Harley Davidson Technical Guide
. Removing or altering factory installed parts can adversely affect performance and could result in death or serious injury. (00001a) Use only Harley-Davidson approved parts and accessories. Use of certain other manufacturer's performance parts will void your new motorcycle warranty. See your Harley- Davidson dealer for details. Do not store motorcycle with gasoline in tank within the home or garage where open flames, pilot lights, sparks or electric motors are present. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury.
Donny'S Unauthorized Technical Guide to Harley-Davidson. And millions of other books are available for Amazon Kindle. Donny Petersen, who studied privately with Harley-Davidson engineers, shares practical knowledge and street-wise tips in the fifth volume of his unauthorized. Donny is the Winner of the 2012 International Book Awards. Donny Petersen offers the real deal in performancing your Harley-Davidson Twin Cam. Graphics, pictures, and charts guide the reader on a sure-footed journey to a thorough H-D Twin Cam performance understanding.
(00003a) Engine exhaust from this product contains chemicals known to the State of California to cause cancer, and birth defects or other reproductive harm. (00009a) When carrying passengers, it is your responsibility to instruct them on proper riding procedures. (See Riding Tips for Motorcyclist included in your Harley-Davidson Owner's Kit.) Do not allow other individuals, under any circumstances, to operate your motorcycle unless you know they are experienced, licensed riders and are thoroughly familiar with the operation of your particular motorcycle.
Replace punctured or damaged tires. In some cases, small punctures in the tread area may be repaired from within the demounted tire by a Harley-Davidson dealer. Speed should NOT exceed 50 mph (80 km/h) for the first 24 hours after repair, and the repaired tire should NEVER be used over 80 mph (130 km/h).
Wash hands after handling. (00019e) Consult a Harley-Davidson dealer regarding any questions or problems that occur in the operation of your motorcycle. Failure to do so can aggravate an initial problem, cause costly repairs, cause an accident and could result in death or serious injury.
Accessories and Cargo Harley-Davidson Motor Company cannot test and make specific recommendations concerning every accessory or combination of accessories sold. Therefore, the rider must be responsible for safe operation of the motorcycle when installing accessories or carrying additional weight. See the Accessory and Cargo section in your Owner's Manual. Improper loading of cargo or installation of accessories can affect motorcycle stability and handling, which could result in death or serious injury. (00022a) Large surfaces such as fairings, windshields, back rests, and luggage racks can adversely affect handling. Only genuine Harley-Davidson items designed specifically for the motorcycle model should be used with proper installation. An abbreviated V.I.N.
Is stamped on the left side crankcase at the base of the rear cylinder. NOTE: Always give the full 17-digit Vehicle Identification Number when ordering parts or making any inquiry about your motorcycle.
Typical Harley-Davidson V.I.N.: 2009 Touring Models Harley-Davidson V.I.N. Breakdown: 2009 Touring Models POSITION DESCRIPTION. CODE MODEL CODE MODEL ® ® ® FLHR Road King FLHTCU Ultra Classic Electra Glide ® ® ® ® FLHTCU Ultra Classic Electra Glide with FLHTCU Ultra Classic Electra Glide sidecar Shrine ® ® FLTR Road Glide FLHT Electra Glide ®. Specifications Specifications: 2009 Touring Models Engine: 2009 Touring Models ITEM SPECIFICATION Number of cylinders 2 Type 4-cycle, 45 degree V-Type, air cooled Compression ratio 9.2-1 Bore 3.750 in. 95.25 mm Stroke 4.380 in. 111.25 mm Displacement 96.00 cu.
Cm Torque (North 92.60 ft-lbs @ 125.57 Nm @. DRIVE ITEM NUMBER OF TEETH Primary Engine Clutch Final Transmission Rear wheel Capacities: 2009 Touring Models ITEM U.S. LITERS Fuel tank (total) 6.00 gal 22.71 Low fuel warning light on 1.00 gal 3.79 Oil tank with filter 4.00 qt. 3.79 Transmission 1.00 qt. Tire Sizes: 2009 Touring Models MODEL MOUNT SIZE NUMBER FLHRC front 16 in. D407F 130/90 B16 All models except FLHRC front 17 in.
D407F 130/80 B17 All models rear 16 in. D407 180/65 B16 2009 vehicles use Dunlop Harley-Davidson tires only. Bulb Chart: 2009 Touring Models LAMP DESCRIPTION BULBS CURRENT HARLEY- DRAW DAVIDSON (ALL LAMPS 12 VOLT) REQUIRED AMPERAGE PART NUMBER Headlamp FLHT/C/U, FLHR/C, FLHX 1 4.58/5.0 68329-03 FLTR 4.58/5.0 68329-03 Position lamp, 0.32 53438-92 international Position lamp, FLTR 0.32 53436-97 Japan Tail and stop Tail/stop lamp. (00024a) Tubeless tires fitted with the correct size inner tubes may be used on all Harley-Davidson laced (wire spoked) wheels.
Protective rubber rim strips must be used with tubeless tires (fitted with correct size inner tubes) when mounted on laced (wire spoked) wheels. Reformulated gasolines use additives to oxygenate the gas. Your motorcycle will run normally using this type of gas and Harley-Davidson recommends you use it when possible, as an aid to cleaner air in our environment. Do not operate catalytic converter-equipped vehicle with engine misfire or a non-firing cylinder. If you operate the vehicle under these conditions, the exhaust will become abnormally hot, which can cause vehicle damage, including emission control loss. (00149a) Use only unleaded fuel in catalytic converter-equipped motorcycles. Using leaded fuel will damage the emission control system.
(00043a) Some features explained are unique to certain models. These features may be available as accessories for your Harley-Davidson motorcycle. See a Harley-Davidson dealer for a complete list of accessories that will fit your specific motorcycle. Ignition/Headlamp Key Switch: Touring Models The automatic-on headlamp feature provides increased visibility of the rider to other motorists. The lamps illuminate when the switch is in the IGNITION position, as required by law in some localities.
Ignition/Headlamp Switch Positions: Touring Models MODEL FUNCTION LABEL OPERATION FLHT Key Lock LOCK Locks the switch in either the FORK LOCK or ACCESS switch position. See Fork Lock: FLHR/FLHRC. On FLHR/FLHRC models, the fork lock is located at the top of the steering head, behind the headlamp nacelle and inset in the handlebar clamp shroud.
See Ignition/Headlamp Key Switch: Touring Models. On FLHT/FLTR/FLHX models, the fork lock is integrated into the ignition switch. See Basic Handlebar Controls: FLHRC Shown (typical).
The electric starter switch is located on the right handlebar control group. See Starting the Engine for detailed operation procedures. Put the engine off/run switch in the RUN position and the transmission in neutral. Neutral (green) indicator lamp should be illuminated.
left handlebar and is operated with the fingers of the left hand. Slowly pull clutch hand lever in against handlebar grip to fully disengage clutch. Shift to first gear using the gear shifter lever. See Cruise Control: Touring Models. Slowly release the clutch hand lever to engage clutch. A clutch switch is incorporated into the left handlebar switch assembly. Clutch hand lever Horn switch Headlamp dimmer switch Left turn signal switch Master cylinder reservoir Electric starter switch Engine off/run switch Brake hand lever Throttle control grip Throttle friction adjusting screw (not shown, not used on cruise control models) Right turn signal switch Basic Handlebar Controls: FLHRC Shown (typical) Electronic Throttle Control (ETC) Touring models are equipped with Electronic Throttle Control (ETC).
Hazard Warning 4-Way Flasher Use the following method to activate the four-way flashers. With the ignition key ON and security system disarmed (if equipped), press the left and right turn signal switches at the same time. Turn the ignition key OFF and arm the security system if present and desired. The four-way flashers will continue for two hours. Speedometer Travel at speeds appropriate for road and conditions and never travel faster than posted speed limit. Excessive speed can cause loss of vehicle control, which could result in death or serious injury. (00008a) See Indicator Lamps: Touring Models.
The speedometer registers miles per hour (U.S. Models) or kilometers per hour (international models) of forward speed.
Tachometer See OPERATING RECOMMENDATIONS section. Do not operate the engine above maximum safe RPM as shown under OPERATION (red zone on tachometer). Lower the RPM by upshifting to a higher gear or reducing the amount of throttle. Failure to lower RPM may cause equipment damage. (00159a) See Indicator Lamps: Touring Models. The engine lamp normally comes on when the ignition is first turned on and remains on for approximately 4 seconds, as the engine management system runs a series of self-diagnostics. If the engine lamp comes on at any other time, see a Harley-Davidson dealer.
Low Fuel Lamp. ABS detects that the system is malfunctioning.
In the diagnostic mode, the lamp will also illuminate to indicate the presence of diagnostic trouble codes (DTCs). See a Harley-Davidson dealer for service. If ABS lamp remains on continuously, the ABS is not operating. The standard brake system is operational, but wheel lock up can occur. control is ON. If the orange icon does NOT come on, the system is NOT ON. You cannot SET cruise speed, see your dealer.
See RESUME/SET Switch. RESUME/SET switch located in the right handlebar control group.
The RESUME/SET switch controls several system functions, including set, resume, accelerate and decelerate. See Indicator Lamps: Touring Models. Turn the cruise control switch to the ON position. The orange icon on the cruise gauge face will light when activated. With the motorcycle traveling at the desired cruise speed of 30-85 mph 48-137 km/h, momentarily push the RESUME/SET switch on the right handlebar to SET. Turn cruise control switch to the OFF position.
The orange icon in the gauge is extinguished to indicate the system is OFF. NOTES: System will NOT work if: Rider operates at vehicle speeds below 30 mph 48 km/h or above 85 mph 137 km/h. Brake lamps are on constantly. Shift Pattern: 6-Speed Touring Models Shifting While Stopped When difficulty of shifting gears is experienced, do not under any circumstances, attempt to force the shift. The results of such abuse will be a damaged or broken shifter mechanism.
(00161a) When the motorcycle is standing still in first gear with the engine off or in neutral with the engine running, the transmission may not shift gears. (00053a) Anti-lock Brake System (ABS) Harley-Davidson's Anti-Lock Brake System assists the rider in maintaining control when braking in a straight-line emergency situation. ABS operates independently on front and rear brakes to keep the wheels rolling and prevent uncontrolled wheel lock-ups either on dry pavement or on slick surfaces such as gravel, leaves or when riding in wet conditions. SYMPTOM CONDITION event Clicking sound Normal condition.
During an ABS event ABS lamp flashing Normal condition - key turned to IGNITION - speed under 3 mph 5 km/h. Perceived 'surge' Normal condition - most noticeable when braking with one brake (front only or while braking rear only). The rider may clear the text messages at any time by pressing the function switch once while the vehicle is powered up. NOTE: If the operation of raising the jiffy stand and putting the transmission in gear is rapidly executed, the jiffy stand bouncing off the frame could cause the jiffy stand interlock system to activate and stop the engine. (00028a) Do not use aftermarket fuel caps. Aftermarket fuel caps may fit improperly and leak, which could lead to death or serious injury. See a Harley-Davidson dealer for approved fuel caps.
(00034a) Rear Air Suspension General See Rear Air Suspension Air Valve. SHOCK LOAD TOTAL WEIGHT PRESSURE Solo rider up to 150 up to 68 150-200 68-91 0-10 0-69 200-250 91-113 10-20 69-138 250-300 113-136 20-30 138-206 over 300 over 136 30-50 206-345 Solo rider with capacity luggage of 40 lbs 18 kg up to 150 up to 68 10-20. Do NOT pull on any electrical wires.
Pulling on electrical wires may damage the internal conductor causing high resistance, which may result in minor or moderate injury. (00168a) The Tour-Pak can be located in two positions. See the service manual or a Harley-Davidson dealer about Tour-Pak removal/relocation.
Tour-Pak Lock and Draw Catch Lock Draw catch Tour-Pak Lock and Draw Catch Saddlebags: FLHR/FLHT/FLHX/FLTR Opening See Saddlebags: FLHR/FLHT/FLHX/FLTR. Unlock latch. Place fingers under latch and lift. Place one hand at OUTSIDE CORNER of cover and other hand at opposite outside corner. Lift outside edge of cover, pivoting inside edge of cover in brackets.
Unscrew saddlebag fasteners by turning 1/4 turn counterclockwise. Remove saddlebag. Installing Carefully place saddlebag in position on saddlebag rail and align the bail head studs with the support bracket fasteners. See Saddlebags: FLHR/FLHT/FLHX/FLTR.
Fasten studs by pushing into support bracket fasteners and turning 1/4 turn clockwise. Insert the male strap end into the receptacle on the bag and push until a positive 'click' is felt. NOTE: See Leather Care for proper saddlebag care.
Saddlebag Quick Disconnect Windshield: FLHR/C Removal See Windshield: FLHR/C. Insert your fingers into the wire form latch springs at either side of the windshield and move the TOP of the windshield assembly forward, until the TOP bracket notches slide away from the grommets. See Accessory Connector.
There is an accessory connector located in front of the battery that can be activated with the ACC switch. See a Harley-Davidson dealer for possible uses. It is possible to overload your motorcycle's charging system by adding too many electrical accessories. See a Harley-Davidson dealer for advice about the amount of current consumed by additional electrical accessories, or for necessary wiring changes. (00211b) Auxiliary (SPOT) Speakers Cruise control. Fairing Lower Vent Control Rider Footboards Rider footboards are adjustable. See a Harley-Davidson dealer for adjustment.
Passenger Footboards/Footrests Passenger footboards/footrests can be adjusted to one of three positions. Before moving to a new position, remove plastic plugs from holes in the footrest mount in the frame as necessary. The Advanced Audio System by Harman/Kardon is based on an electronic unit mounted inside the front fairing of selected Harley-Davidson Touring models. For FLHX, FLHTC, and FLTR: The Advanced Audio System is a multi-band radio receiver that includes a Compact Disc (CD)/MP3 player and an auxiliary (AUX) port for media players. More than 10 hours of MP3 music - 150 MP3 songs (10 albums) on one 650MB disc. Anti-skip protection (40 second memory and mechanical dampers).
Remote controls for frequency tuning, band change, CD select, volume, and bass/treble/fader mixing. Automatic Volume Control (AVC) - automatically adjusts volume to compensate for ambient noise due to motorcycle speed. NOTE: With the headsets/microphones plugged into the rider and/or passenger intercom sockets, the intercom is voice activated (VOX). Active only with the Advanced Audio System accessory, NAV is the GPS positioning and turn-to-turn navigation setup button. Press the NAV pushbutton to display the navigational menu.
The liquid crystal display (LCD) displays the operational status of the stereo receiver and that of any accessory. Soft keys (4, 5/Left Arrow, 6) Liquid crystal display (LCD) Soft keys (1, 2, 3) ON key GPS navigation module Intercom setup Advanced Audio System Front Panel Left Handlebar Controls See LH Audio Controls: FLHTC, FLHX Upper - FLHTCU, FLTR Lower. Easy to operate while riding, audio controls are mounted on the left hand switch housing on the left handgrip. +/AUDIO/- PTT / +/SQ/- LH Audio Controls: FLHTC, FLHX Upper - FLHTCU, FLTR Lower Right Handlebar Controls See RH Audio Controls: FLHTC, FLHX (Upper) - FLHTCU, FLTR (Lower).
The mode select (MODE SEL) switch is located on the right handlebar switch assembly. UP/MODE SEL/DN Switch MODE SEL With the radio power ON, press and release the MODE SEL switch to sequence between the radio. NOTE: The intercom and CB can be activated at the same time with the receiver modes. The intercom and CB signals are passed to the audio circuits only if the signal strength exceeds the threshold established by CB squelch or VOX microphone sensitivity levels. Depending on the position of the speaker control switch in the fairing switch cap, the receiver function, the CB, and the VOX microphone can be heard in the headsets simultaneously.
Refer to Receiver Frequency Bands. When a CD/MP3 disc is present in the CD slot and/or an auxiliary player is plugged into the AUX port, the MODE SEL switch will cycle through the CD and AUX modes as well as the frequency bands. Volume See D in FLHX, FLHTC and FLTR LCD Display Examples. The radio has several tuning modes in each of the frequency bands: Manual, Seek, Scan, Preset Memory and Preset Scan.
Harley Davidson Technical Guided Tours Usa
Tuning in all three modes continuously wraps around the ends of the band. Manual Tuning To manually tune the radio to a different frequency: Press the Up Arrow button or the Down Arrow button to select the frequency in that direction. To select a station, cancel preset SCAN while the radio is tuned to that station. Press the MODE SEL switch UP or DN to cancel a preset SCAN. Adjusting Volume Volume can be adjusted in any radio band. See D in FLHX, FLHTC and FLTR LCD Display Examples. Volume is adjusted with the AUDIO switch on the left hand grip.
FLHX, FLHTC and FLTR LCD Display Examples Adjusting Display Contrast See Character Display Illumination. Select Display from the Audio/Setup menu with the AUDIO switch.
Press the AUDIO up (+) to increase or down (-) to decrease the contrast of the characters in the display. Do not change compact discs while riding, and do not select a volume level that blocks out traffic noise. Distractions or a volume level that blocks out traffic noise, could cause loss of control resulting in death or serious injury. (00086a) Do not disassemble unit. To change CD/MP3 tracks, use the right thumb and press and release the MODE SEL switch on the right hand grip. Press UP and release to select higher numbered tracks or press DN and release to select lower number tracks.
Pressing the Up Arrow and Down Arrow keys will also advance tracks. NOTE: The files will be numbered sequentially. CD/MP3 Display Examples Recommendations for Handling CDs Use caution when handling a CD. Avoid touching the bottom (shiny) side. Store audio CD/MP3 discs in acrylic jewel cases to protect against dust, scratches, light, and changes in humidity.
Please check with local authorities and obey all applicable laws and regulations. (00173a) A Harley-Davidson dealer can help you select the correct genuine Harley-Davidson headsets and microphones for your year and model Harley-Davidson. Harley-Davidson stereo helmet headsets with 7 pin DIN jacks fit the rider and the passenger intercom sockets. Other headset microphones will not work. A three position speaker (SPKR) switch is located on the inner fairing cap of the FLHTCU and the FLTR. See FLHTCU SPKR Switch.
NOTE: The SPKR switch found on the FLTR is inoperable. Off/Forward: In the forward position, the speakers are off.
Audio (radio, CD/MP3, AUX and CB) is played in the headsets only. radio band selection, tuning, CD/MP3 operation and all functions of the hand grip mounted MODE SEL switch. NOTE: For information on routing audio signals to the passenger speakers and headsets, refer to Audio Routing and Mixing Combinations. PTT and +/VOL/- Switch See FLHTCU Passenger Controls.
Headset socket PTT/+/VOL/- MODE/+/TUNE/- TLE Ultra Sidecar Audio Controls Speaker Output Power MODEL TOTAL SPEAKERS OHMS PER WATTS SPEAKER FLTR 2 speakers, FLHTC 20 watts each FLHTCU 4 speakers, 20 watts each TLE Sidecar 2 speakers, w/amplifier 20 watts each Intercom Operation Operation To speak over the intercom, press and hold either rider or passenger PTT switch to enable the. pressing INT. NOTE: To ensure privacy, the intercom can only be heard through the headsets. To turn OFF the intercom and the VOX microphones, press the INT button to open the Intercom Setup display and press the On/Off soft key (1).
Adjusting VOX Sensitivity VOX sensitivity should be adjusted so that the microphones break VOX at a normal voice level. Activating the CB See H and I in Display Examples.
To activate the Citizen Band transceiver, press and release the COM pushbutton on the front panel. Press soft key 1 to turn the CB ON/OFF. The CB will activate in CB Setup with squelch threshold and channel settings from the previous use.
Adjusting Squelch See K in Display Examples. The CB signal is passed to the speakers or headsets only if signal strength exceeds the threshold set with the squelch control switch (PTT/+/SQ/-).
When CB signals exceed the threshold, they are said to 'break squelch.' Refer to Squelch Control Switch. To lower the threshold to process the weakest CB signals, press SQ - or rearward.
Display Examples Audio Routing and Mixing General Refer to Audio Routing and Mixing Combinations. Whether audio is routed to the headsets, speakers or both depends on the SPKR control switch and the INT and CB buttons on the receiver. A single audio source routed to headset or speaker can be controlled with the riders AUDIO switch or the passenger VOL switch. AUDIO ROUTING COMBINATIONS VOLUME CONTROL SPEAKER AUDIO AUDIO OUT AUDIO +/- OR VOL CONTROL SOURCE(S) SWITCH Intercom and Intercom in the headsets Music. music.
Music. in the speakers CB and music. CB in the headsets Music. in the speakers Music is muted during CB recption Intercom and CB Both in the headsets (Music is MUTED during CB. If it is necessary to replace the radio fuses, follow the fuse replacement procedures in this manual or see your Harley-Davidson dealer for service. See Radio Fuses.
Radio fuses are located in the fuse block under the left side cover. Do not relocate the module or the antenna on the motorcycle. Options Several options are available for the Harley-Davidson Smart Security System from the Harley- Davidson Genuine Motor Accessories and Motor Parts catalog.
Options include: Smart Siren and Smart Siren II. The serial number of the fob is also found on the inside of the fob. See Fob Battery. The module will arm only if the fob has been assigned by a Harley-Davidson dealer and a Personal Identification Number (PIN) has been entered in the system.
The PIN should be recorded on the Personal Information page in the front of this Owner's Manual and on the removable wallet card. Do not leave the fob attached to the handlebars or store the fob in a saddlebag or ® Tour-Pak. Unintentionally leaving the fob with the motorcycle when it's parked prevents the system from activating the alarm. Do not ride with the fob stored in a metal case or with the fob closer than 3.0 in. 76 mm to a cell phone, PDA, display or other electronic device.
Arming and Disarming Arming When the motorcycle is parked and the ignition key is turned to OFF, the Harley-Davidson Smart Security System arms automatically within five seconds if no motion is detected. Even when the fob is present, the system will arm. Do not turn handlebars, straddle seat or lift motorcycle off the jiffy stand. During a PIN disarm, if the Smart Security System detects motorcycle motion the system will activate the alarm. Entering a PIN to Disarm Harley-Davidson Smart Security System STEP. STEP ACTION WAIT FOR CONFIRMATION NOTES Enter fifth digit (e) in the PIN The fifth digit (e) in the odometer by pressing left turn switch will be the fifth digit in the PIN. Press right turn switch 1 The fifth digit is stored.
The alarm will also activate the LED, vibration or audible modes of a Harley-Davidson Security Pager. A pager can operate either in silent or in combination with an optional Smart Siren.
The range of a pager can be up to 0.5 mile 0.8 km. See a Harley-Davidson dealer for details. Optional Smart Siren Deactivate the Alarm Key Fob: Bring the fob to the motorcycle. Owner's Manual instructions for storage. Refer to Motorcycle Storage. Service Departments When the motorcycle is to be left at a Harley-Davidson dealer, there are two options: Leave an assigned fob with the dealer.
To maintain possession of the fob, ask the dealer to disable the module for service (service mode) before leaving the dealership. On motorcycles with a sidecar, the turn signal module (TSM) or the Hands-Free Security Module (HFSM) must be switched from the factory solo vehicle setting to the sidecar setting. Consult a Harley-Davidson dealer for complete details. If a sidecar is permanently removed from the motorcycle, the TSM or the HFSM must be reconfigured. If the system key icon stays illuminated while riding, see a Harley-Davidson dealer. With the fob present, if the Smart Security System continues to actuate warnings and alarms, one of the following can be the cause: Electromagnetic Interference: Other electronic devices, power lines, or other electromagnetic sources can cause the Smart Security System to operate inconsistently.
Operation Operating Recommendations: Touring Models Motorcycles are different from other vehicles. They operate, steer, handle and brake differently. Unskilled or improper use could result in loss of control, death or serious injury.
(00556c) Take a rider training course. Read Owner's Manual before riding, adding accessories or servicing. Wear a helmet, eye protection and protective clothing. Break-in Riding Rules The First 500 Miles (800 Kilometers) The sound design, quality materials, and workmanship that are built into your new Harley-Davidson will give you optimum performance right from the start. To allow your engine to wear in its critical parts, we recommend that you observe the riding rules provided below for the first 500 miles 800 kilometers.
Handlebars should turn smoothly without binding. Be sure tires are properly inflated, balanced and have adequate tread. Inspect your tires regularly and see a Harley-Davidson dealer for replacements. Riding with excessively worn, unbalanced or under-inflated tires can adversely affect stability and handling, which could result in death or serious injury. General The engine should be allowed to run slowly for 15-30 seconds. This will allow the engine to warm up and let oil reach all surfaces needing lubrication.
Failure to comply can result in engine damage. (00563b) Do not roll the throttle before starting.
Rolling the throttle before starting the motorcycle is unnecessary. Engine off/run switch Engine start switch Right Handlebar Controls: Touring Models (typical) Engine Idle Temperature Management System For those riders who frequently find themselves in riding conditions where the vehicle is subjected to prolonged idle conditions or traffic congestion, the motorcycle is equipped with an Engine Idle Temperature Management System (EITMS) to provide limited cooling of the rear cylinder. Press the foot shift lever down to end of its travel and release.
The transmission is now in first gear. To start forward motion, ease out the clutch lever slowly and at the same time, open throttle gradually.
Upshift (Acceleration) Refer to Upshift (Acceleration) Gear Speeds: Six Speed. Downshift (Deceleration) Gear Speeds: Six Speed GEAR CHANGE Sixth to fifth Fifth to fourth Fourth to third Third to second Second to first NOTE: The shifting points shown in the tables are recommendations. Vehicle owners may determine that their own individual shifting patterns may differ than those stated and are additionally appropriate for individual riding styles. Refer to Regular Service Intervals: 2009 Touring Models. After a new motorcycle has been ridden its first 1000 miles 1600 kilometers, it should be taken to an authorized Harley-Davidson dealer for initial service operations. Recommended Engine Oils.
Your authorized dealer has the proper oil to suit your requirements. If it is necessary to add oil and Harley-Davidson oil is not available, use an oil certified for diesel engines. Acceptable diesel engine oil designations include: CF-4, CG-4, CH-4 and CI-4. Perform engine oil level COLD CHECK as follows: For pre-ride inspection, place vehicle on level ground and rest the vehicle on its jiffy stand (unless sidecar is attached). Remove filler plug/dipstick and wipe off the dipstick. Insert the dipstick and tighten into the fill spout.
ADD QT (lower) mark Cold check level FULL (hot check) mark Engine Oil Dipstick Changing Oil and Oil Filter Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed. Use of inferior lubricants can damage the engine. (00184a) Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Use Harley-Davidson oil filter wrench for filter removal. This tool can prevent damage to crankshaft position sensor and/or sensor cable.
(00192b) See Oil Filter Wrench (Part No. Remove the oil filter using OIL FILTER WRENCH HD-42311 or OIL FILTER WRENCH HD-44067A and hand tools. Do not use with air tools. Thin oil film ONLY Oil filter Mounting plate Applying Thin Oil Film Winter Lubrication In colder climates, the engine oil should be changed often. If motorcycle is used frequently for short trips, less than 15 miles 24 kilometers, in ambient temperatures below 60° F 16° C, oil change intervals should be reduced to 1500 miles 2400 kilometers.
GENUINE Harley-Davidson FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT (Part No. 99851-05 quart).
The transmission fluid capacity is approximately 32 fluid ounces 0.95 liters. Inspect o-ring for tears or damage. Replace if required.
Wipe any foreign material from plug. Remove seal ring from clutch inspection cover and discard. If the fluid level can be seen, it is adequate. Otherwise, pour enough GENUINE Harley-Davidson FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT (Part No. 99851-05, U.S.
Quart) in through the clutch inspection cover opening until it is visible along the bottom portion of the clutch assembly. Inspect drain plug O-ring for cuts, tears or signs of deterioration. Replace as necessary.
Install drain plug into primary chaincase and tighten to 14-21 ft-lbs (19.0-28.5 Nm). 1124 ml of GENUINE Harley-Davidson FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT (Part No. 99851-05 quart) through the clutch inspection cover opening. Belt deflection should be within specification as shown in Belt Deflection. If belt tension adjustment is necessary, see a Harley-Davidson dealer or follow the instructions given in the applicable Service Manual. If fork does not appear to be working properly or an appreciable amount of oil leakage should develop, see a Harley-Davidson dealer.
If there is insufficient oil in either side of fork, the rebound action will be incorrect. Adjustments to front fork bearings should be performed by a Harley-Davidson dealer. Improperly adjusted bearings can adversely affect handling and stability, which could result in death or serious injury. (00051a) Refer to Regular Service Intervals: 2009 Touring Models.
Check front fork for proper bearing adjustment and lubricate bearings at proper intervals. Use only D.O.T. 4 HYDRAULIC BRAKE FLUID (Part No.
99953-99A) approved for brake system use and available from your Harley-Davidson dealer. Harley-Davidson has provided your new motorcycle with the optimum brake pad friction material available. It is selected to give the best performance possible under dry, wet and high operating temperature conditions. Same as original equipment tires should be used.
Other tires may not fit correctly, could adversely affect handling, and may be hazardous to use. Tires are a critical safety component. Contact a Harley-Davidson dealer for tire repair or replacement. Improper tire service can adversely affect stability and handling, which could result in death or serious injury. Tire Replacement Inspection Harley-Davidson tires are equipped with wear bars that run horizontally across the tread. When wear bars become visible and only 1/32 in.
(0.8 mm) tread depth remains, replace tire immediately. Using a worn tire can adversely affect stability and handling, which could result in death or serious injury.
Wear Bar Appearance (Typical) Shock Absorbers Refer to Regular Service Intervals: 2009 Touring Models. Inspect shock absorbers and rubber bushings for leaks and bushing deterioration at proper intervals.
Spark Plugs Refer to Regular Service Intervals: 2009 Touring Models. Check the spark plugs at proper intervals. Allow filter to either air dry or blow it dry, from the inside, with low pressure air. Do not use an air cleaner filter oil on the Harley-Davidson paper/wire mesh air filter element. Install air filter before running engine. Failure to do so can draw debris into the engine and could result in engine damage. Handle bulb carefully and wear eye protection.
Bulb contains gas under pressure, which, if not handled carefully, could cause serious eye injury. (00062b) Bulb Tabs Headlamp Bulb: FLTR Headlamp Alignment The automatic-on headlamp feature provides increased visibility of the rider to other motorists.
Perpendicular line Vertical line 25 feet (7.6 meters) High beam bulb centerline Horizontal line 2.1 in. (53.3 mm) lower than bulb centerline Check Headlamp Alignment NOTE: As the weight of the rider will compress the suspension slightly, have a person whose weight is approximately the same as that of the principal rider sit on the motorcycle. Right only counterclockwise Left only counterclockwise to the left Right only clockwise Left and right equally clockwise upward Left and right equally counterclockwise downward Auxiliary Lamps See a Harley-Davidson dealer or service manual for bulb replacement or alignment of auxiliary lamps.
Turn Signal Bulb Replacement: Bullet Style See Lens Cap Notch. Insert a coin or the blade of a small screwdriver into the notch at the bottom of the lens cap. Carefully twist until the lens cap pops out of the lamp housing. Push in bulb and rotate counterclockwise.
Turn ignition on and test for proper turn signal operation. NOTE: If the turn signal or running lamp will not light after replacing a bulb, check the wiring, the ground at the socket and/or the switch. Screws (2) Lens Bulb Lamp housing Turn Signal Lamp Assembly: Flat Lens Style Tail Lamp Bulb Replacement: Standard Style. This unit requires no interval attention. If any electrical system trouble is experienced that might be traceable to the alternator or voltage regulator, the motorcycle should be taken to a Harley-Davidson dealer who has the necessary electrical testing equipment to give the required attention. Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, rubberized gloves and protective clothing when working with batteries.
KEEP BATTERIES AWAY FROM CHILDREN. (00063a) Explosive hydrogen gas, which escapes during charging, could cause death or serious injury. Battery Warning Label Voltmeter Test Refer to Voltmeter Test. The voltmeter test provides a general indicator of battery condition. Check the voltage of the battery to verify that it is in a 100 percent fully charged condition.
If the open circuit (disconnected) voltage reading is below 12.6V, charge the battery and then re-check the voltage after the battery has set for one to two hours. Electric starter sounds weak.
Battery has not been used for an extended period of time. Explosive hydrogen gas, which escapes during charging, could cause death or serious injury. Charge battery in a well-ventilated area. Keep open flames, electrical sparks and smoking materials away from battery at all times.
KEEP BATTERIES AWAY FROM CHILDREN. Step away from the battery and turn on the charger.
Unplug or turn OFF battery charger before disconnecting charger cables from battery. Disconnecting clamps with charger ON can cause a spark and battery explosion, which could result in death or serious injury. (00067a) After the battery is fully charged, turn OFF the charger and disconnect the black battery charger lead to the negative (-) terminal of the battery. Capacity Months of non-use Measured at 105° F (40° C) Measured at 77° F (25° C) Effective Rate of Temperature on Battery Self-discharging Rate Battery Disconnection and Removal Remove seat. See Top Caddy. If present, move purge solenoid (1) forward to release from top caddy.
Release HFSM antenna (2) from top caddy and move out of the way. Purge solenoid HFSM antenna Cable ties Fastener Top Caddy Top caddy Lifting strap Move Top Caddy Aside Installation and Connection Connect the cables to the correct battery terminals. Failure to do so could result in damage to the motorcycle electrical system.
(00215a) Do not allow positive (+) battery cable to contact ground with negative (-) cable connected. KEEP BATTERIES AWAY FROM CHILDREN. (00065a) Harley-Davidson motorcycles have a 12 Volt battery. Be sure the booster vehicle has a 12 Volt system. Failure to do so could result in vehicle damage. (00220a) NOTE: This procedure presumes the BOOSTER battery is in another vehicle. (00223a) Fuses are located under left side cover.
For electrical problems, it is best to see a Harley-Davidson dealer who has necessary parts and equipment to perform electrical services. NOTE: See Left Side Cover Removed: Touring Models. Place the ignition/headlamp key switch in the OFF position. Remove left saddlebag and side cover. See Left Side Cover Removed: Touring Models.
Press latch on bottom of fuse block cover and swing bottom of the cover out. Remove the cover. NOTE: The fuse block cover has a fuse puller attachment that may be used to remove fuses. ITEM FUSE ITEM FUSE ITEM FUSE ITEM FUSE Brake (15 amp) Accessory (15 P&A (15 amp) Radio power (15 amp) amp) Radio memory (15 Battery (15 ECM power (15 Exhaust control amp) amp) amp) (15 amp) System relay Start relay Fuel pump (15 P&A ignition (2A amp). See Seat Mounting Slot.
Place seat on frame backbone. See Seat Tongue. Firmly push front of seat downward and then forward until slot engages tongue on rear fuel tank bracket. Install seat mounting fastener. Tighten to 20-40 in-lbs (2.3-4.5 Nm).
NOTE: If the seat retention nut is damaged or lost, see service manual for instructions. Seat Mounting Slot Seat: FLHTC/U Removal See Tour-Pak. Open Tour-Pak to move passenger seat backrest out of the way. NOTE: The Tour-Pak must be positioned to the rear to gain access to the seat mounting bracket screw. If the Tour-Pak is in the forward position, remove Tour-Pak and install in rearward position. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury.
(00070b) Pull up on seat to verify that it is properly secured, front and rear. See Seat Strap Bracket Screw (typical). Placing Motorcycle in Storage Proper storage is important for the trouble-free operation of your motorcycle. See your Owner's Manual for storage recommendations or see a Harley-Davidson dealer.
Improper storage procedures can lead to equipment damage. (00046a) If the motorcycle will not be operated for several months, such as during the winter season, there are several tasks which should be performed. Check steering for smoothness by turning the handlebars through the full operating range. Be sure tires are properly inflated, balanced and have adequate tread.
Inspect your tires regularly and see a Harley-Davidson dealer for replacements. Riding with excessively worn, unbalanced or under-inflated tires can adversely affect stability and handling, which could result in death or serious injury. General Maintenance Maintain chrome and aluminum regularly to check that they retain their original shine and luster. Take care to keep your new Harley-Davidson motorcycle cleaned and waxed as often as possible to inhibit rust and corrosion. Cleaning Your Motorcycle To aid you in keeping your motorcycle clean, see your Harley-Davidson dealer for cleaning, polishing and waxing products. Leather Care NOTE: Many Harley-Davidson accessories and seats are either made of leather or have leather inserts. Natural materials age differently and require different care than man-made materials.
Seat covers and panels made of leather will gain 'character', such as wrinkles, with age. Leather is porous and organic and each leather product will settle into its own distinct form with use. Do not clean in hot sun or high temperature. Powdered, abrasive or alkaline cleanser will damage the windscreen/windshield. Do not use harsh chemicals including rain sheeting products on Harley-Davidson windshields. They can cause dulling or hazing.
If you want to use a windshield. Troubleshooting Troubleshooting: General The troubleshooting section of the Owner's Manual is a guide to diagnose problems. Read the service manual before performing any work. Improper repair and/or maintenance could result in death or serious injury. (00080a) The following checklist of possible operating troubles and their probable causes will be helpful in keeping your motorcycle in good operating condition. Battery nearly discharged.
Loose wire or cable connection(s) at one of the battery terminals or at coil. Engine oil too heavy (winter operation). Water or dirt in fuel system. Fuel pump inoperative.
Starts But Runs Irregularly or Misses Spark plugs in bad condition or partially fouled. Spark plug cables in bad condition and leaking. Alternator Does Not Charge Module not grounded. Engine ground wire loose or broken. Loose or broken wires in charging circuit.
Alternator Charge Rate is Below Normal Weak battery. Excessive use of add-on accessories. Loose or corroded connections. Extensive periods of idling or low speed riding. ABS lamp does not shut off above 3 mph 5 km/h. Other ABS symptoms. Refer to ABS Symptoms and Conditions.
Harley Davidson Technical Training
Brakes Do Not Hold Normally Master cylinder low on fluid. Brake line contains air bubbles.
Master or wheel cylinder piston worn. It is the owner's responsibility to follow the scheduled mileage intervals as specified; all of the specified maintenance services must be performed to keep your warranty valid.
Make an appointment with a Harley-Davidson dealer for inspection and service just before you have ridden 1000 miles 1600 kilometers. California Evaporative Emission Controls: 2009 Models All new model year 2009 Harley-Davidson motorcycles sold in the State of California are equipped with an evaporative emission control system. This system is designed to meet the CARB regulations in effect at the time of manufacture. Transfer Notification Form. It is critical that new owner information is communicated to Harley- Davidson.
New owner information is required to be on file with Harley-Davidson to transfer an Extended Service Plan Contract. Harley-Davidson is also required by the National Traffic and Motor Vehicle Safety Act to notify all owners in the event of a recall. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. TO THE FULLEST EXTENT ALLOWED BY LAW, HARLEY-DAVIDSON AND ITS DEALERS SHALL NOT BE LIABLE FOR LOSS OF USE, INCONVENIENCE, LOST TIME, COMMERCIAL LOSS OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES.
Any cosmetic condition existing at the time of retail delivery that has not been documented by the selling dealer prior to retail delivery. Defects or damage to the motorcycle caused by alterations outside of Harley-Davidson factory specifications.
Important: Read Carefully Our dealers are independently owned and operated and may sell other products. LIMITED WARRANTY and EMISSION CONTROL SYSTEM LIMITED WARRANTY, and applies only to motorcycles sold in the U.S. Harley-Davidson Motor Company warrants that this vehicle is designed and built so as to conform at the time of sale with applicable regulations of the U.S.
Environmental Protection Agency (as tested following F-76 Drive-By test procedure) and that it is free from defects in materials and workmanship which would cause this motorcycle not to meet U.S. MOTORCYCLE WARRANTY and NOISE CONTROL SYSTEM LIMITED WARRANTY, and applies only to motorcycles sold in the U.S. Harley-Davidson Motor Company warrants that this vehicle is designed and built so as to conform at the time of sale with applicable regulations of the U.S. Federal Environmental Protection Agency, and that it is free from defects in materials and workmanship which would cause this motorcycle not to meet U.S. If the motorcycle/sidecar was used as a demonstrator, then the warranty period may have started and/or expired prior to the initial retail sale.
See a Harley-Davidson Dealer for details. Maintenance Scheduling Regular Service Intervals Regular lubrication and maintenance will help keep your new Harley-Davidson operating at peak performance. Your Harley-Davidson dealer knows best how to service your motorcycle with factory approved methods and equipment assuring you of thorough and competent workmanship.
Verify component and system functions NOTES: 1. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically qualified. Disassemble, lubricate and inspect every 50,000 miles 80,000 kilometers. Perform annually. 50,000 MI 80,000 KM Service Literature Refer to Service Literature: 2009 Touring Models.
Visit any Harley-Davidson dealer or go to www.harley-davidson.com to purchase a service or parts manual for your motorcycle. Factory authorized manuals are the most complete and detailed source of information outside of your Harley-Davidson dealer.
Donny is the Winner of the 2012 International Book Awards. Donny Petersen offers the real deal in performancing your Harley-Davidson Twin Cam. Graphics, pictures, and charts guide the reader on a sure-footed journey to a thorough H-D Twin Cam performance understanding. Petersen's insight makes technical issues understandable even for the novice.
Donny simply explains what unfailingly works in performancing the Twin Cam. This is the second volume of Petersen's long-awaited Donny's Unauthorized Technical Guide to Harley Davidson 1936 to Present. This twelve-volume series by the dean of motorcycle technology examines the theory, design, and practical aspects of Twin Cam performance. Donny studied privately with Harley-Davidson engineers, having worked on Harleys for over 35 years. He founded Toronto's Heavy Duty Cycles in 1974, North America's premier motorcycle shop.
Donny has ridden hundreds of performanced Shovels, Evos, and Twin Cams across four continents doing all of his own roadside repairs. He has acquired his practical knowledge the hard way. Donny has the privilege of sharing his performance secrets the easy way. Donny will walk you through detailed performancing procedures like headwork, turbo-supercharging, nitrous, big-inch Harleys and completing simple hop-up procedures like air breathers, exhausts, and ignition modifications. Donny Petersen feels honored to share the wealth of his motorcycle knowledge and technical expertise.