Harley Davidson Touring Models 2009 Service Manual PDF

For complete service information also see:
Harley Davidson 2019 Touring Models Service Manual
Harley Davidson Touring Models 2017 Service Manual
Harley Davidson Touring Models 2015 Service Manual
Harley Davidson Touring Models 2014 Service Manual
Harley Davidson Touring Models 2010 Service Manual

To avoid unnecessary damage to Harley Davidson Motorcycles Touring Models 2009, you should purchase the PDF Service Manual provided on the website.

This manual will acquaint the user with the construction of the Harley Davidson product and assist in the performance of basic maintenance and repair. It will introduce to the professional Harley Davidson Technician the latest field-tested and factory-approved major repair methods.

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Document Part Number:
99483-09

Models covered:
TOURING MODELS

CONTENTS:

• MAINTENANCE
  • 1.1 FASTENER TORQUE VALUES
  • 1.2 GENERAL
  • 1.3 MAINTENANCE SCHEDULE
  • 1.4 FUEL AND OIL
  • 1.5 BULB REQUIREMENTS
  • 1.6 ENGINE OIL AND FILTER
  • 1.7 PRIMARY CHAIN
  • 1.8 TRANSMISSION LUBRICANT
  • 1.9 AIR CLEANER AND EXHAUST SYSTEM
  • 1.10 TIRES AND WHEELS
  • 1.11 CLUTCH
  • 1.12 REAR BELT AND SPROCKETS
  • 1.13 REAR BELT DEFLECTION
  • 1.14 BRAKES
  • 1.15 BRAKE PADS AND DISCS
  • 1.16 BLEEDING BRAKES
  • 1.17 BATTERY MAINTENANCE
  • 1.18 SUSPENSION ADJUSTMENTS
  • 1.19 FRONT FORK OIL
  • 1.20 SPARK PLUGS
  • 1.21 STEERING HEAD BEARINGS
  • 1.22 CABLE AND CHASSIS LUBRICATION
  • 1.23 HEADLAMP ALIGNMENT
  • 1.24 ENGINE MOUNTS
  • 1.25 STORAGE
  • 1.26 TROUBLESHOOTING
  • 1.27 CRITICAL FASTENERS
• CHASSIS
  • 2.1 FASTENER TORQUE VALUES
  • 2.2 SPECIFICATIONS
  • 2.3 VEHICLE IDENTIFICATION NUMBER (V.I.N.)
  • 2.4 FRONT WHEEL
  • 2.5 REAR WHEEL
  • 2.6 REAR WHEEL COMPENSATOR
  • 2.7 CHECKING RIM RUNOUT
  • 2.8 WHEEL LACING: 16 INCH FRONT RIM
  • 2.9 WHEEL LACING: 16 INCH REAR RIM
  • 2.10 WHEEL LACING: 17 INCH RIM
  • 2.11 SEALED WHEEL BEARINGS
  • 2.12 TRUING LACED WHEELS
  • 2.13 CHECKING CAST WHEEL RUNOUT
  • 2.14 FRONT BRAKE MASTER CYLINDER
  • 2.15 FRONT BRAKE CALIPER
  • 2.16 REAR BRAKE MASTER CYLINDER
  • 2.17 REAR BRAKE CALIPER
  • 2.18 TIRES
  • 2.19 FRONT FORK
  • 2.20 AIR BAFFLE: FLTR
  • 2.21 STEERING HEAD BEARINGS
  • 2.22 REAR AIR SUSPENSION
  • 2.23 REAR SHOCK ABSORBERS
  • 2.24 REAR FORK
  • 2.25 CLUTCH CABLE
  • 2.26 HANDLEBARS
  • 2.27 MIRRORS
  • 2.28 SEAT
  • 2.29 SADDLEBAGS
  • 2.30 SADDLEBAG SERVICE
  • 2.31 TOUR-PAK
  • 2.32 TOUR-PAK SERVICE
  • 2.33 TOUR-PAK LIGHTS
  • 2.34 TOUR-PAK BACKREST
  • 2.35 TOUR-PAK SPEAKER BOX: FLHTCU
  • 2.36 LOWER FAIRING AND ENGINE GUARD
  • 2.37 UPPER FAIRING AND WINDSHIELD: FLHX, FLHT/C/U
  • 2.38 FAIRING CAP: FLHX, FLHT/C/U
  • 2.39 INNER FAIRING: FLHX, FLHT/C/U
  • 2.40 AIR DEFLECTORS
  • 2.41 UPPER FAIRING AND WINDSHIELD: FLTR
  • 2.42 INSTRUMENT BEZEL: FLTR
  • 2.43 INSTRUMENT NACELLE: FLTR
  • 2.44 INNER FAIRING: FLTR
  • 2.45 GLOVE BOX DOOR AND HINGE: FLTR
  • 2.46 WINDSHIELD: FLHR/C
  • 2.47 HEADLAMP NACELLE: FLHR/C
  • 2.48 FRONT FENDER
  • 2.49 REAR FENDER
  • 2.50 REAR FASCIA: FLHX
  • 2.51 REAR FRAME
  • 2.52 FOOTBOARDS AND FOOTRESTS
  • 2.53 JIFFY STAND
  • 2.54 FRONT ENGINE MOUNT
• ENGINE
  • 3.1 FASTENER TORQUE VALUES
  • 3.2 SPECIFICATIONS
  • 3.3 SERVICE WEAR LIMITS
  • 3.4 ENGINE OIL FLOW
  • 3.5 OIL PUMP OPERATION
  • 3.6 BREATHER OPERATION
  • 3.7 OIL PRESSURE
  • 3.8 TROUBLESHOOTING
  • 3.9 HOW TO USE THIS SECTION
  • 3.10 TOP END SERVICE
  • 3.11 BOTTOM END SERVICE
  • 3.12 STRIPPING MOTORCYCLE FOR SERVICE
  • 3.13 ASSEMBLING MOTORCYCLE AFTER SERVICE
  • 3.14 REMOVING ENGINE FROM CHASSIS
  • 3.15 INSTALLING ENGINE IN CHASSIS
  • 3.16 TOP END OVERHAUL: DISASSEMBLY
  • 3.17 TOP END OVERHAUL: ASSEMBLY
  • 3.18 BOTTOM END OVERHAUL: DISASSEMBLY
  • 3.19 BOTTOM END OVERHAUL: ASSEMBLY
  • 3.20 BREATHER ASSEMBLY
  • 3.21 ROCKER ARM SUPPORT PLATE
  • 3.22 PUSH RODS, LIFTERS AND COVERS
  • 3.23 CYLINDER HEAD
  • 3.24 CYLINDER
  • 3.25 PISTON
  • 3.26 CAM SUPPORT PLATE AND COVER
  • 3.27 OIL PUMP
  • 3.28 CRANKCASE
  • 3.29 FLYWHEEL AND CONNECTING RODS
  • 3.30 OIL PAN
• FUEL SYSTEM
  • 4.1 FASTENER TORQUE VALUES
  • 4.2 SPECIFICATIONS: FUEL SYSTEM
  • 4.3 ELECTRONIC FUEL INJECTION (EFI)
  • 4.4 AIR CLEANER ASSEMBLY
  • 4.5 FUEL TANK
  • 4.6 FUEL TANK TOP PLATE
  • 4.7 FUEL FILTER
  • 4.8 FUEL PRESSURE REGULATOR
  • 4.9 FUEL LEVEL SENDER
  • 4.10 TWIST GRIP SENSOR
  • 4.11 THROTTLE CONTROL ACTUATOR (TCA)
  • 4.12 ENGINE TEMPERATURE SENSOR (ET)
  • 4.13 INDUCTION MODULE
  • 4.14 TEMPERATURE MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP)
  • 4.15 OXYGEN SENSORS (O2)
  • 4.16 FUEL INJECTORS
  • 4.17 FUEL PUMP
  • 4.18 FUEL PRESSURE TEST
  • 4.19 EXHAUST SYSTEM
  • 4.20 ACTIVE EXHAUST (HDI)
  • 4.21 INTAKE LEAK TEST
  • 4.22 EVAPORATIVE EMISSIONS CONTROL (CA MODELS)
• DRIVE
  • 5.1 FASTENER TORQUE VALUES
  • 5.2 SPECIFICATIONS: DRIVE
  • 5.3 PRIMARY CHAINCASE COVER
  • 5.4 DRIVE COMPONENTS
  • 5.5 PRIMARY CHAINCASE HOUSING
  • 5.6 CLUTCH
  • 5.7 TRANSMISSION SPROCKET
  • 5.8 DRIVE BELT
• TRANSMISSION
  • 6.1 FASTENER TORQUE VALUES
  • 6.2 SPECIFICATIONS:TRANSMISSION
  • 6.3 TRANSMISSION
  • 6.4 SHIFTER LINKAGE
  • 6.5 CLUTCH RELEASE COVER
  • 6.6 TRANSMISSION ASSEMBLY
  • 6.7 MAIN DRIVE GEAR AND BEARING
  • 6.8 TRANSMISSION CASE
• ELECTRICAL
  • 7.1 FASTENER TORQUE VALUES
  • 7.2 SPECIFICATIONS: ELECTRICAL
  • 7.3 VOLTAGE REGULATOR
  • 7.4 ELECTRONIC CONTROL MODULE (ECM)
  • 7.5 IGNITION COIL
  • 7.6 SYSTEM FUSES AND RELAYS
  • 7.7 ELECTRICAL CADDIES
  • 7.8 SECURITY SIREN
  • 7.9 STARTER
  • 7.10 STARTER SOLENOID
  • 7.11 HEADLAMP: ALL EXCEPT FLTR
  • 7.12 HEADLAMP: FLTR
  • 7.13 AUXILIARY LAMPS AND BRACKETS
  • 7.14 TAIL LAMP
  • 7.15 FENDER TIP LAMPS
  • 7.16 TURN SIGNAL LAMPS
  • 7.17 TSM/HFSM
  • 7.18 IGNITION/LIGHT KEY SWITCH AND FORK LOCK
  • 7.19 FAIRING CAP SWITCHES: FLHTC/U
  • 7.20 INSTRUMENT NACELLE SWITCHES:
  • 7.21 CRANKSHAFT POSITION SENSOR (CKP)
  • 7.22 ALTERNATOR
  • 7.23 VEHICLE SPEED SENSOR (VSS)
  • 7.24 NEUTRAL SWITCH
  • 7.25 OIL PRESSURE SWITCH AND SENDER
  • 7.26 STOPLIGHT SWITCHES
  • 7.27 HORN
  • 7.28 CIGARETTE LIGHTER: FLHX, FLHT/C/U, FLTR
  • 7.29 GAUGES AND INSTRUMENTS: FLHX, FLHT/C/U, FLTR
  • 7.30 INDICATOR LAMPS: FLHX, FLHT/C/U, FLTR
  • 7.31 GAUGES AND INSTRUMENTS: FLHR/C
  • 7.32 INDICATOR LAMPS: FLHR/C
  • 7.33 ADVANCED AUDIO SYSTEM
  • 7.34 WIRE TROUGH
  • 7.35 MAIN WIRING HARNESS
  • 7.36 INTERCONNECT HARNESS
  • 7.37 RADIO ANTENNA CABLE
  • 7.38 AUDIO HARNESS: FLHTCU
  • 7.39 CB ANTENNA CABLE: FLHTCU
  • 7.40 HANDLEBAR SWITCH ASSEMBLIES
• APPENDIX A CONNECTOR REPAIR
  • A.1 AMP MULTILOCK CONNECTORS
  • A.2 AUTOFUSE ELECTRICAL
  • A.3 DELPHI CONNECTORS
  • A.4 DELPHI MAIN FUSE HOUSING
  • A.5 DEUTSCH ELECTRICAL CONNECTORS
  • A.6 DEUTSCH STANDARD TERMINAL REPAIR
  • A.7 DEUTSCH SOLID BARREL MINI TERMINAL REPAIR
  • A.8 DEUTSCH MINI TERMINAL REPAIR
  • A.9 MOLEX CONNECTORS
  • A.10 PACKARD 150 METRI-PACK CONNECTORS
  • A.11 PACKARD 280 METRI-PACK RELAY AND FUSE BLOCK CONNECTORS
  • A.12 PACKARD 480 METRI-PACK CONNECTORS
  • A.13 PACKARD 630 METRI-PACK CONNECTORS
  • A.14 PACKARD METRI-PACK TERMINALS
  • A.15 ECM CONNECTOR
  • A.16 PACKARD MICRO-64 CONNECTORS
  • A.17 SEALED SPLICE CONNECTORS
• APPENDIX B WIRING
  • B.1 CONNECTORS
  • B.2 WIRING DIAGRAMS
• APPENDIX C ABS
  • C.1 ABS MODULE
  • C.2 WHEEL SPEED SENSORS
  • C.3 ABS BRAKE LINES
• APPENDIX D CONVERSIONS
  • D.1 METRIC CONVERSION
  • D.2 FLUID CONVERSIONS
  • D.3 TORQUE CONVERSIONS
• APPENDIX E GLOSSARY
  • E.1 GLOSSARY
• REFERENCE MATERIAL
  • TOOLS
  • TORQUE VALUES
  • INDEX