Harley-Davidson Softail, Fat Boy, Rocker, Night Train, Heritage Softail Classic, and Cross Bones 2009 Service & Electrical Diagnostic Manual Set (P/N 99482-09)

The service manual provides component removal, inspection, and repair procedures. Its electrical companion supplies the fault trees and circuit tests used to pinpoint the fault before taking a component apart or replacing it.

The 2009 FXSTSSE3 requires its own service manual (P/N 99494-09). The ZIP contains only the reference to that publication on the contents sheet.

Search, Bookmarks, and Wiring Detail

Text search and diagram detail: Both manuals have searchable text and chapter bookmarks. The separate contents sheet is also searchable. Zoom in on dense wiring diagrams to read small pin numbers, connector IDs, and wire-color codes.

The ZIP contains three printable PDFs totaling 1,105 pages, including the separate one-page contents sheet. The original covers, front matter, and appendices are included in the individual manual page counts.

Powertrain, Chassis, and Electrical Faults

These are selected workshop topics. The service manual also includes vehicle alignment checks and engine storage and return-to-service procedures.

• Scheduled maintenance: Engine oil and filter service, primary and transmission lubricant changes, clutch and rear-belt adjustment, brake bleeding, battery care, fork oil replacement, and headlamp alignment.
• Chassis and brakes: Wheel and sealed-bearing service, master cylinder and caliper repair, hydraulic and Springer fork work, steering-head checks, rear shocks, and rear fork service.
• Twin Cam 96B overhaul: Step-by-step procedures for engine removal and installation, cylinder heads and valves, pistons and cylinders, pushrods and lifters, cam chains, oil pump, flywheel and connecting rods, and counterbalancers.
• Primary drive and transmission: Chaincase housing and drive-component service, clutch pack and bearing work, sprocket and belt replacement, shifter-linkage adjustment, and transmission teardown, inspection, and reassembly.
• Fuel and EFI: Fuel tank and pump/sender service, injector and sensor work, fuel-pressure testing, and intake leak checks.
• Starting, charging, and instruments: On-bike starter current-draw tests, starter and solenoid bench tests, charging-system fault isolation, battery conductance and load tests, speedometer self-diagnostics, and fuel-gauge troubleshooting.
• Wiring and connector repair: Connector-location tables, terminal removal and crimping, sealed-splice repair, and separate domestic and international wiring sheets where the circuits differ.

Harley-Davidson’s forewords describe the basic service material as a way to learn the machine and the major repair and diagnostic methods as material for professional technicians.

Cross Bones and Rocker Chassis

The Cross Bones has dedicated procedures for its front wheel and caliper, Springer fork, steering-head and rocker bearings, handlebar, fenders, and seat. The Rocker and Rocker Custom have separate coverage where their oil tank, rear fender, seat, instrument console, speedometer, or indicator lamps differ.

Wheel service includes lacing procedures for 16-, 17-, and 21-inch rims, lateral and radial truing, and cast-wheel runout checks. The front master cylinder procedure flags a specific risk during removal or installation: without the specified lever support, the stoplight switch boot and plunger can be damaged.

Engine Access, Transmission, and Tools

The engine chapter distinguishes cam-compartment work that can be done with the engine in the frame from flywheel-compartment work that requires engine removal and splitting the crankcases. It also warns that using a large breaker bar on the rear cam sprocket bolt can damage the chain drive.

The cam support plate oil-flow and Balance Chain illustrations show how the lubrication and counterbalancer systems are laid out. Transmission Power Flow traces the gear paths alongside main-drive-gear, bearing, and case service. Reference tables cover torque, fluid capacities, tire fitment, wear limits, clearances, gear ratios, and conversions.

The tools index identifies the HD-42310-25A Softail Engine Cradle, HD-42325-A camshaft needle-bearing tool, HD-35316-C main-drive-gear and bearing tool, and HD-44060A wheel-bearing installer/remover.

EFI, Security, and Circuit Tracing

For an engine that cranks without starting, the diagnostic flowcharts help separate inadequate fuel pressure from a loss of spark and trace crank-position sensor or harness faults. Separate paths cover stalling, idle control, and misfires. B-, P-, and U-code charts guide checks of intake and engine-temperature sensors, throttle position, oxygen sensors, injectors, vehicle-speed signals, coils, relays, and ECM power.

California evaporative-emissions service is covered in the mechanical volume. The electrical volume covers international active intake, active exhaust, and jiffy-stand sensor circuits. Its Japan/Korea appendix treats the TSM/TSSM configuration separately, including turn signals, bank-angle functions, security faults, and password learning. Selected security and ECM procedures call for Digital Technician II (HD-48650), and circuit tests identify the HD-43876 breakout box where required.

Both volumes include the model-specific wiring appendix, with Main Harness, Starting and Charging Circuits, and Security Circuit diagrams. The connector appendices cover AMP Multilock, Delphi, Deutsch, Molex, Packard, and Metri-Pack terminals.

Brake Runout and Ignition Resistance Examples

The brake inspection section specifies a maximum disc lateral runout and warpage of 0.008 in. (0.2 mm), measured near the outside diameter of the disc.

For FXCWC misfire diagnosis, the electrical manual lists 1,840–5,084 ohms for each spark plug cable, front and rear. The other Softail models have a separate resistance table.

Follow the factory warnings for fuel, electrical, and brake work, and support the motorcycle securely before major service.