2016 Harley-Davidson Sportster Models Service Manual

Harley Davidson 2016 Sportster Models Service Manual

This official 2016 service manual offers an in-depth, factory-authorized guide for maintaining, diagnosing, and repairing all Harley-Davidson Sportster models from the 2016 lineup. Covering everything from engine overhaul to electronic control systems, this manual is designed for both professionals and serious motorcycle owners who demand accuracy and factory-level procedures.

Model Covers:

Harley-Davidson 2016 SPORTSTER models:
• XL 883L – SuperLow
• XL 883N – Iron 883
• XL 1200C – 1200 Custom
• XL 1200CA – Custom Limited A
• XL 1200CB – Custom Limited B
• XL 1200CP – 1200 Custom Police
• XL 1200T – SuperLow 1200T (Touring)
• XL 1200X – Forty-Eight
• XL 1200V – Seventy-Two

Covers configuration-specific assemblies including:
• India-specific models (Saree guard, front/rear license plates)
• XL 1200T Touring accessories (saddlebags, windshield)
• Integrated tail/turn/stop lighting variants
• Fork lock, jiffy stand, rider/passenger foot controls (mid & forward)

File Format: PDF

Size: 161.97 MB

No. of pages: 580

Language: English

Delivery Method: Instant Download – Access your file immediately after purchase.

📑 Included Sections:

Routine Maintenance and Inspection

• Torque specs, service intervals, oil & filter changes
• Brake pad/disc checks, air cleaner, drive belt tension
• Throttle, clutch, chassis lubrication, headlamp alignment

Engine Service and Overhaul

• Crankcase breathing, oil flow diagrams and lubrication systems
• Top-end and bottom-end teardown/reassembly
• Crankshaft, pistons, cylinder head, gearcase, oil pump servicing

Chassis, Suspension and Brakes

• Complete fork and shock absorber disassembly & service
• Brake system bleeding, EHCU diagnostics, front/rear calipers
• Rear fork, swingarm, jiffy stand, and handlebar installation

Fuel System and Sensors

• Fuel injector, TPS, TMAP, and IAC diagnostics
• Fuel pump and pressure tests, intake leak detection
• Evaporative emissions system (EVAP) for California models

Transmission and Final Drive

• Primary drive, clutch service, and gear power flow overview
• Transmission case disassembly and gear rebuild
• Belt and sprocket inspection, adjustment, and installation

Electrical and Diagnostic Systems

• Complete wiring diagrams and harness routing (Appendix A)
• Modules: ECM, BCM, H-DSSS, and Smart Siren configuration
• Sensors: CKP, VSS, WSS, TPS, IAT, alternator and voltage regulator

This Harley Davidson 2016 Sportster Service Manual is an essential tool for ensuring optimal performance, detailed diagnostics, and longevity for every variant of the 2016 Sportster line.