2009 Harley-Davidson Touring FLHT, FLHTC, FLHTCU, FLTR, FLHX, FLHR, FLHRC, and FLHTCUTG Service Manual (P/N 99483-09)

• Coverage: 2009 FLHT Electra Glide, FLHTC Electra Glide Classic, FLHTCU Ultra Classic Electra Glide, FLTR Road Glide, FLHX Street Glide, FLHR Road King, and FLHRC Road King Classic. The VIN section also identifies Shrine and factory FLHTCU sidecar model codes. Covered models use the Twin Cam 96 1584 cc air-cooled, fuel-injected engine.
• Engine repair: Covers engine removal/installation, top- and bottom-end overhaul, cylinder-head disassembly, valve-guide and seat work, cylinder inspection/boring/honing, piston service, camshaft and cam-support-plate work, oil-pump service, crankcase work, and flywheel/connecting-rod inspection.
• Chassis and brakes: Includes wheel and sealed-bearing service, laced-wheel truing, front-fork disassembly, steering-head bearing service, rear air-suspension checks, master-cylinder and caliper work, brake bleeding, rear-fork service, plus model-specific fairing, windshield, Tour-Pak, and saddlebag procedures.
• Fuel, drive, clutch, and transmission: Details fuel-tank and in-tank component service, fuel-pressure and intake-leak testing, induction-module and sensor replacement, automatic primary-chain tensioner service, clutch-pack inspection, drive-belt adjustment, and six-speed transmission disassembly and repair.
• Electrical, wiring, and ABS: Covers the ECM, starter, alternator, TSM/HFSM, instruments, Advanced Audio components, main/interconnect harnesses, connector repair, model-specific wiring diagrams, ABS module and wheel-speed-sensor replacement, ABS brake lines, and Digital Technician II procedures required after specified ABS repairs.
• Factory publication: Harley-Davidson 2009 Touring Models Service Manual, P/N 99483-09, 702-page PDF. Seven main service chapters are followed by appendices for Connector Repair, Wiring, ABS, Conversions, and the Glossary.

Technical Scope and Shop Application

Routine service goes well beyond an interval chart. The manual covers engine and transmission lubrication, primary-chaincase service, clutch adjustment, brake-pad inspection and replacement, brake bleeding, rear-belt inspection and deflection adjustment, front-fork oil service, steering-head bearing checks, headlamp alignment, battery service, and rear air-suspension setup. The suspension tables distinguish FLHR/C, FLTR and FLHX applications from FLHT/C/U and provide load-based settings for solo, luggage, passenger, and maximum-load conditions.

The engine chapter separates top-end and bottom-end service and carries the repair through rocker supports, pushrods and lifters, cylinder heads, valve guides and seats, cylinders, pistons, cam support plate, camshafts, oil pump, crankcase, flywheel, and connecting rods. Compression and cylinder-leakdown testing are included, along with service wear limits, dimensional inspection data, oil-flow information, oil-pressure testing, and component-specific torque tables. Camshaft timing-mark alignment and primary/secondary cam-chain tensioner inspection are part of the internal engine procedures.

Drive and transmission sections cover the compensating sprocket, primary chain and automatic tensioner, clutch pack and bearing, primary chaincase housing, transmission sprocket, rear drive belt, clutch-release cover, shifter cam and forks, mainshaft, countershaft, side-door bearings, main drive gear and bearing, and transmission case. The procedures also identify where special pullers, drivers, holding fixtures, or replacement-only parts are required.

Fuel, Electrical, ABS, and Diagram Coverage

Fuel-system service covers the tank top plate, filter, regulator, level sender, twist-grip sensor, throttle control actuator, induction module, TMAP and O2 sensors, injectors, fuel pump, fuel-pressure testing, HDI active exhaust, intake-leak testing, and California EVAP components. A key scope limit is worth noting: the EFI troubleshooting section directs the technician to the separate Electrical Diagnostic Manual for full diagnostic information, and several sensor/function tests do the same.

The electrical chapter covers the voltage regulator, ECM, ignition coil, fuses and relays, starter and solenoid, lighting, TSM/HFSM security components, switches, sensors, gauges, Advanced Audio hardware, and main/interconnect harness removal and installation. Appendix A adds terminal-level repair for AMP Multilock, Delphi, Deutsch, Molex, Packard/Metri-Pack, ECM, and sealed-splice connectors.

Appendix B supplies connector-location tables and model-specific electrical schematics. Representative material includes the five-part Main Harness diagrams, Starting and Charging circuits, Tail Lamp/Auxiliary Lamp/Directional Lamp/Tour-Pak wiring, the Composite Ultra Audio Circuit, Camshaft Timing Marks, and ABS Module Connections. Appendix C covers the ABS HCU/ECU assembly, front and rear wheel-speed sensors, and brake lines. Certain ABS repairs require Digital Technician II (HD-48650) for ECU programming or the ABS Service procedure used to confirm proper bleeding.

Factory Data, Tools, and Repair Cautions

Specification sections provide fastener torque tables, fluid-capacity data, service wear limits, clearances, pressure-test specifications, electrical data, maintenance tables, tire/wheel fitment, and model-specific adjustment information. Special-tool callouts include the HD-35381A Belt Tension Gauge, HD-48219 Primary Drive Locking Tool, HD-47956 Camshaft Assembly Tool, HD-41182 Fuel Pressure Gauge, and HD-48646 Cam Ring Remover/Installer.

The manual also flags repair traps specific to this platform. ABS wheel-speed sensors and encoder bearings can be damaged by magnetic fields. The twist-grip sensor connector latch can break if it is pried or pulled incorrectly, forcing jumper-harness replacement. On the six-speed transmission, hammering the shafts to free a stuck side door can damage the side-door bearings.

Brake, fuel-system, engine, and electrical work can create serious safety hazards if procedures are improvised or required equipment is omitted. Use the model-specific factory procedure, listed service tools, and final operational checks for the repair being performed.