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

This 1,105-page PDF set pairs the 646-page 2009 Softail Models Service Manual (P/N 99482-09) with the 458-page 2009 Harley-Davidson Softail Models Electrical Diagnostic Manual (P/N 99498-09), plus a one-page contents sheet. Mechanical coverage is centered on the 1584 cc Twin Cam 96B balanced, fuel-injected engine and six-speed transmission used in the listed 2009 models.

• Model coverage: FXST Softail Standard, FXSTB Night Train, FXSTC Softail Custom, FXCW Rocker, FXCWC Rocker Custom, FLSTC Heritage Softail Classic, FLSTF Fat Boy, FLSTN Softail Deluxe, and FLSTSB Cross Bones. The VIN table also lists FLSTF/FLSTC Shrine editions and a Brazil-only FLST. FXSTSSE3 is not included; it uses separate P/N 99494-09.
• Engine repair: engine removal and installation, top- and bottom-end overhaul, cylinder-head and valve service, pistons and cylinders, pushrods and lifters, cam support plate, cam chains, oil pump, crankcase, flywheel and connecting rods, and the Twin Cam 96B counterbalancer system.
• Chassis and brake work: front and rear wheel service, sealed wheel-bearing replacement, factory rim lacing and truing, cast-wheel runout checks, master-cylinder and caliper repair, telescopic and Springer fork service, steering-head work, rear shock absorbers, and rear-fork service.
• Primary drive and transmission: primary chaincase housing and drive-component removal and installation, clutch-pack and bearing service, transmission sprocket and belt work, shifter-linkage adjustment, complete transmission disassembly and reassembly, and main-drive-gear, bearing, and case repair.
• Fuel and electrical diagnosis: fuel tank and pump/sender service, injector and EFI sensor work, fuel-pressure and intake-leak testing, starter and charging tests, speedometer self-diagnostics, TSM/HFSM turn-signal and hands-free security troubleshooting, and engine-management fault trees.
• Wiring and connector support: connector-location tables and terminal repair for AMP Multilock, Delphi, Deutsch, Molex, Packard, and Metri-Pack families. The model-specific wiring appendix is repeated in both volumes and covers domestic/international main-harness, ignition, lighting, starting/charging, security, and dedicated FXCWC circuits.

Model-Specific Detail

The Cross Bones is handled as a distinct chassis configuration, with dedicated front-wheel, front-caliper, Springer fork, steering-head, rocker-bearing, handlebar, fender, and seat information. Rocker and Rocker Custom coverage separates the oil tank, rear fender, seat, instrument console, speedometer, and indicator-lamp work where their construction differs from other Softails.

The regional sections matter too. California models get evaporative-emissions procedures. The electrical volume covers international-market active intake, active exhaust, and jiffy-stand sensor circuits, while Appendix E handles the Japan/Korea TSM/TSSM configuration, including turn-signal, bank-angle, security, DTC, and password-learn functions.

Service Data and Diagnostic Depth

Routine maintenance includes engine oil and filter service, primary and transmission lubricant changes, clutch and rear-belt adjustment, brake bleeding, battery testing and storage, suspension adjustment, steering-head checks, fork-oil replacement, headlamp alignment, and scheduled service inspections. The wheel chapters separate 16-, 17-, and 21-inch laced-rim procedures, lateral and radial truing, cast-wheel runout, and sealed-bearing removal and installation.

The engine chapter distinguishes cam-compartment work that can be performed in the chassis from flywheel-compartment repair that requires engine removal and split crankcases. Factory reference material is organized by system, with component-specific torque tables, fluid capacities, tire fitment, service wear limits, clearances, runout data, gear ratios, electrical test values, conversion tables, and consolidated tool and torque indexes.

The electrical diagnostic manual is built around test paths, not schematics alone. It covers on-bike starter current-draw tests, bench testing of the starter and solenoid, charging-system fault isolation, battery conductance and load testing, instrument and fuel-gauge diagnosis, security-module service modes, and B-, P-, and U-code charts. Engine-management sections isolate manifold absolute pressure, intake-air and engine-temperature sensors, throttle position, oxygen sensors, injectors, crank and vehicle-speed signals, ignition coils, system relays, and ECM power circuits. Separate troubleshooting sections address an engine that cranks but will not start, starts then stalls, idle-control faults, misfire, and absent or intermittent combustion.

The tools index ties factory jobs to the required equipment, including the HD-42310-25A Softail Engine Cradle, HD-42325-A camshaft needle-bearing remover/installer, HD-35316-C main-drive-gear/bearing remover and installer, and HD-44060A wheel-bearing installer/remover. Electrical diagnosis references the HD-43876 Breakout Box and HD-48650 Digital Technician II for selected security and ECM functions.

Named illustrations include “Cam Support Plate Oil Flow,” “Balance Chain,” “Transmission Power Flow,” “Main Harness,” “Starting and Charging Circuits,” and “Security Circuit,” backed by exploded assemblies and terminal views.

The service manual also flags easy-to-miss repair traps. It warns that using a large breaker bar on the rear cam bolt can damage the chain drive, and that front master-cylinder removal without the specified lever support can damage the stoplight-switch boot and plunger.

Motorcycle repair involves fuel, electrical, lifting, rotating-component, and brake-system hazards. Follow every factory warning, support the motorcycle securely, and use the specified service tools before beginning major work.