2009 Harley-Davidson Touring Service Manual – PDF DOWNLOAD

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2009 Harley-Davidson Touring Service Manual – PDF DOWNLOAD

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2009 Harley-Davidson Touring Service Manual – PDF DOWNLOAD

ABOUT THIS MANUAL
GENERAL
This Service Manual has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the Harley-Davidson product and assist in the performance of basic maintenance and repair. Secondly, it will introduce to the professional Harley-Davidson Technician the latest field-tested and factory-approved major repair methods. We sincerely believe that this Service Manual will make your association with Harley-Davidson products more pleasant and profitable.
HOW TO USE YOUR SERVICE MANUAL
Refer to the table below for the content layout of this manual.
NO. CHAPTER
1 Maintenance
2 Chassis
3 Engine
4 Fuel System
5 Drive
6 Transmission
7 Electrical
A Appendix A Connector Repair
B Appendix B Wiring
C Appendix C ABS
D Appendix D Conversions
E Appendix E Glossary

• Use the TABLE OF CONTENTS (which follows this FOREWORD) and the INDEX (at the back of this manual) to quickly locate subjects. Sections and topics in this manual are sequentially numbered for easy navigation.
• For example, a cross-reference shown as 2.1 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFICATIONS. For quick and easy reference, all pages contain a section number followed by a page number. For example, page 3-5 refers to page 5 in section 3.

TABLE OF CONTENTS:

2009 Harley-Davidson Touring Service Manual – PDF DOWNLOAD

FOREWORD........................................................................................  7
TABLE OF CONTENTS...............................................................................  9
1. MAINTENANCE.................................................................................. 23
	1.1 FASTENER TORQUE VALUES.................................................................. 25
		Fastener Torque Values in this Chapter.................................................. 25
	1.2 GENERAL................................................................................. 27
		Servicing a New Motorcycle.............................................................. 27
		Safe Operating Maintenance.............................................................. 27
		Shop Practices.......................................................................... 27
		Repair and Replacement Procedures....................................................... 28
		Cleaning................................................................................ 29
		Tool Safety............................................................................. 29
	1.3 MAINTENANCE SCHEDULE.................................................................... 31
		General................................................................................. 31
	1.4 FUEL AND OIL............................................................................ 34
		Fuel.................................................................................... 34
		Gasoline Blends......................................................................... 34
		Engine Lubrication...................................................................... 34
		Winter Lubrication...................................................................... 35
	1.5 BULB REQUIREMENTS....................................................................... 36
		General................................................................................. 36
	1.6 ENGINE OIL AND FILTER................................................................... 38
		Checking Oil Level...................................................................... 38
		Changing Oil and Oil Filter............................................................. 39
	1.7 PRIMARY CHAIN........................................................................... 41
		General................................................................................. 41
		Chaincase Lubricant..................................................................... 41
	1.8 TRANSMISSION LUBRICANT.................................................................. 42
		Transmission Lubrication................................................................ 42
	1.9 AIR CLEANER AND EXHAUST SYSTEM.......................................................... 44
		Removal................................................................................. 44
		Installation............................................................................ 45
		Exhaust System Leak Check............................................................... 45
	1.10 TIRES AND WHEELS....................................................................... 46
		Tires................................................................................... 46
		Tire Replacement........................................................................ 46
		Wheel Bearings.......................................................................... 47
		Wheel Spokes............................................................................ 47
	1.11 CLUTCH................................................................................. 49
		Adjustment.............................................................................. 49
	1.12 REAR BELT AND SPROCKETS................................................................ 51
		General................................................................................. 51
		Cleaning................................................................................ 51
		Inspection.............................................................................. 51
	1.13 REAR BELT DEFLECTION................................................................... 53
		Checking Belt Deflection................................................................ 53
		Setting Belt Deflection................................................................. 53
	1.14 BRAKES................................................................................. 56
		Fluid Inspection........................................................................ 56
	1.15 BRAKE PADS AND DISCS................................................................... 57
		Inspection.............................................................................. 57
		Brake Pad Replacement................................................................... 57
	1.16 BLEEDING BRAKES........................................................................ 61
		General................................................................................. 61
		Procedure............................................................................... 61
	1.17 BATTERY MAINTENANCE.................................................................... 63
		General................................................................................. 63
		Cleaning and Inspection................................................................. 64
		Battery................................................................................. 64
		Voltmeter Test.......................................................................... 65
		Charging Battery........................................................................ 65
		Storage................................................................................. 66
	1.18 SUSPENSION ADJUSTMENTS................................................................. 68
		General................................................................................. 68
	1.19 FRONT FORK OIL......................................................................... 70
		Replacing Fork Oil...................................................................... 70
	1.20 SPARK PLUGS............................................................................ 71
		Inspection.............................................................................. 71
		Spark Plug Cable Inspection............................................................. 71
	1.21 STEERING HEAD BEARINGS................................................................. 73
		Lubrication............................................................................. 73
		Checking................................................................................ 73
		Adjustment.............................................................................. 73
	1.22 CABLE AND CHASSIS LUBRICATION.......................................................... 75
		General................................................................................. 75
		Steering Head Bearings.................................................................. 75
		Jiffy Stand............................................................................. 75
	1.23 HEADLAMP ALIGNMENT..................................................................... 76
		Headlamp Alignment...................................................................... 76
		Main Headlamp Adjustment................................................................ 76
		Auxiliary Lamp Alignment................................................................ 78
	1.24 ENGINE MOUNTS.......................................................................... 79
		Inspection.............................................................................. 79
	1.25 STORAGE................................................................................ 80
		General................................................................................. 80
		Placing in Storage...................................................................... 80
		Removal from Storage.................................................................... 80
	1.26 TROUBLESHOOTING........................................................................ 82
		General................................................................................. 82
		Engine.................................................................................. 82
		Lubrication System...................................................................... 83
		Electrical System....................................................................... 84
		Transmission............................................................................ 84
		Handling................................................................................ 84
		Brakes.................................................................................. 85
	1.27 CRITICAL FASTENERS..................................................................... 86
		Inspection.............................................................................. 86
2. CHASSIS...................................................................................... 87
	2.1 FASTENER TORQUE VALUES.................................................................. 89
		Fastener Torque Values in this Chapter.................................................. 89
	2.2 SPECIFICATIONS.......................................................................... 95
		Specifications.......................................................................... 95
	2.3 VEHICLE IDENTIFICATION NUMBER (V.I.N.).................................................. 98
		Vehicle Identification Number: Touring Models........................................... 98
	2.4 FRONT WHEEL............................................................................. 99
		Removal................................................................................. 99
		Cleaning and Inspection.................................................................100
		Installation............................................................................100
	2.5 REAR WHEEL..............................................................................102
		Removal.................................................................................102
		Cleaning and Inspection.................................................................103
		Installation............................................................................104
	2.6 REAR WHEEL COMPENSATOR..................................................................106
		Isolator Replacement....................................................................106
		Sprocket Bearing Replacement............................................................106
	2.7 CHECKING RIM RUNOUT.....................................................................109
		Inspection..............................................................................109
	2.8 WHEEL LACING: 16 INCH FRONT RIM.........................................................110
		General.................................................................................110
		Procedure...............................................................................110
		Spoke Tightness.........................................................................112
	2.9 WHEEL LACING: 16 INCH REAR RIM..........................................................113
		Procedure...............................................................................113
	2.10 WHEEL LACING: 17 INCH RIM..............................................................116
		General.................................................................................116
		Procedure...............................................................................116
	2.11 SEALED WHEEL BEARINGS..................................................................119
		Inspection..............................................................................119
		Removal.................................................................................119
		Installation............................................................................121
	2.12 TRUING LACED WHEELS....................................................................123
		General.................................................................................123
		Lateral Truing..........................................................................123
		Radial Truing...........................................................................124
	2.13 CHECKING CAST WHEEL RUNOUT.............................................................126
		General.................................................................................126
		Lateral Runout..........................................................................126
		Radial Runout...........................................................................126
	2.14 FRONT BRAKE MASTER CYLINDER............................................................127
		General.................................................................................127
		Removal and Disassembly.................................................................127
		Cleaning and Inspection.................................................................129
		Assembly and Installation...............................................................129
		Front Brake Line - Non-ABS Equipped.....................................................129
	2.15 FRONT BRAKE CALIPER....................................................................132
		Removal.................................................................................132
		Installation............................................................................132
	2.16 REAR BRAKE MASTER CYLINDER.............................................................133
		General.................................................................................133
		Removal and Disassembly.................................................................133
		Cleaning and Inspection.................................................................136
		Assembly and Installation...............................................................136
		Rear Brake Line: Non-ABS Equipped.......................................................136
	2.17 REAR BRAKE CALIPER.....................................................................139
		Removal.................................................................................139
		Installation............................................................................139
	2.18 TIRES..................................................................................140
		General.................................................................................140
		Removal.................................................................................140
		Cleaning, Inspection and Repair.........................................................141
		Installation............................................................................141
	2.19 FRONT FORK.............................................................................143
		Changing Fork Oil.......................................................................143
		Removal.................................................................................144
		Disassembly.............................................................................144
		Cleaning and Inspection.................................................................146
		Assembly................................................................................147
		Installation............................................................................148
	2.20 AIR BAFFLE: FLTR.......................................................................149
		Air Baffle (FLTR).......................................................................149
	2.21 STEERING HEAD BEARINGS.................................................................150
		Removal.................................................................................150
		Inspection..............................................................................151
		Installation............................................................................151
	2.22 REAR AIR SUSPENSION....................................................................153
		Check for Air Leaks.....................................................................153
	2.23 REAR SHOCK ABSORBERS...................................................................156
		Removal.................................................................................156
		Cleaning and Inspection.................................................................156
		Disassembly and Assembly................................................................156
		Installation............................................................................156
	2.24 REAR FORK..............................................................................157
		Removal.................................................................................157
		Disassembly and Assembly................................................................158
		Installation............................................................................159
	2.25 CLUTCH CABLE...........................................................................160
		Removal.................................................................................160
		Installation............................................................................160
	2.26 HANDLEBARS.............................................................................163
		Adjustment..............................................................................163
		Removal.................................................................................163
		Installation............................................................................164
		Left Hand Grip..........................................................................164
		Rubber Mounts...........................................................................165
	2.27 MIRRORS................................................................................167
		All Models Except FLHX..................................................................167
		FLHX....................................................................................167
	2.28 SEAT...................................................................................169
		Seat: FLHT, FLTR, FLHX..................................................................169
		Seat: FLHTC/U...........................................................................170
		Seat: FLHR/C............................................................................170
		Seat Retention Nut Replacement..........................................................171
	2.29 SADDLEBAGS.............................................................................172
		Removal.................................................................................172
		Installation............................................................................172
	2.30 SADDLEBAG SERVICE......................................................................173
		Saddlebag Hardware......................................................................173
		Saddlebag Guard/Support Rail............................................................174
	2.31 TOUR-PAK...............................................................................176
		Removal/Installation....................................................................176
		Adjustment..............................................................................177
		Luggage Rack/Tour-Pak Support...........................................................177
	2.32 TOUR-PAK SERVICE.......................................................................179
		Lockset.................................................................................179
		Hinges..................................................................................179
		Latches/Lockset Catch...................................................................180
		Catches.................................................................................180
		Tether..................................................................................180
		Tether Brackets.........................................................................181
	2.33 TOUR-PAK LIGHTS........................................................................182
		General.................................................................................182
		Side Marker Lights (FLHTCU).............................................................182
		Tour-Pak Lights Harness.................................................................182
		Wrap-Around Lights (FLHTCU).............................................................183
	2.34 TOUR-PAK BACKREST......................................................................185
		Passenger Backrest......................................................................185
		Rubber Isolators........................................................................185
		Passenger Backrest Flap (FLHTCU)........................................................186
	2.35 TOUR-PAK SPEAKER BOX: FLHTCU...........................................................187
		Speaker Box (FLHTCU)....................................................................187
	2.36 LOWER FAIRING AND ENGINE GUARD.........................................................188
		Lower Fairing (FLHTCU)..................................................................188
		Serrated Washer Replacement.............................................................189
		Engine Guard............................................................................189
	2.37 UPPER FAIRING AND WINDSHIELD: FLHX, FLHT/C/U...........................................191
		Outer Fairing and Windshield............................................................191
	2.38 FAIRING CAP: FLHX, FLHT/C/U............................................................192
		Fairing Cap.............................................................................192
	2.39 INNER FAIRING: FLHX, FLHT/C/U..........................................................193
		Removal.................................................................................193
		Installation............................................................................195
	2.40 AIR DEFLECTORS.........................................................................197
		Air Deflectors (FLHTCU).................................................................197
		Mid-Frame Air Deflectors................................................................197
	2.41 UPPER FAIRING AND WINDSHIELD: FLTR.....................................................198
		Windshield..............................................................................198
		Outer Fairing...........................................................................198
	2.42 INSTRUMENT BEZEL: FLTR.................................................................201
		Bezel...................................................................................201
	2.43 INSTRUMENT NACELLE: FLTR...............................................................203
		Instrument Nacelle......................................................................203
	2.44 INNER FAIRING: FLTR....................................................................206
		Removal.................................................................................206
		Installation............................................................................208
	2.45 GLOVE BOX DOOR AND HINGE: FLTR.........................................................210
		Glove Box Door and Hinge................................................................210
	2.46 WINDSHIELD: FLHR/C.....................................................................211
		Windshield..............................................................................211
		Windshield Window.......................................................................211
	2.47 HEADLAMP NACELLE: FLHR/C...............................................................214
		Removal.................................................................................214
		Installation............................................................................215
	2.48 FRONT FENDER...........................................................................216
		Removal.................................................................................216
		Installation............................................................................216
	2.49 REAR FENDER............................................................................217
		Removal.................................................................................217
		Installation............................................................................217
		Rear Fender Lights Conduit..............................................................218
	2.50 REAR FASCIA: FLHX......................................................................219
		Removal.................................................................................219
		Installation............................................................................219
		Stud Plate..............................................................................219
		Rear Fascia Lamp........................................................................219
	2.51 REAR FRAME.............................................................................220
		Rear Frame..............................................................................220
	2.52 FOOTBOARDS AND FOOTRESTS...............................................................222
		Rider Footboards........................................................................222
		Passenger Footboard.....................................................................223
		Passenger Footrest: FLHX................................................................223
	2.53 JIFFY STAND............................................................................225
		General.................................................................................225
		Removal.................................................................................225
		Installation............................................................................225
		Jiffy Stand Bracket.....................................................................226
		Jiffy Stand Interlock Sensor............................................................226
	2.54 FRONT ENGINE MOUNT.....................................................................227
		Removal.................................................................................227
		Installation............................................................................227
3. ENGINE.......................................................................................229
	3.1 FASTENER TORQUE VALUES..................................................................231
		Fastener Torque Values in this Chapter..................................................231
	3.2 SPECIFICATIONS..........................................................................233
		Specifications..........................................................................233
	3.3 SERVICE WEAR LIMITS.....................................................................235
		General.................................................................................235
	3.4 ENGINE OIL FLOW.........................................................................237
		Oil Feed................................................................................237
		Top End.................................................................................237
		Bottom End..............................................................................239
		Oil Return..............................................................................241
	3.5 OIL PUMP OPERATION......................................................................243
		General.................................................................................243
		Operation...............................................................................243
	3.6 BREATHER OPERATION......................................................................245
		General.................................................................................245
	3.7 OIL PRESSURE............................................................................246
		Oil Pressure Indicator Lamp.............................................................246
		Checking Oil Pressure...................................................................246
	3.8 TROUBLESHOOTING.........................................................................247
		Diagnosing Valve Train Noise............................................................247
		Compression Test........................................................................247
		Cylinder Leakdown Test..................................................................247
		Diagnosing Smoking Engine or High Oil Consumption.......................................248
	3.9 HOW TO USE THIS SECTION.................................................................249
		General.................................................................................249
		Top End Overhaul........................................................................249
		Bottom End Overhaul.....................................................................249
		Subassembly Service and Repair..........................................................250
	3.10 TOP END SERVICE........................................................................251
		Engine in Chassis.......................................................................251
		Engine Removed from Chassis.............................................................252
	3.11 BOTTOM END SERVICE.....................................................................253
		Engine in Chassis.......................................................................253
		Engine Removed From Chassis.............................................................254
	3.12 STRIPPING MOTORCYCLE FOR SERVICE.......................................................255
		Procedure...............................................................................255
	3.13 ASSEMBLING MOTORCYCLE AFTER SERVICE....................................................256
		Procedure...............................................................................256
	3.14 REMOVING ENGINE FROM CHASSIS...........................................................257
		Procedure...............................................................................257
	3.15 INSTALLING ENGINE IN CHASSIS...........................................................258
		Procedure...............................................................................258
	3.16 TOP END OVERHAUL: DISASSEMBLY..........................................................259
		General.................................................................................259
		Rocker Covers...........................................................................259
		Rocker Arm Support Plate................................................................259
		Push Rods, Lifters and Covers...........................................................261
		Cylinder Head...........................................................................262
		Cylinder................................................................................263
		Piston..................................................................................263
	3.17 TOP END OVERHAUL: ASSEMBLY.............................................................265
		General.................................................................................265
		Piston..................................................................................265
		Cylinder................................................................................266
		Cylinder Head...........................................................................268
		Push Rods, Lifters and Covers...........................................................272
		Rocker Arm Support Plate................................................................273
		Breather Assembly.......................................................................274
	3.18 BOTTOM END OVERHAUL: DISASSEMBLY.......................................................276
		General.................................................................................276
		Cam Support Plate and Cover.............................................................276
		Crankcase...............................................................................278
	3.19 BOTTOM END OVERHAUL: ASSEMBLY..........................................................280
		General.................................................................................280
		Crankcase...............................................................................280
		Cam Support Plate and Cover.............................................................282
	3.20 BREATHER ASSEMBLY......................................................................287
		Removal Overview........................................................................287
		Disassembly.............................................................................287
		Cleaning and Inspection.................................................................287
		Assembly................................................................................287
		Installation Overview...................................................................287
	3.21 ROCKER ARM SUPPORT PLATE...............................................................288
		Removal Overview........................................................................288
		Disassembly.............................................................................288
		Cleaning and Inspection.................................................................288
		Assembly................................................................................290
		Installation Overview...................................................................290
	3.22 PUSH RODS, LIFTERS AND COVERS..........................................................291
		Removal Overview........................................................................291
		Disassembly.............................................................................291
		Cleaning and Inspection.................................................................291
		Lifter Inspection.......................................................................292
		Assembly................................................................................292
		Installation Overview...................................................................293
	3.23 CYLINDER HEAD..........................................................................294
		Removal Overview........................................................................294
		Disassembly.............................................................................294
		Cleaning................................................................................295
		Inspection..............................................................................296
		Valve Guide Replacement.................................................................297
		Valve and Seat Refacing.................................................................301
		Assembly................................................................................303
		Installation Overview...................................................................304
	3.24 CYLINDER...............................................................................305
		Removal Overview........................................................................305
		Cleaning................................................................................305
		Inspection..............................................................................306
		Deglazing Cylinder......................................................................307
		Boring and Honing Cylinder..............................................................308
		Installation Overview...................................................................308
	3.25 PISTON.................................................................................309
		Removal Overview........................................................................309
		Disassembly.............................................................................309
		Cleaning................................................................................309
		Inspection..............................................................................310
		Assembly................................................................................311
		Installation Overview...................................................................313
	3.26 CAM SUPPORT PLATE AND COVER............................................................314
		Removal Overview........................................................................314
		Camshafts...............................................................................314
		Oil Pressure Relief Valve...............................................................316
		Cam Needle Bearings.....................................................................316
		Cleaning and Inspection.................................................................319
		Installation Overview...................................................................319
	3.27 OIL PUMP...............................................................................320
		Removal Overview........................................................................320
		Cleaning and Inspection.................................................................320
		Installation Overview...................................................................320
	3.28 CRANKCASE..............................................................................321
		Removal Overview........................................................................321
		Right Crankcase Half....................................................................321
		Left Crankcase Half.....................................................................322
		Sprocket Shaft Bearing Inner Race.......................................................325
		Cylinder Studs..........................................................................327
		Pipe Plug and Oil Fittings..............................................................328
		Cleaning and Inspection.................................................................328
		Installation Overview...................................................................328
	3.29 FLYWHEEL AND CONNECTING RODS...........................................................329
		Removal Overview........................................................................329
		Inspection..............................................................................329
		Installation Overview...................................................................329
	3.30 OIL PAN................................................................................330
		Removal.................................................................................330
		Installation............................................................................330
4. FUEL SYSTEM..................................................................................333
	4.1 FASTENER TORQUE VALUES..................................................................335
		Fastener Torque Values in this Chapter..................................................335
	4.2 SPECIFICATIONS: FUEL SYSTEM.............................................................337
		Specifications..........................................................................337
	4.3 ELECTRONIC FUEL INJECTION (EFI).........................................................338
		Troubleshooting.........................................................................338
	4.4 AIR CLEANER ASSEMBLY....................................................................339
		Removal.................................................................................339
		Installation............................................................................339
	4.5 FUEL TANK...............................................................................341
		Removal.................................................................................341
		Installation............................................................................342
		Evaporative Emissions Tube: Non-CA Models...............................................342
		Fuel Supply Check Valve/Tube............................................................343
	4.6 FUEL TANK TOP PLATE.....................................................................344
		Removal.................................................................................344
		Installation............................................................................345
	4.7 FUEL FILTER.............................................................................347
		Removal.................................................................................347
		Installation............................................................................347
	4.8 FUEL PRESSURE REGULATOR.................................................................348
		Removal.................................................................................348
		Installation............................................................................348
	4.9 FUEL LEVEL SENDER.......................................................................349
		Removal.................................................................................349
		Installation............................................................................349
	4.10 TWIST GRIP SENSOR......................................................................350
		Removal.................................................................................350
		Installation............................................................................351
		Twist Grip Sensor Jumper Harness........................................................352
	4.11 THROTTLE CONTROL ACTUATOR (TCA)........................................................354
		General.................................................................................354
	4.12 ENGINE TEMPERATURE SENSOR (ET).........................................................355
		Removal.................................................................................355
		Installation............................................................................355
	4.13 INDUCTION MODULE.......................................................................356
		Removal.................................................................................356
		Installation............................................................................357
	4.14 TEMPERATURE MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP)...................................359
		General.................................................................................359
		Removal.................................................................................359
		Installation............................................................................359
	4.15 OXYGEN SENSORS (O2)....................................................................360
		General.................................................................................360
		Removal.................................................................................360
		Installation............................................................................360
	4.16 FUEL INJECTORS.........................................................................361
		General.................................................................................361
		Removal.................................................................................361
		Installation............................................................................361
	4.17 FUEL PUMP..............................................................................363
		General.................................................................................363
		Removal.................................................................................363
		Installation............................................................................363
		Fuel Pump and Fuel Level Sender Wire Harness............................................364
	4.18 FUEL PRESSURE TEST.....................................................................365
		General.................................................................................365
		Testing.................................................................................365
	4.19 EXHAUST SYSTEM.........................................................................367
		Mufflers................................................................................367
		System Removal..........................................................................367
		System Installation.....................................................................368
	4.20 ACTIVE EXHAUST (HDI)...................................................................370
		Exhaust Valve Actuator..................................................................370
		Exhaust Valve Actuator Cable............................................................370
		Active Exhaust Valve....................................................................370
	4.21 INTAKE LEAK TEST.......................................................................371
		General.................................................................................371
		Leak Tester.............................................................................371
		Procedure...............................................................................371
	4.22 EVAPORATIVE EMISSIONS CONTROL (CA MODELS)..............................................373
		General.................................................................................373
		Vapor Valve.............................................................................374
		Fuel Vapor Vent Tube....................................................................374
		Canister-to-Solenoid Tube...............................................................374
		Solenoid-to-Induction Module Tube.......................................................374
		Purge Solenoid..........................................................................375
		Charcoal Canister.......................................................................375
5. DRIVE........................................................................................377
	5.1 FASTENER TORQUE VALUES..................................................................379
		Fastener Torque Values in this Chapter..................................................379
	5.2 SPECIFICATIONS: DRIVE...................................................................380
		Specifications..........................................................................380
	5.3 PRIMARY CHAINCASE COVER.................................................................381
		General.................................................................................381
		Removal.................................................................................381
		Installation............................................................................381
	5.4 DRIVE COMPONENTS........................................................................383
		Removal.................................................................................383
		Installation............................................................................384
	5.5 PRIMARY CHAINCASE HOUSING...............................................................388
		Removal.................................................................................388
		Inspection..............................................................................388
		Mainshaft Bearing and Lip Seal..........................................................388
		Mainshaft Bearing Inner Race............................................................389
		Shifter Shaft Bushings..................................................................390
		Installation............................................................................391
	5.6 CLUTCH..................................................................................393
		Removal and Installation................................................................393
		Clutch Pack Only........................................................................393
		Clutch Pack and Bearing.................................................................395
	5.7 TRANSMISSION SPROCKET...................................................................398
		Removal.................................................................................398
		Cleaning and Inspection.................................................................398
		Installation............................................................................398
	5.8 DRIVE BELT..............................................................................400
		Removal and Adjustment..................................................................400
		Installation............................................................................400
6. TRANSMISSION.................................................................................401
	6.1 FASTENER TORQUE VALUES..................................................................403
		Fastener Torque Values in this Chapter..................................................403
	6.2 SPECIFICATIONS: TRANSMISSION............................................................404
		Specifications..........................................................................404
		Service Wear Limits.....................................................................404
	6.3 TRANSMISSION............................................................................405
		Power Flow..............................................................................405
	6.4 SHIFTER LINKAGE.........................................................................407
		Shifter Rod.............................................................................407
	6.5 CLUTCH RELEASE COVER....................................................................408
		Removal and Disassembly.................................................................408
		Cleaning and Inspection.................................................................409
		Assembly and Installation...............................................................409
	6.6 TRANSMISSION ASSEMBLY...................................................................410
		Removal.................................................................................410
		Disassembly.............................................................................411
		Cleaning and Inspection.................................................................417
		Assembly................................................................................417
		Installation............................................................................421
	6.7 MAIN DRIVE GEAR AND BEARING.............................................................423
		Removal.................................................................................423
		Cleaning and Inspection.................................................................424
		Mainshaft Seal Replacement..............................................................426
		Installation............................................................................427
	6.8 TRANSMISSION CASE.......................................................................430
		Removal.................................................................................430
		Installation............................................................................430
		Disassembly.............................................................................431
		Cleaning and Inspection.................................................................431
		Assembly................................................................................432
7. ELECTRICAL...................................................................................435
	7.1 FASTENER TORQUE VALUES..................................................................437
		Fastener Torque Values in this Chapter..................................................437
	7.2 SPECIFICATIONS: ELECTRICAL..............................................................440
		Specifications..........................................................................440
	7.3 VOLTAGE REGULATOR.......................................................................441
		Removal.................................................................................441
		Installation............................................................................441
	7.4 ELECTRONIC CONTROL MODULE (ECM).........................................................442
		ECM.....................................................................................442
	7.5 IGNITION COIL...........................................................................443
		Removal.................................................................................443
		Installation............................................................................443
	7.6 SYSTEM FUSES AND RELAYS.................................................................444
		Main Fuse...............................................................................444
		Main Fuse Holder........................................................................444
		System Fuses and Relays.................................................................444
		Fuse Blocks.............................................................................445
	7.7 ELECTRICAL CADDIES......................................................................446
		Top Caddy...............................................................................446
		Left Side Caddy.........................................................................446
		Battery Tray............................................................................448
	7.8 SECURITY SIREN..........................................................................450
		Removal.................................................................................450
		Installation............................................................................450
	7.9 STARTER.................................................................................451
		General.................................................................................451
		Removal.................................................................................451
		Field Coil Assembly.....................................................................451
		Drive Assembly..........................................................................453
		Installation............................................................................454
	7.10 STARTER SOLENOID.......................................................................455
		Solenoid Assembly.......................................................................455
		Solenoid Plunger........................................................................455
		Solenoid Contacts.......................................................................455
	7.11 HEADLAMP: ALL EXCEPT FLTR..............................................................458
		Headlamp Assembly.......................................................................458
		Headlamp Bulb Replacement...............................................................458
	7.12 HEADLAMP: FLTR.........................................................................460
		Headlamp Assembly.......................................................................460
		Headlamp Bulb Replacement...............................................................460
	7.13 AUXILIARY LAMPS AND BRACKETS...........................................................462
		Auxiliary Lamp Bulb.....................................................................462
		Auxiliary Lamp Housing..................................................................463
		Auxiliary Lamp Bracket..................................................................465
		Adjustment..............................................................................465
	7.14 TAIL LAMP..............................................................................466
		Tail Lamp/Tail Lamp Bulb................................................................466
		Circuit Board/Chrome Base...............................................................466
		Rear Fender Lights Harness..............................................................468
	7.15 FENDER TIP LAMPS.......................................................................470
		Front Fender Tip Lamp...................................................................470
		Front Fender Tip Lamp Jumper Harness....................................................470
		Rear Fender Tip Lamp....................................................................472
	7.16 TURN SIGNAL LAMPS......................................................................474
		Bulb Replacement........................................................................474
		Front Turn Signal Lamp..................................................................474
		Rear Turn Signal Lamp...................................................................478
		Rear Turn Signal Lamps Bracket..........................................................479
	7.17 TSM/HFSM...............................................................................481
		Removal.................................................................................481
		Installation............................................................................481
		HFSM Antenna............................................................................481
	7.18 IGNITION/LIGHT KEY SWITCH AND FORK LOCK................................................482
		FLHX, FLHT/C/U, FLTR....................................................................482
		FLHR/C..................................................................................485
	7.19 FAIRING CAP SWITCHES: FLHTC/U..........................................................487
		Removal.................................................................................487
		Installation............................................................................487
	7.20 INSTRUMENT NACELLE SWITCHES: FLTR......................................................489
		Removal.................................................................................489
		Installation............................................................................490
	7.21 CRANKSHAFT POSITION SENSOR (CKP).......................................................493
		General.................................................................................493
		Removal.................................................................................493
		Installation............................................................................493
	7.22 ALTERNATOR.............................................................................494
		Removal.................................................................................494
		Cleaning and Inspection.................................................................494
		Installation............................................................................495
	7.23 VEHICLE SPEED SENSOR (VSS).............................................................496
		VSS.....................................................................................496
	7.24 NEUTRAL SWITCH.........................................................................497
		Removal.................................................................................497
		Installation............................................................................497
	7.25 OIL PRESSURE SWITCH AND SENDER.........................................................498
		Removal.................................................................................498
		Installation............................................................................498
	7.26 STOPLIGHT SWITCHES.....................................................................499
		Front Stoplight Switch..................................................................499
		Rear Stoplight Switch...................................................................499
	7.27 HORN...................................................................................500
		Inspection..............................................................................500
		Removal.................................................................................500
		Installation............................................................................500
	7.28 CIGARETTE LIGHTER: FLHX, FLHT/C/U, FLTR................................................501
		Troubleshooting.........................................................................501
		Removal.................................................................................501
		Installation............................................................................501
	7.29 GAUGES AND INSTRUMENTS: FLHX, FLHT/C/U, FLTR...........................................502
		2 Inch Diameter Gauges: Fuel Level, Ambient Air Temperature, Voltmeter, Oil Pressure....502
		Tachometer..............................................................................502
		Speedometer.............................................................................503
	7.30 INDICATOR LAMPS: FLHX, FLHT/C/U, FLTR..................................................504
		Indicator Lamps.........................................................................504
	7.31 GAUGES AND INSTRUMENTS: FLHR/C.........................................................505
		Fuel Gauge..............................................................................505
		Speedometer.............................................................................505
	7.32 INDICATOR LAMPS: FLHR/C................................................................507
		Indicator Lamps.........................................................................507
	7.33 ADVANCED AUDIO SYSTEM..................................................................508
		Radio (Storage Box).....................................................................508
		Front Fairing Speakers..................................................................509
		Front Headset Receptacle................................................................509
		Rear Headset Receptacle.................................................................510
		Rear Passenger Switches.................................................................510
		Rear Speakers...........................................................................512
		CB Module...............................................................................512
	7.34 WIRE TROUGH............................................................................513
		Removal.................................................................................513
		Installation............................................................................514
	7.35 MAIN WIRING HARNESS....................................................................515
		Removal: All Models (Part 1)............................................................515
		Removal: FLHR/C (Part 2)................................................................515
		Removal: FLHX, FLHT/C/U (Part 2)........................................................516
		Removal: FLTR (Part 2)..................................................................518
		Removal: All Models (Part 3)............................................................518
		Installation: All Models (Part 1).......................................................520
		Installation: FLHR/C (Part 2)...........................................................523
		Installation: FLHX, FLHT/C/U (Part 2)...................................................524
		Installation: FLTR (Part 2).............................................................524
		Installation: All Models (Part 3).......................................................524
	7.36 INTERCONNECT HARNESS...................................................................525
		FLHX, FLHT/C/U..........................................................................525
		FLTR....................................................................................530
	7.37 RADIO ANTENNA CABLE....................................................................534
		FLHTC/U.................................................................................534
		FLHX, FLTR..............................................................................535
	7.38 AUDIO HARNESS: FLHTCU..................................................................537
		Removal.................................................................................537
		Installation............................................................................537
	7.39 CB ANTENNA CABLE: FLHTCU...............................................................539
		Removal.................................................................................539
		Installation............................................................................539
	7.40 HANDLEBAR SWITCH ASSEMBLIES............................................................541
		Removal.................................................................................541
		Disassembly.............................................................................541
		Specific Repair Procedures: Upper Switch Housings.......................................542
		Specific Repair Procedures: Right Side Lower Switch Housings............................544
		Specific Repair Procedures: Left Side Lower Switch Housings.............................547
		General Repair Procedures...............................................................550
		Assembly: Right Side Handlebar Switches.................................................551
		Assembly: Left Side Handlebar Switches..................................................552
		Installation............................................................................552
A. APPENDIX A CONNECTOR REPAIR..................................................................557
	A.1 AMP MULTILOCK CONNECTORS................................................................559
		AMP Multilock Connector Repair..........................................................559
	A.2 AUTOFUSE ELECTRICAL CONNECTORS..........................................................563
		Autofuse Connector Repair...............................................................563
	A.3 DELPHI CONNECTORS.......................................................................564
		Delphi Connector Repair.................................................................564
	A.4 DELPHI MAIN FUSE HOUSING................................................................566
		Delphi Main Fuse Housing Repair.........................................................566
	A.5 DEUTSCH ELECTRICAL CONNECTORS...........................................................567
		Deutsch Connector Repair................................................................567
	A.6 DEUTSCH STANDARD TERMINAL REPAIR........................................................571
		Deutsch Standard Terminal Crimps........................................................571
	A.7 DEUTSCH SOLID BARREL MINI TERMINAL REPAIR...............................................572
		Deutsch Solid Barrel Terminal Crimps....................................................572
	A.8 DEUTSCH MINI TERMINAL REPAIR............................................................574
		Deutsch Mini Terminal Crimps............................................................574
	A.9 MOLEX CONNECTORS........................................................................575
		Molex Connector Repair..................................................................575
		Crimp Terminal to Lead..................................................................576
	A.10 PACKARD 150 METRI-PACK CONNECTORS......................................................579
		150 Metri-Pack Connector Repair.........................................................579
	A.11 PACKARD 280 METRI-PACK RELAY AND FUSE BLOCK CONNECTORS.................................581
		Fuse Block Repair.......................................................................581
	A.12 PACKARD 480 METRI-PACK CONNECTORS......................................................582
		480 Metri-Pack Connector Repair.........................................................582
	A.13 PACKARD 630 METRI-PACK CONNECTORS......................................................583
		630 Metri-Pack Connector Repair.........................................................583
	A.14 PACKARD METRI-PACK TERMINALS...........................................................584
		Metri-Pack Terminal Crimps..............................................................584
	A.15 ECM CONNECTOR..........................................................................586
		Delphi 73-Terminal ECM Connector........................................................586
	A.16 PACKARD MICRO-64 CONNECTORS............................................................588
		Packard Micro-64 Connector Repair.......................................................588
	A.17 SEALED SPLICE CONNECTORS...............................................................591
		Sealed Splice Connector Repair..........................................................591
B. APPENDIX B WIRING............................................................................593
	B.1 CONNECTORS..............................................................................595
		Connector Locations.....................................................................595
	B.2 WIRING DIAGRAMS.........................................................................613
		Wiring Diagram Information..............................................................613
		2009 Touring Wiring Diagrams............................................................614
C. APPENDIX C ABS...............................................................................647
	C.1 ABS MODULE..............................................................................649
		Removal.................................................................................649
		Installation............................................................................650
	C.2 WHEEL SPEED SENSORS.....................................................................652
		Front Wheel Speed Sensor................................................................652
		Rear Wheel Speed Sensor.................................................................653
	C.3 ABS BRAKE LINES.........................................................................654
		Front Master Cylinder to ABS Module.....................................................654
		ABS Module to Front Brake Calipers......................................................655
		Rear Master Cylinder to ABS Module......................................................657
		ABS Module to Rear Brake Caliper........................................................659
D. APPENDIX D CONVERSIONS.......................................................................661
	D.1 METRIC CONVERSION.......................................................................663
		Conversion Table........................................................................663
	D.2 FLUID CONVERSIONS.......................................................................664
		United States System....................................................................664
		Metric System...........................................................................664
		British Imperial System.................................................................664
	D.3 TORQUE CONVERSIONS......................................................................665
		United States System....................................................................665
		Metric System...........................................................................665
E. APPENDIX E GLOSSARY..........................................................................667
	E.1 GLOSSARY................................................................................669
		Acronyms and Abbreviations..............................................................669
TOOLS...........................................................................................673
TORQUE VALUES...................................................................................679
INDEX...........................................................................................695

2009 HARLEY-DAVIDSON TOURING SERVICE MANUAL – PDF DOWNLOAD:

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