Harley Davidson FLSTC Heritage Softail 2009 Service Manual
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FOREWORD
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 sin-
cerely believe that this Service Manual will make your associ-
ation with Harley-Davidson products more pleasant and
profitable.
HOW TO USE
YOUR SERVICE MANUAL
Information is arranged as follows:
• Section 1-Maintenance
• Section 2-Ghassis
• Section 3-Engine
• Section 4-Fuel System
• Section 5-Electric Starter
• Section 6-Drive
• Section 7-Transmission
• Section 8-Electrical
• Appendix A-Tools
• Appendix B-Wiring
• Appendix G-Metric Conversions
• Appendix D-Glossary
Use the TABLE OF CONTENTS following this FOREWORD
or the INDEX at the back of the book to find the desired sub-
ject.
Note that each manual section contains sequentially num-
bered topics. The numbering system allows quick cross refer-
ences throughout the document.
For example, the sixth topic (BRAKES) in section one (MAIN-
TENANCE) could be referred to as:
1.6 BRAKES
This cross reference directs the reader to section 1
(MAINTENANCE) and topic 6 (BRAKES).
PREPARATION FOR SERVICE
AWARNING
Stop the engine when refueling or servicing the fuel sys-
tem. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)
Good preparation is very important for efficient service work.
A clean work area at the start of each job will allow you to per-
form the repair as easily and quickly as possible, and will
reduce the incidence of misplaced tools and parts. A motorcy-
cle that is excessively dirty should be cleaned before work
starts. Cleaning will occasionally uncover sources of trouble.
Tools, instruments and any parts needed for the job should be
gathered before work is started. Interrupting a job to locate
tools or parts is a distraction and causes needless delay. See
APPENDIX A-TOOLS for equipment required for special ser-
vice work.
NOTE
• Toavoid unnecessary disassembly, carefully read all rel-
ative service information before repair work is started.
• In figure legends, the number which follows the name of
a part indicates the quantity necessary for one complete
assembly.
SERVICE BULLETINS
In addition to the information presented in this Service
Manual, Harley-Davidson Motor Company will periodically
issue Service Bulletins to Harley dealers. Service Bulletins
cover interim engineering changes and supplementary infor-
mation.
USE GENUINE
REPLACEMENT PARTS
AWARNING
When replacement parts are required, use only genuine
Harley-Davidson parts or parts with equivalent character-
istics (which include type , strength and material). Failure
to do so may result in product malfunction. This could
result in death or serious injury.
To ensure satisfactory and lasting repairs, carefully follow the
Service Manual instructions and use only genuine Harley-
Davidson replacement parts. Behind the emblem bearing the
words GENUINE HARLEY-DAVIDSON stand more than 100
years of design, research, manufacturing, testing and
inspecting experience. This is your assurance that the parts
you are using will fit right, operate properly and last longer
i.
WARNINGS AND CAUTIONS
Statements in this service manual preceded by the following
words are of special significance.
ADANGER
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious
injury.
AWARNING
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury. (00119a)
ACAUTION
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury. (00139a)
CAUTION
CAUTION used without the safety alert symbol indicates
a potentially hazardous situation which, if not avoided,
may result in property damage (00140a)
AWARNING
• Proper service and repair is important for the safe,
reliable operation of all mechanical products. The
service procedures recommended and described in
this Service Manual are effective methods for per-
forming service operations. Some of these service
operations require the use of tools specially
designed for the purpose.These special tools should
be used when and as recommended. It is important
to note that some warnings against the use of spe-
cific service methods, which could damage the
motorcycle or render it unsafe, are stated in this Ser-
vice Manual. However, please remember that these
warnings are not all-inclusive. Inadequate safety pre-
cautions could result in death or serious injury.
• Since Harley-Davidson could not possibly know,
evaluate or advise the service trade of all possible
ways in which service might be performed, or of the
possible hazardous consequences of each method,
we have not undertaken any such broad evaluation.
Accordingly, anyone who uses a service procedure
or tool which is not recommended by Harley-David-
son must first thoroughly satisfy himself that neither
his nor the operator's safety will be jeopardized as a
result.This could result in death or serious injury.
• Wear eye protection when using hammers, arbor or
hydraulic presses, gear pullers, spring compressors,
slide hammers and similar tools. Be especially cau-
tious when using pulling, pressing or compressing
equipment. The forces involved can cause parts to
fly outward with considerable force, possibly result-
ing in death or serious injury.
ii.
PRODUCT REFERENCES
AWARNING
Follow the directions listed on all products. Carefully
read all labels, warnings and cautions before use. Inade-
quate safety precautions could result in death or serious
injury.
When reference is made in this Service Manual to a specific
brand name product , tool or instrument, an equivalent
product , tool or instrument may be substituted.
Kent-Moore Products
All tools mentioned in this manual with an "HD", "J" or "8 "
preface must be ordered through:
Kent-Moore
SPX Corporation
28635 Mound Road
Warren, Michigan USA 48092-3499
Sealing and Threadlocking Products
LOCTITE PRODUCTS
Some procedures in this Service Manual call for the use of
Loctite® products. If you have any questions regarding Loctite
product usage or retailer/wholesaler locations , please contact
Loctite Corp. at www.loctite.com.
CONTENTS
All photographs, illustrations and procedures may not neces-
sarily depict the most current model or component, but are
based on the latest production information available at the
time of publication.
Since product improvement is our continual goal, Harley-
Davidson reserves the right to change specifications, equip-
ment or designs at any time without notice and without incur-
ring obligation .
TABLE OF CONTENTS
Page No. Page No.
SECTION 1-MAINTENANCE
1.1 General .
Servicing a New Motorcycle .
Safe Operating Maintenance ..
Shop Practices .
Repair Notes .
Safety .
Remov ing Parts .
Cleaning .
Disassembly and Assembly ..
Repair and Replacement Procedures ..
Hardware and Threaded Parts ..
Threadl ock ing Agents ..
Wiring, Hoses and Lines ..
Instruments and Gauges ..
Bearings .
Bushings .
Exhaust System Leakage ..
Gaskets .
Lip Type Seals .
O-Rings (Prefo rmed Packings) ..
Gears .
Shafts .
Part Replacement .
Cleaning .
Part Protectio n .
Cleaning Process .
Rust or Corrosion Removal .
Tool Safety .
Air Tools ..
Wrenches ..
Pliers/Cutters/Prybars .
Hammers .
Punches /Chisels .
Screwdrivers .
Ratchets and Handles ..
Sockets .
Storage Units .
1.2 Fuel and Oil .
Fuel .
Gasoline Blends .
Engine Oil .
Winter Lubrication .
1.3 Maintenance Schedule .
First Scheduled Maintenance ..
1.4 Engine Oil and Filter ..
Checking and Adding Oil ..
Type of Oil ..
Checking Oil Level .
Recommended Oil Grades (table) ..
Changi ng Oil and Filter .
1-1
1-1
1-1
1-1
1-1
1-1
1-1
1-2
1-2
1-2
1-2
1-2
1-2
1-2
1-2
1-2
1-2
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-4
1-4
1-4
1-4
1-4
1-4
1-4
1-5
1-5
1-5
1-5
1-5
1-6
1-6
1-11
1-11
1-11
1-11
1-11
1-12
1.5 Battery Maintenance .
General .
Battery Electrolyte Antidotes (table) .
Disconnection and Removal. .
Installation and Connect ion .
Inspection ..
Storage ..
1.6 Brakes .
Fluid Inspection .
Rear Brake Pedal .
Pedal Height .
Pedal Lubricati on .
Pedal Pad .
1.7 Bleeding Brakes ..
General .
Procedure .
1.8 Brake Pads and Discs ..
Inspection .
Brake Pads .
Brake Disc Thickness ..
Brake Disc Lateral Runout and Warpage :
Brake Pad Replaceme nt .
Rear Brake Caliper ..
Front Brake Caliper: All But FLSTSC ..
1.9 Tires and Wheels ..
Tires .
Tire Pressures (table) .
Tire Replacement .
Whee l Bearings .
Whee l Spokes .
1.10 Primary Chain .
General .
1.11 Primary Chaincase Lubricant .
Chang ing Lubricant .
1.12 CIutch .
Adjustment .
1.13 Transmission Lubricant .
Changing Lubricant .
1.14 Rear Belt Deflection .
Inspection .
Rear Belt Deflection (Table) ..
Adjustment ..
1.15 Rear Belt and Sprockets .
Genera l ..
Cleaning .
Inspection .
Sprockets .
Rear Belt .
Drive Belt Wear Analysis (table) ..
1-13
1-13
1-13
1-14
1-14
1-15
1-15
1-16
1-16
1-17
1-17
1-17
1-17
1-18
1-18
1-18
1-19
1-19
1-19
1-19
1-19
1-20
1-20
1-22
1-23
1-23
1-23
1-24
1-24
1-24
1-25
1-25
1-26
1-26
1-28
1-28
1-30
1-30
1-31
1-31
1-31
1-32
1-33
1-33
1-33
1-33
1-33
1-33
1-34
1.16 Suspension Adjustments 1-35
Rear Shock Preload 1-35
iii
Page No. Page No.
1.26 Headlamp Alignment 1-50
Inspection .................................................................. 1-50
Adjustment.. .................. 1-51
FLSTSC Models 1-51
FLSTC/FLSTF/FLSTN/FXST/FXSTB/FXSTC Models 1-51
FXSTD Models ...................................................... 1-51
1.17 Steering Head Bearings: All But
FLSTSC .
Adjustment .
Bearing Adjustment (Fall-away) ..
Lubrication .
1.18 Steering Head Bearings:
FLSTSC .
General ..
Lubrication .
Adjustment .
Adjustment .
1.19 Rocker Bearings: FLSTSC .
Inspection .
1.20 Front Fork Oil .
Replacing Fork Oil. .
1.21 Spark Plugs .
Inspection .
1.22 Air Cleaner Filter .
Removal .
Installation ..
1.23 Cable and Chassis Lubrication
General .
Cables and Hand Levers .
Jiffy Stand .
1.24 Throttle Cables .
Cable Inspection, Lubrication and Adjustment.. ..
Inspection and Lubrication .
Adjustment ..
1.25 Engine Mounts .
Inspection .
1.27 Critical Fasteners .
Inspection .
Critical Fasteners (table) .
1.28 Storage .
General ..
Removal From Storage .
iv
1-36
1-36
1-36
1-36
1-37
1-37
1-37
1-37
1-38
1-39
1-39
1-41
1-41
1-43
1-43
1-44
1-44
1-45
1-46
1-46
1-46
1-46
1-47
1-47
1-47
1-48
1-49
1-49
1-52
1-52
1-52
1-53
1-53
1-54
1.29 Troubleshooting .
General ..
Engine .
Starter Motor Does Not Operate or Does Not
Turn Engine Over ..
Engine Turns Over But Does Not Start ..
Starts Hard ..
Starts But Runs Irregularly or Misses ..
A Spark Plug Fouls Repeatedly ..
Pre-Ignition or Detonation (Knocks or Pings) .
Overheating ..
Valve Train Noise ..
Excessive Vibration .
Check Engine Light Illuminates During Operation
Lubrication System .
Oil Does Not Return To Oil Tank ..
Engine Uses Too Much Oil Or Smokes Excessively
Engine Leaks Oil From Cases, Push Rods, Hoses
Low Oil Pressure .
High Oil Pressure ..
Electrical System .
Alternator Does Not Charge ..
Alternator Charge Rate Is Below Normal. .
Speedometer Operates Erratically ..
Transmission ..
Shifts Hard .- ..
Jumps Out Of Gear .
Clutch Slips .
Clutch Drags Or Does Not Release .
Clutch Chatters .
Handling .
Irregularities ..
Brakes .
Brake Does Not Hold Normally .
SECTION 2-CHASSIS
2.1 Specifications .
Tires ..
Tire Fitment, Tubeless Cast Wheels (table) .
Tire Fitment, Laced Wheels (table) ..
Tire Pressure, All Models (table) .
2.2 Torque Values .
2.3 Vehicle Identification
Number (V.I.N.) .
General ..
2.4 Front Wheel: All But
FLSTSCIFXSTD .
Removal .
Disassembly .
Disc Wheel. ..
Laced Wheel .
Cleaning and Inspection .
Assemb ly .
Disc Wheel .
Laced Wheel .
Installation .
1-55
1-55
1-55
1-55
1-55
1-55
1-55
1-56
1-56
1-56
1-56
1-56
1-56
1-56
1-56
1-56
1-56
1-57
1-57
1-57
1-57
1-57
1-57
1-57
1-57
1-57
1-57
1-57
1-57
1-58
1-58
1-58
1-58
2-1
2-2
2-2
2-2
2-3
2-4
2-7
2-7
2-9
2-9
2-9
2-9
2-9
2-11
2-11
2-11
2-11
2-11
Page No. Page No.
2.14 Vehicle Alignment...................... 2-36
Inspection 2-36
2.5 Front Wheel: FXSTD .
Remova l .
Disassembly .
Cleaning and Inspection ..
Assemb ly .
Installation .
2.6 Front Wheel: FLSTSC .
Remova l .
Disassembly ..
Cleaning and Inspection .
Assembly .
Installation .
2.7 Rear Wheel .
Removal. .
Disassembly .
Cleaning and Inspection ..
Assembly ..
Installat ion .
2.8 Sealed Wheel Bearings .
Inspection .
Removal. .
Installation .
2.9 Wheel Lacing: 16 In. Rim .
General .
Procedure .
2.10 Wheel Lacing: 21 In. Rim .
Procedure ..
2.11 Truing Laced Wheel .
General .
Lateral Truing .
Wheel Offset Dimensio ns (table) ..
Radial Truing .
2.12 Disc Rim Runout ..
General .
Lateral Runout .
Radial Runout .
2.13 Tires .
Genera l .
Removal .
Cleaning, Inspection and Repair ..
Installation .
Tube Type Tires .
Tubeless Tires ..
2-12
2-12
2-12
2-12
2-13
2-13
2-14
2-14
2-14
2-14
2-14
2-16
2-17
2-17
2-17
2-19
2-19
2-19
2-20
2-20
2-20
2-21
2-22
2-22
2-23
2-25
2-25
2-28
2-28
2-28
2-29
2-31
2-32
2-32
2-32
2-32
2-33
2-33
2-34
2-34
2-35
2-35
2-35
2.16 Rear Brake Master
Cylinder/Reservoir .
Removal ..
Installation .
Disassembly .
Cleaning and Inspection .
Assemb ly .
2.17 Front Brake Caliper:
All But FLSTSC .
Removal .
Disassembly .
Cleaning , Inspection and Repair .
Assembly ..
Installation .
2.18 Front Brake Caliper: FLSTSC .
Front Brake Caliper ..
Removal .
Disassembly .
Cleaning and Inspection .
Assembly ..
Installation .
Brake Reaction Link .
Removal .
Installation .
2.19 Rear Brake Caliper: All But
FXSTIFXSTBIFXSTCIFLSTF .
Remova l : .
Disassembly ..
Cleaning, Inspection and Repair ..
Assembly ..
Installation .
2.20 Rear Brake Caliper:
FXSTIFXSTBIFXSTCIFLSTF .
Remova l · .
Disassembly .
Cleaning , Inspection and Repair ..
Assembly .
Installation .
2.21 Front Forks: All But FLSTSC .
Genera l .
Removal .
Disassembly .
Cleaning and Inspection .
Assemb ly .
Installation .
2-42
2-42
2-42
2-45
2-46
2-46
2-48
2-48
2-48
2-51
2-52
2-53
2-54
2-54
2-54
2-54
2-55
2-56
2-56
2-58
2-58
2-58
2-60
2-60
2-60
2-63
2-63
2-64
2-65
2-65
2-65
2-68
2-69
2-70
2-71
2-71
2-71
2-71
2-71
2-75
2-75
2.15 Front Brake Master Cylinder 2-37
General............. 2-37
Remova l/Disass embly ...... 2-37
Cleaning and Inspection 2-38
Assembly/Installation 2-40
v
Page No. Page No.
2.22 Springer Fork: FLSTSC .
General .
Handlebar and Risers .
Removal .
Installation .
Front Shock Absorber ..
Removal .
Installation .
Rigid Fork .
Removal .
Installation .
Spring Fork .
Disassembly .
Assembly .
Fork Rockers .
Removal .
Installation .
Fork Stem Bearings .
Removaillnstallation .
2.23 Steering Head ..
Removal .
FLSTC, FLSTF, FLSTN Models .
FXSTD, FXST, FXSTC, FXSTB Models ..
FLSTSC Models .
Cleaning and Inspection .
All Models .
Disassembly .
Removing Lower Bearings From Fork Stem .
Steering Head Bearing Race Removal ..
Assembly .
Installation .
FLSTC, FLSTF, FLSTN Models ..
FXSTD, FXST, FXSTC, FXSTB Models .
FLSTSC Models .
2.24 Rear Fork ..
Removal .
Cleaning and Inspection .
Installation .
2.25 Rear Shock Absorbers .
General .
Removal .
Installation .
2.26 Throttle ControL .
RemovallDi sassembly .
Cleaning and Inspection ..
Assembly/Installation .
Cable Routing .
All Models Except FLSTSC/FXSTD .
FLSTSC Models .
FXSTD Models .
2.27 Handlebars: All but
FLSTFIFLSTSC .
Removal .
FXSTD .
Installation .
FXSTD .
vi
2-76
2-76
2-76
2-76
2·76
2-78
2·78
2-78
2-79
2-79
2-79
2-80
2-80
2-82
2-84
2-84
2-84
2-85
2-85
2-86
2-86
2·86
2-86
2-87
2-87
2-87
2-87
2-87
2-88
2-88
2-89
2-89
2-89
2-89
2-90
2-90
2-90
2-91
2-92
2-92
2-92
2-92
2-93
2·93
2-93
2-93
2-94
2-94
2-94
2-94
2-95
2-95
2-96
2-97
2-97
2.28 Handlebars: FLSTF 2-99
Removal........................ 2-99
Installation................................................. 2-100
FXSTD 2-102
2.29 Clutch Hand Control 2-102
Removal.................................................................... 2-102
Installation ;... 2-102
2.30 Front Fender: All But FLSTSC .. 2-103
FXST, FXSTB, FXSTC Models................................. 2-103
Removal..... 2-103
Installation ............................................................. 2-103
FLSTC, FLSTN Models 2·103
Removal................................................................ 2-103
Installation............................................................. 2-103
FLSTF Models .......................................................... 2-104
Removal................................................................ 2-104
Installation............................................. 2-104
FXSTD Models........................ 2-104
Removal.......................................... 2-104
Installation....... 2-104
2.31 Front Fender: FLSTSC 2-105
Removal.. 2-105
Front Fender.. 2-105
Front Fender Bearing Replacement 2-105
Installation............................................ 2-106
2.32 Rear Fender: FLSTC................... 2-107
Removal.................................................................... 2-107
Installation... 2-108
2.33 Rear Fender: FLSTF 2-109
Removal.................................................................... 2-109
Installation.... 2-110
2.34 Rear Fender:
FXSTIFXSTBIFXSTC 2-111
Removal............. ....................................................... 2-111
Installation................... 2-112
2.35 Rear Fender: FXSTD 2-113
Removal.................................................................... 2-113
Disassembly ............................................................. 2-113
Assembly.... .............................................................. 2-114
Installation................................................................. 2-114
2.36 Rear Fender: FLSTSC 2-115
Removal.................................................................... 2-115
Disassembly.. ........................................................... 2-115
Assembly... ............................. 2-116
Installation........................ 2-116
2.37 Rear Fender: FLSTN 2-117
Removal........... 2-117
Disassembly ............................................................. 2-117
Assembly.... 2-119
Installation........................................................... 2-119
2.38 Rear Fender Wire Conduit:
All But FXSTD 2-120
Installation ................................................................. 2-120
Page No. Page No.
2.42 SeaVStrap Retention NuL......... 2-126
Replacement............................................................. 2-126
2.41 Fork Lock.................................... 2-125
Removal................... .. 2-125
Installation ........ 2-125
2.40 Jiffy Stand................................... 2-123
Cleaning .................................................................... 2-123
Removal.................................................................... 2-124
Installation ...... 2-124
2.39 Belt Guard/Debris Deflector .
Removal. .
Belt Guard .
Debris Deflector ..
Installation .
Belt Guard .
Debris Deflector .
2-122
2-122
2-122
2-122
2-122
2-122
2-122
3.5 Oil Pump Operation .
General. .
Operation .
3.6 Breather Operation .
General. .
3.7 Oil Pressure .
Oil Pressure Indicator Lamp .
Checking Oil Pressure .
3.8 How To Use This Section .
Top End Repair ..
Bottom End Repair ..
Typical Symptoms .
3.9 Top End Service .
Engine In Chassis ..
Engine Removed From Chassis .
3-12
3-12
3-12
3-13
3-13
3-14
3-14
3-14
3-15
3-15
3-15
3-15
3-16
3-16
3-17
2.43 Seat: FXSTIFXSTB 2-127
Removal/Installation 2-127
Seat Strap ....................... 2-127
Seat 2-127
3.10 Bottom End Service .
Engine In Chassis : Cam Compartment Service .
Engine Removed : Flywheel Compartme nt
Service or Complete Engine Overhaul ..
3-18
3-18
3-19
2.44 Seat: FXSTC 2-128
Removal/Installation 2-128
Seat Strap ............................................................. 2-128
Seat 2-128
2.45 Seat: FXSTD 2-129
Removal/Installation 2-129
2.46 Seat: FLSTSCIFLSTNI
FLSTFIFLSTC 2-130
Removal/Installation 2-130
2.47 Luggage Rack: FLSTN............... 2-131
Removaill nstallation 2-131
2.48 Saddlebags: FLSTC 2-132
Removal........ 2-132
Installation............ 2-132
3.11 Troubleshooting 3-20
Diagnosing Valve Train Noise 3-20
Compression Test 3-20
Compression Test Results (table) 3-20
Cylinder Leakage Test 3-21
Diagnosing Smoking Engine or High Oil Consumption 3-21
Check Prior To Cylinder Head Removal.............. 3-21
Check After Cylinder Head Removal.................... 3-21
3.12 Stripping Motorcycle For Service 3-22
Procedure ................................................................. 3-22
3.13 Assembling Motorcycle
After Service 3-23
Procedure ................................................................. 3-23
3.14 Removing Engine From Chassis 3-24
Procedure... ...................................................... 3-24
2.49 Windshield: FLSTC 2-133
Removal................................................................ 2-133
Installation ....................... 2-133
SECTION 3-ENGINE
3.1 Specifications 3-1
3.2 Engine Torque Values (table) 3-3
3.3 Service Wear Limits 3-4
General ..................................................................... 3-4
3.4 Engine Oil Flow............................ 3-6
Oil Feed 3-6
Top End 3-7
Bottom End ............................................................... 3-7
Chain Guide Bracket................................................. 3-11
Oil Return.................................................................. 3-11
3.15 Installing Engine In Chassis .
Procedure .
3.16 Top End Overhaul: Disassembly
General. .
Breather Assembly .
Rocker Arm Support Plate ..
Push Rods, Lifters and Covers .
Cylinder Head .
Cylinder .
Piston .
3.17 Top End Overhaul: Assembly ..
General .
Piston .
Cylinder .
Cylinder Head .
Push rods, Lifters and Covers ..
Rocker Arm Support Plate .
Breather Assembly .
3-25
3-25
3-27
3-27
3-27
3-28
3-29
3·30
3-31
3-33
3-34
3-34
3-34
3-35
3-38
3-41
3-42
3-43
vii
Page No. Page No.
3.18 Bottom End Overhaul:
Disassembly....................................... 3-45
General . ... 3-45
Cover and Cam Support Plate 3·45
Crankcase ................................................................. 3-49
Counterbalancer Assembly .. 3-50
3.19 Bottom End Overhaul: Assembly 3-53
General ............................... 3-53
Counterbalancer Assembly ............ 3-53
Balance Sprocket Spacers (table) ......................... 3-54
Crankcase ..... 3·56
Cover and Cam Support Plate 3-60
Rear Cam Sprocket Spacers (Table) 3-62
3.27 Oil Pump 3-107
Removal Overview.................................................... 3-107
Cleaning and Inspection 3-107
Installation and Overview.. ........................................ 3-108
3.28 Crankcase 3-109
Removal Overview.................................................... 3-109
Right Crankcase Half ........ 3-109
Chain Guide Screen 3-109
Crankshaft Bearing.... ..... 3-109
Piston Jets 3-110
Left Crankcase Half .. 3-111
Crankshaft (Roller) Bearing 3-111
Cylinder Studs................. 3-113
Removal ................................................................ 3-113
Installation............................................................. 3-113
Pipe Plug and Oil Fittings ............. 3-113
Removaillnstallation 3-113
Cleaning and Inspection 3-114
Installation Overview.. ............................................... 3-114
3.20 Breather Assembly ..
Removal Overview .
Disassembly .
Cleaning and Inspection .
Assembly .
Installation Overview .
3.21 Rocker Arm Support Plate ..
Removal Overview .
Disassembly .
Cleaning and Inspection .
Assembly .
Installation Overview .
3.22 Push Rods, Lifters and Covers
Removal Overview .
Disassembly .
Cleaning and Inspection ..
Lifter Inspection ..
Assembly .
Installation Overview .
3.23 Cylinder Head .
Removal Overview .
Disassembly .
Cleaning ..
Inspection .
Cylinder Head .
Valve Guides ..
Valve Stem To Guide Clearance Service
Wear Limits (table) .
Valves .
Valve Springs ..
Tapered Keepers .
Valve Seats .
Valve Guide Replacement ..
Removal ..
Installation .
Valve Stem To Guide Clearance (table) .
Valve and Seat Refacing ..
Assembly .
Installation Overview .
viii
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3-65
3-65
3-65
3-65
3-65
3-66
3-66
3-66
3-66
3-69
3-69
3-70
3-70
3-70
3-70
3-71
3-72
3·72
3-73
3-73
3-73
3-75
3-75
3-75
3-76
3-76
3-76
3-76
3-76
3-76
3-77
3-77
3-78
3-81
3-82
3-85
3-87
3.24 Cylinder .
Removal Overview .
Cleaning .
Inspection .
Deglazing Cylinder .
Boring and Honing Cylinder .
Installation Overview .
Oversize Pistons/Cylinder Bores (table) ..
3.25 Piston .
Removal Overview .
Disassembly ..
Piston Rings .
Cleaning .
Inspection ..
Assembly ..
Piston Rings .
Installation Overview .
3.26 Cover and Cam Support Plate .
Removal Overview .
Camshafts .
Removal .
Assembly .
Oil Pressure Relief Valve ..
Removal .
Installation .
Cam Needle Bearings .
Removal .
Installation .
Cleaning and Inspection ..
Oil Pressure Valve .
Cam Support Plate ..
Installation Overview .
3-88
3-88
3-88
3-89
3-90
3-92
3-92
3-92
3-93
3-93
3-93
3-93
3-93
3-94
3-96
3-96
3-97
3-99
3-99
3-100
3-100
3-101
3-103
3·103
3-103
3-104
3-104
3-105
3-106
3-106
3-106
3-106
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This workshop service manual for the Harley Davidson FLSTC Heritage Softail Classic 2009 is an instant digital download, eliminating shipping costs and waiting time. It is available in .PDF format and is printable on Windows, Mac, and Linux OS with Adobe Reader.
Designed for both professional mechanics and DIY enthusiasts, this manual provides comprehensive data, instructions, and methodologies for vehicle and component repair interventions. It includes special notes, important points, service data, precautions, and detailed illustrations, exploded diagrams, drawings, and photos to guide through every service repair procedure.
The manual covers adjustment and repair operations, referencing service tool numbers and providing detailed explanations of installation, removal, disassembly, assembly, repair, and check procedures. It is a valuable reference for maintenance, adjustments, service, removal, and installation of vehicle components.
With a focus on simplifying repair work, the manual contains information on construction, function, troubleshooting, servicing specifications, tightening torque, checking and adjusting, disassembling, and assembling procedures. It is divided into groups containing general information, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for vehicle systems and components.
For maximum satisfaction and reliability, it is essential to follow the provided service methods and repair procedures. The manual also emphasizes the importance of using genuine parts, approved lubricants, and observing safety measures during maintenance and repair work.
To ensure complete repair work and vehicle maintenance, it is recommended to follow the maintenance requirements, investigate unusual noises, use genuine parts, and keep complete records of all maintenance and repairs. The manual also provides technical information, adjustment values, and necessary safety measures for all maintenance and repair work.
It is important to note that this manual is designed primarily for use by trained technicians in a properly equipped workshop, but it contains enough detail and basic information to be useful to owners who desire to perform their own basic maintenance and repair work.
For detailed specifications and a comprehensive list of components and systems covered in this manual, please refer to the full list provided in the manual.
