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

This 702-page PDF contains Harley-Davidson’s 2009 Touring Models Service Manual, P/N 99483-09 (©2008), for the Twin Cam 96 Touring models. Coverage includes 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.

• Engine diagnosis and overhaul: Compression, cylinder leakdown, and oil-pressure testing lead into engine removal, top- and bottom-end rebuilding, valve-guide replacement, and cylinder boring and honing.
• Primary drive and transmission repair covers the compensating sprocket, automatic chain tensioner, clutch pack and bearings, plus six-speed gearset disassembly, shifter forks, and main drive gear service.
• Chassis procedures cover front fork rebuilding, rear air-suspension leak checks, rear fork pivot-bearing replacement, and rear wheel compensator service. Wheel work includes laced-wheel truing, cast-wheel runout checks, and sealed-bearing replacement.
• Fuel-system testing includes fuel-pressure and intake-leak checks, with replacement procedures for the pump, regulator, injectors, and twist grip sensor.
• Brake coverage separates ABS and non-ABS work, including master-cylinder repair, caliper replacement, wheel-speed sensors, and ABS hydraulic and electronic control-unit replacement.
• Starter and solenoid repair, alternator replacement, and handlebar-switch work are supported by model-specific harness routing, wiring schematics, and connector repair procedures.

Manual Organization

Chapters flow logically from general maintenance through the chassis, engine, fuel system, drive components, transmission, and electrical systems. Appendices cover connector repair, wiring diagrams, ABS, conversion tables, and a glossary.

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, and the fork section separates conventional Road King forks from the damper-valve forks used on other models.

Model-specific bodywork 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

The engine section distinguishes in-chassis top-end and cam-compartment work from engine-out flywheel-compartment service. The cam and lubrication sections cover 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.

Factory cautions warn that using cam-sprocket flange bolts to turn the engine can break the bolts and damage the camshaft or flywheel.

EFI and ABS: Diagnostic Requirements

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

For EFI troubleshooting and extended electrical diagnostics, this publication refers to the separate Electrical Diagnostic Manual, not included with this PDF. ABS procedures specify Digital Technician II (HD-48650) for brake-bleeding verification and programming a new ABS module or ECU. ABS service notes identify magnetic parts trays as a damage risk for wheel-speed sensors.

Wiring Diagrams and Assembly References

Starting and Charging schematics separate Road King wiring from the fairing-equipped models; the 2009 Composite Ultra Audio Circuit documents the audio connections. Connector-location tables identify plug type, location, and reference numbers. Terminal repair sections cover AMP Multilock, Deutsch, Delphi, Molex, and Packard connectors.

Alongside exploded-view diagrams, the engine and transmission chapters include Camshaft Timing Marks and Transmission Power Flow illustrations. The labeled Induction Module Assembly view and Drive Belt Wear Analysis chart support component identification and wear inspection.

Specification and Reference Data

Component-specific torque tables, service wear limits, clearances, and electrical test values accompany the procedures. Fluid references cover the engine, transmission, primary chaincase, and fuel tank, including low-fuel warning data and wet-versus-dry primary fill distinctions. Maintenance tables list brake-disc thickness and runout limits, plus spark plug gap specifications.

The tool index identifies equipment such as the HD-47941 crankshaft/camshaft sprocket locking tool and HD-48219 primary drive locking tool.

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