Harley Davidson FLHR Road King 2009 Workshop Service Manual
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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:...
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.
Provides essential technical data and procedures for maintaining and repairing the Harley-Davidson FLHR Road King, saving time and money on dealership service.
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
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.