evolved significantly over decades, consistently representing Harley-Davidson's flagship for long-distance travel and comfort.
Production
Manufacturing Location:
USA (York, Pennsylvania; Milwaukee, Wisconsin; Kansas City, Missouri)
2009 Updates:
The 2009 models saw refinements to the Twin Cam 96 powertrain, chassis updates for improved handling, and technology integration.
🏆 Awards & Recognition
Recognitions
Brand Accolades:
Harley-Davidson consistently ranks high in customer satisfaction for large-displacement motorcycles. Specific awards for the 2009 model year are often tied to overall model line performance and sales.
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