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Harley Davidson FLHR Road King 2009 Workshop Service Manual

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$133.00
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$133.00
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The 2009 FLHR Road King is an iconic cruiser touring motorcycle, celebrated for its timeless styling, comfortable long-distance capabilities, and the distinctive rumble of its Twin Cam 96 V-Twin engine. This model embodies the freedom and heritage associated with the brand, offering a customizable platform for riders who appreciate a classic aesthetic combined with reliable performance. Its robust construction and thoughtful design make it a popular choice for both spirited rides and extended journeys, appealing to those who seek an authentic American motorcycle experience. This comprehensive workshop service manual provides detailed guidance for the maintenance, repair, and troubleshooting of the 2009 FLHR Road King. It covers all major systems, including the Twin Cam 96 engine, 6-speed Cruise Drive transmission, drivetrain, braking, suspension, and electrical systems, alongside bodywork and fuel systems. With step-by-step procedures, diagnostic information, and technical specifications, this manual serves as an indispensable resource for owners and technicians alike, ensuring the longevity and optimal performance of the vehicle. 🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHR Road King Year: 2009 Codes Chassis Code: FLHR Engine Code: TWIN CAM 96 👋 Introduction Market Position Segment: Cruiser Touring Target Audience: Harley-Davidson owners seeking to perform their own maintenance and repairs, independent motorcycle repair shops. Competitive Analysis Competitors: Indian Chief, Victory Kingpin Key Features Vehicle Appeal: Iconic styling, comfortable touring capability, V-twin rumble, customizable platform. Manual Value: Provides essential technical data and procedures for maintaining and repairing the Harley-Davidson FLHR Road King, saving time and money on dealership service. 📋 Manual Details Coverage Areas Primary Coverage: Repair, Maintenance, Troubleshooting, Diagnostics, Electrical System, Engine, Transmission, Drivetrain, Chassis, Suspension, Brakes, Fuel System, Ignition System, Cooling System, Exhaust System, Bodywork, Wiring Diagrams Page Count Total Pages: 702 Manual Type Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Twin Cam 96 V-Twin Engine, Engine Disassembly/Reassembly, Cylinder Head, Piston, Connecting Rod, Crankshaft, Camshaft, Valvetrain, Lubrication System, Oil Pump, Oil Cooler, Oil Filter Transmission: 6-Speed Cruise Drive Transmission, Transmission Disassembly/Reassembly, Clutch, Primary Drive, Gearbox Components, Shifting Mechanism Drivetrain: Belt Drive System, Rear Pulley, Drive Belt Inspection and Replacement, Wheel Bearings Brakes: Front and Rear Hydraulic Brake Systems, Brake Caliper Overhaul, Master Cylinders, Brake Lines, Brake Pads, Brake Discs, ABS System (if equipped) Suspension: Front Fork (Telescopic), Rear Shock Absorbers, Suspension Adjustment, Fork Seal Replacement, Shock Absorber Replacement Electrical: Complete Electrical System Schematics, Battery, Charging System (Alternator/Regulator), Ignition System (Sparks Plugs, Coils), Starting System (Starter Motor), Lighting (Headlight, Taillight, Signals), Horn, Instrumentation, Gauges, Security System (H-D Smart Security System), Diagnostic Codes, EFI System (Fuel Injection) Fuel System: Fuel Tank, Fuel Pump, Fuel Filter, Fuel Injectors, Throttle Body, Idle Air Control (IAC) Motor Bodywork: Fairing, Saddlebags, Fenders, Seat, Handlebars, Controls, Paint and Finish Repair, Body Panel Removal/Installation Procedures Included Maintenance: Oil Changes, Filter Replacements, Spark Plug Replacement, Air Filter Cleaning/Replacement, Tire Pressure Checks, Chain/Belt Adjustment, Brake Fluid Flush, Battery Maintenance, General Inspection Troubleshooting: Systematic Diagnostic Procedures for Common and Uncommon Issues, Fault Code Interpretation, Symptom-Based Troubleshooting Guides Repair: Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation for all major systems. Diagnostics: Detailed procedures for using diagnostic tools (e.g., HD-VCI, diagnostic scan tools), interpreting diagnostic data, and performing system tests. Technical Depth Depth: Comprehensive coverage from basic routine maintenance to complete engine and transmission overhauls, including detailed specifications, torque values, and tolerances. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Likely Searchable (dependent on scan quality) Print Quality Resolution: Typically high for digital manuals, ensuring clarity of diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, Twin Cam 96 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 Valvetrain: Pushrod actuated, overhead valves, 2 valves per cylinder Performance Horsepower: Approx. 70 HP (at rear wheel, typical) Torque: Approx. 85 ft-lbs (at rear wheel, typical) Fuel System Fuel Delivery: Electronic Sequential Port Fuel Injection (ESPFI) Fuel Type: Unleaded gasoline, minimum 91 octane Lubrication Oil Type: Harley-Davidson SYN3 (Full Synthetic) or SAE 20W50 Motorcycle Oil Oil Capacity: 3.7 U.S. quarts (3.5 liters) with filter change Ignition Ignition System: High-performance electronic ignition Spark Plugs: Harley-Davidson recommended (e.g., NGK DCPR8E) 🔧 Transmission Standard Transmission Type: 6-speed Cruise Drive Optional Optional Transmission: N/A Features Gear Ratios: 1st: 9.311, 2nd: 6.438, 3rd: 4.795, 4th: 3.824, 5th: 3.207, 6th: 2.750 Primary Drive: Patented diaphragm spring clutch, 34 tooth. Primary chain drive to transmission, 32 tooth. (Ratio 1.07:1) Final Drive: Enclosed Belt Drive, 32 tooth. Rear pulley, 70 tooth. (Ratio 2.1875:1) Fluid Specifications Transmission Oil: Harley-Davidson Transmission Lubricant (Formula +) or equivalent SAE 80W-90 Hypoid Gear Lubricant Fluid Capacities Transmission Oil Capacity: 2.6 U.S. quarts (2.4 liters) 📐 Dimensions Exterior Length: 93.1 in (2365 mm) Wheelbase:...
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Harley Davidson FLHR Road King 2009 Workshop Service ManualHarley Davidson FLHR Road King 2009 Workshop Service ManualHarley Davidson FLHR Road King 2009 Workshop Service ManualHarley Davidson FLHR Road King 2009 Workshop Service Manual
The 2009 FLHR Road King is an iconic cruiser touring motorcycle, celebrated for its timeless styling, comfortable long-distance capabilities, and the distinctive rumble of its Twin Cam 96 V-Twin engine. This model embodies the freedom and heritage associated with the brand, offering a customizable platform for riders who appreciate a classic aesthetic combined with reliable performance. Its robust construction and thoughtful design make it a popular choice for both spirited rides and extended journeys, appealing to those who seek an authentic American motorcycle experience. This comprehensive workshop service manual provides detailed guidance for the maintenance, repair, and troubleshooting of the 2009 FLHR Road King. It covers all major systems, including the Twin Cam 96 engine, 6-speed Cruise Drive transmission, drivetrain, braking, suspension, and electrical systems, alongside bodywork and fuel systems. With step-by-step procedures, diagnostic information, and technical specifications, this manual serves as an indispensable resource for owners and technicians alike, ensuring the longevity and optimal performance of the vehicle.
🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FLHR Road King
Year:
2009
Codes
Chassis Code:
FLHR
Engine Code:
TWIN CAM 96
👋 Introduction
Market Position
Segment:
Cruiser Touring
Target Audience:
Harley-Davidson owners seeking to perform their own maintenance and repairs, independent motorcycle repair shops.
Competitive Analysis
Competitors:
Indian Chief, Victory Kingpin
Key Features
Vehicle Appeal:
Iconic styling, comfortable touring capability, V-twin rumble, customizable platform.
Manual Value:
Provides essential technical data and procedures for maintaining and repairing the Harley-Davidson FLHR Road King, saving time and money on dealership service.
📋 Manual Details
Coverage Areas
Primary Coverage:
Repair, Maintenance, Troubleshooting, Diagnostics, Electrical System, Engine, Transmission, Drivetrain, Chassis, Suspension, Brakes, Fuel System, Ignition System, Cooling System, Exhaust System, Bodywork, Wiring Diagrams
Page Count
Total Pages:
702
Manual Type
Type:
Workshop Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Twin Cam 96 V-Twin Engine, Engine Disassembly/Reassembly, Cylinder Head, Piston, Connecting Rod, Crankshaft, Camshaft, Valvetrain, Lubrication System, Oil Pump, Oil Cooler, Oil Filter
Transmission:
6-Speed Cruise Drive Transmission, Transmission Disassembly/Reassembly, Clutch, Primary Drive, Gearbox Components, Shifting Mechanism
Drivetrain:
Belt Drive System, Rear Pulley, Drive Belt Inspection and Replacement, Wheel Bearings
Brakes:
Front and Rear Hydraulic Brake Systems, Brake Caliper Overhaul, Master Cylinders, Brake Lines, Brake Pads, Brake Discs, ABS System (if equipped)
Suspension:
Front Fork (Telescopic), Rear Shock Absorbers, Suspension Adjustment, Fork Seal Replacement, Shock Absorber Replacement
Electrical:
Complete Electrical System Schematics, Battery, Charging System (Alternator/Regulator), Ignition System (Sparks Plugs, Coils), Starting System (Starter Motor), Lighting (Headlight, Taillight, Signals), Horn, Instrumentation, Gauges, Security System (H-D Smart Security System), Diagnostic Codes, EFI System (Fuel Injection)
Fuel System:
Fuel Tank, Fuel Pump, Fuel Filter, Fuel Injectors, Throttle Body, Idle Air Control (IAC) Motor
Bodywork:
Fairing, Saddlebags, Fenders, Seat, Handlebars, Controls, Paint and Finish Repair, Body Panel Removal/Installation
Procedures Included
Maintenance:
Oil Changes, Filter Replacements, Spark Plug Replacement, Air Filter Cleaning/Replacement, Tire Pressure Checks, Chain/Belt Adjustment, Brake Fluid Flush, Battery Maintenance, General Inspection
Troubleshooting:
Systematic Diagnostic Procedures for Common and Uncommon Issues, Fault Code Interpretation, Symptom-Based Troubleshooting Guides
Repair:
Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation for all major systems.
Diagnostics:
Detailed procedures for using diagnostic tools (e.g., HD-VCI, diagnostic scan tools), interpreting diagnostic data, and performing system tests.
Technical Depth
Depth:
Comprehensive coverage from basic routine maintenance to complete engine and transmission overhauls, including detailed specifications, torque values, and tolerances.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Likely Searchable (dependent on scan quality)
Print Quality
Resolution:
Typically high for digital manuals, ensuring clarity of diagrams and text.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, Twin Cam 96 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
Valvetrain:
Pushrod actuated, overhead valves, 2 valves per cylinder
Performance
Horsepower:
Approx. 70 HP (at rear wheel, typical)
Torque:
Approx. 85 ft-lbs (at rear wheel, typical)
Fuel System
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane
Lubrication
Oil Type:
Harley-Davidson SYN3 (Full Synthetic) or SAE 20W50 Motorcycle Oil
Oil Capacity:
3.7 U.S. quarts (3.5 liters) with filter change
Ignition
Ignition System:
High-performance electronic ignition
Spark Plugs:
Harley-Davidson recommended (e.g., NGK DCPR8E)
🔧 Transmission
Standard
Transmission Type:
6-speed Cruise Drive
Optional
Optional Transmission:
N/A
Features
Gear Ratios:
1st: 9.311, 2nd: 6.438, 3rd: 4.795, 4th: 3.824, 5th: 3.207, 6th: 2.750
Primary Drive:
Patented diaphragm spring clutch, 34 tooth. Primary chain drive to transmission, 32 tooth. (Ratio 1.07:1)
Final Drive:
Enclosed Belt Drive, 32 tooth. Rear pulley, 70 tooth. (Ratio 2.1875:1)
Fluid Specifications
Transmission Oil:
Harley-Davidson Transmission Lubricant (Formula +) or equivalent SAE 80W-90 Hypoid Gear Lubricant
Fluid Capacities
Transmission Oil Capacity:
2.6 U.S. quarts (2.4 liters)
📐 Dimensions
Exterior
Length:
93.1 in (2365 mm)
Wheelbase:
63.5 in (1615 mm)
Seat Height Laden:
26.5 in (673 mm)
Ground Clearance:
5.1 in (130 mm)
Handlebars Rise:
1.8 in (46 mm)
Handlebars Pullback:
3.1 in (79 mm)
Weights
Dry Weight:
720 lbs (326.6 kg)
Wet Weight:
752 lbs (341.1 kg)
Gross Vehicle Weight Rating Gvwr:
1280 lbs (580 kg)
Cargo
Saddlebag Capacity:
Approx. 2.2 cubic feet total
Wheels Tires
Front Tire:
Dunlop D402F MH90-21 56H
Rear Tire:
Dunlop D401 HW 150/80B16 71H
Front Wheel:
16-inch chrome aluminum spoke wheel
Rear Wheel:
16-inch chrome aluminum spoke wheel
🛡️ Safety Features
Ratings
Crash Safety:
Motorcycle safety is primarily rider responsibility. Focus on active safety features and proper maintenance.
Active Features
Brakes:
Dual-Disc Front Brakes, Single-Disc Rear Brake. Optional ABS (Anti-lock Braking System) available.
Lighting:
Large Halogen Headlight, Rear Taillight, Front and Rear Turn Signals.
Passive Features
Frame Construction:
Steel frame and swingarm for rigidity and stability.
Ergonomics:
Forward-mounted foot controls, comfortable rider triangle, windscreen for wind deflection.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM radio with CB/Intercom capability and Weatherband. Often equipped with fairing speakers and handlebar-mounted controls.
Display:
Analog gauges with a small LCD display for odometer, trip meter, and gear indication.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) available on some configurations.
Connectivity
Cruise Control:
Electronic cruise control is a standard feature on the FLHR Road King model.
Diagnostics
Diagnostic Interface:
Vehicle Communication Interface (VCI) port for use with Harley-Davidson diagnostic software.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first.
Transmission Oil Change:
Every 10,000 miles (16,000 km) or 12 months.
Primary Chain Case Oil Change:
Every 10,000 miles (16,000 km) or 12 months.
Spark Plug Replacement:
Every 10,000 miles (16,000 km).
Air Filter Cleaning:
Inspect every 5,000 miles (8,000 km), clean or replace as needed.
Brake Fluid Flush:
Every 2 years, regardless of mileage.
Fluid Specifications
Engine Oil:
Harley-Davidson SYN3 (Full Synthetic) or SAE 20W50 Motorcycle Oil
Transmission Oil:
Harley-Davidson Transmission Lubricant (Formula +) or SAE 80W-90 Hypoid Gear Lubricant
Primary Chain Case Oil:
Harley-Davidson Primary Chain Case Lubricant (Formula +) or SAE 80W-90 Hypoid Gear Lubricant
Brake Fluid:
DOT 4 (for ABS models, check manual for specific recommendations)
Known Issues
Common Problems:
Cam chain tensioner wear (early Twin Cam models, addressed by later designs), primary compensator issues, potential fuel injector issues, regulator/stator failures are known to occur on many Harley models. The 2009 models are generally robust but benefit from regular preventative maintenance.
📚 Vehicle History
Brand Heritage
Heritage:
Harley-Davidson has a long-standing reputation for building iconic American motorcycles, synonymous with freedom and the open road.
Model Evolution
Road King Lineage:
The Road King line has been a staple of Harley-Davidson's touring lineup since the early 1990s, evolving to incorporate modern technology while retaining classic styling.
Production
Manufacturing Location:
York, Pennsylvania, USA and Milwaukee, Wisconsin, USA (assembly)
🏆 Awards & Recognition
Recognitions
Market Reputation:
The Harley-Davidson Road King is consistently recognized as a benchmark in the cruiser touring segment for its blend of classic style and long-distance comfort.
Ratings
Consumer Satisfaction:
Generally high consumer satisfaction, often cited for its rider experience and build quality.
Certifications
Manual Certification:
N/A (Third-party publication of workshop manual)
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