2009 Harley-Davidson Touring FLHR FLHT FLHX FLTR Factory Service Manual (P/N 99483-09)

Harley-Davidson’s 2009 Touring Models Service Manual, P/N 99483-09 (©2008), covers the Twin Cam 96 Touring models: FLHR Road King, FLHRC Road King Classic, FLHT Electra Glide, FLHTC Electra Glide Classic, FLHTCU Ultra Classic Electra Glide, FLHX Street Glide, and FLTR Road Glide.

Text Search, Bookmarks and Diagram Detail

Finding procedures and wiring details: Searchable PDF text and embedded bookmarks provide access to chapters and service topics. Small connector, pin and wire-color labels in dense wiring diagrams are readable when enlarged.

One printable, English-language 702-page PDF contains the manual. The total includes 22 pages of front matter, 20 later notes pages, and 16 caption-only pages accompanying the wiring diagrams.

Engine Overhaul, Drivetrain and Chassis Service

The selected coverage below highlights major service areas. Other topics include headlamp alignment and jiffy stand interlock sensor replacement.

• Engine diagnosis and overhaul: Compression, cylinder leakdown and oil-pressure testing; engine removal; top- and bottom-end overhaul; valve-guide replacement; and cylinder boring and honing.

• Primary drive and transmission: Compensating sprocket, automatic chain tensioner, clutch pack and bearings, plus six-speed gearset disassembly, shifter forks and main drive gear service.

• Chassis and wheels: Front fork rebuilding, rear air-suspension leak checks, rear fork pivot bearings, rear wheel compensator service, laced-wheel truing, cast-wheel runout checks and sealed-bearing replacement.

• Fuel-system testing: Fuel-pressure and intake-leak checks, with replacement procedures for the pump, regulator, injectors and twist grip sensor.

• Brakes and ABS: Master-cylinder repair, caliper replacement, wheel-speed sensors, brake lines, and ABS module and electrical control-unit replacement.

• Electrical service: Starter and solenoid repair, alternator replacement and handlebar-switch work, supported by model-specific harness routing, wiring schematics and connector repair procedures.

The manual supports basic maintenance and repair, with its major-repair methods aimed at professional Harley-Davidson technicians using the specified shop equipment.

Maintenance, Suspension and Touring Bodywork

The maintenance chapter maps out service intervals, front fork oil replacement, steering head bearing lubrication and swing-by checks, and rear belt deflection measurement. FLHX-specific belt settings are identified. Fork procedures distinguish conventional Road King forks from the damper-valve forks used on the other models. Rear air shocks are replaced rather than internally repaired.

Model-specific sections separate Electra Glide/Street Glide fairings, Road Glide fairings and Road King headlamp nacelles. Tour-Pak and saddlebag service extends to hinges, latches, locks and supports. Advanced Audio System coverage addresses radio, speaker, headset and CB component replacement.

Powertrain Repair Scope and Tool References

Planning engine work: Service charts distinguish in-chassis top-end and cam-compartment work from engine-out flywheel-compartment service, helping establish engine-removal requirements before a job begins. Step-by-step procedures cover disassembly and reassembly, with cam support plate removal, camshaft needle-bearing replacement, hydraulic lifter inspection and oil-pump alignment.

The flywheel/connecting-rod unit is inspected and replaced as an assembly rather than rebuilt internally. Transmission gearset removal is documented with the case still in the frame.

Tool references identify the HD-47941 crankshaft/camshaft sprocket locking tool and HD-48219 primary drive locking tool. Factory cautions warn that turning the engine with crank or primary cam sprocket flange bolts can break the bolt heads and damage the flywheel or camshaft.

EFI, Throttle Control and Emissions

The fuel-system chapter distinguishes California evaporative-emissions controls from HDI (international) active exhaust equipment. It explains ECM idle-speed initialization after twist grip sensor replacement. The throttle control actuator (TCA) is not sold separately; damage or failure requires an induction module assembly.

For EFI troubleshooting and extended electrical diagnostics, this publication refers to the separate Electrical Diagnostic Manual, which is not included.

ABS Service Requirements

ABS and non-ABS procedures are identified separately. Digital Technician II (HD-48650) is specified for ABS bleeding verification after module, master-cylinder or connecting-line disconnection, and for programming a new ABS module or ECU. ABS service notes warn that magnetic parts trays can damage wheel-speed sensors.

Wiring Diagrams and Workshop References

Starting and Charging schematics distinguish Road King circuits from those on fairing-equipped models. The 2009 Composite Ultra Audio Circuit shows audio connections. Connector-location tables identify plug type, location and reference numbers; terminal repair covers AMP Multilock, Deutsch, Delphi, Molex and Packard connectors.

Camshaft Timing Marks and Transmission Power Flow illustrations explain assembly relationships. The Induction Module Assembly view and Drive Belt Wear Analysis chart support component identification and wear inspection.

Component-specific torque tables, wear limits, clearances and electrical test values accompany the procedures. Fluid references include engine, transmission, primary chaincase and fuel-tank data, low-fuel warning information and wet-versus-dry primary fills. Brake-disc thickness, runout and spark plug gap specifications are included, along with conversion tables and a glossary.

Always ensure your workspace is well-ventilated and use proper lifting equipment when performing these factory procedures to safely maintain your motorcycle.

Compression, Leakdown and Oil-Pressure Examples

Cylinder testing: For a compression test at normal operating temperature when possible, with the throttle plate fully open, the manual treats 125 psi (862 kPa) or more and no more than 10% variation between cylinders as normal. Cylinder leakage greater than 10% indicates internal engine problems.

Lubrication testing: The oil-pressure check specifies 30–38 psi (207–262 kPa) at 2,000 rpm with engine oil at 230°F (110°C).