2016 Harley-Davidson Street Models Service Manual XG500 – Street 500 / XG750 – Street 750

Harley Davidson 2016 Street Models Service Manual (99611-16)

This in-depth service manual offers comprehensive repair procedures, maintenance routines, and technical diagnostics tailored for 2016 Harley Davidson Street motorcycles. Developed for service professionals and advanced DIY enthusiasts, it delivers accurate torque values, lubrication details, and complete teardown guides for engine, chassis, drivetrain, and electrical systems—ensuring reliable performance and long-term durability of your XG500 or XG750 model.

Model Covers:

Harley-Davidson Street 2016 models:
XG500 – Street 500
XG750 – Street 750

File Format: PDF

Size: 172.73 MB

No. of pages: 386

Language: English

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

📑 Included Sections:

Scheduled Maintenance and Adjustments

• Service intervals, brake pad wear checks, and fluid replacement
• Throttle, clutch, and steering head bearing adjustments
• Tire inspection, belt tension, and rear fork bushing evaluations
• Valve lash, spark plug analysis, radiator inspection, and winter storage prep

Engine Repair and Rebuild Procedures

• Step-by-step instructions for top-end disassembly and reassembly
• Timing chain system, rocker arms, valve service, and breather flow logic
• Crankshaft, oil strainer, pump, and balance shaft overhaul techniques
• Precision specs for compression, oil pressure testing, and bearing fitment

Chassis & Suspension Systems

• Wheel lacing, bearing replacement, and compensator inspection
• Front fork rebuild, preload shock adjustment, and rear fork teardown
• Handlebar, jiffy stand, license bracket, and passenger footpeg servicing
• Brake lines bleeding, master cylinder repair, and sealed bearing guidance

Transmission and Final Drive

• Clutch pack servicing, transmission gear diagnostics, and output pulley checks
• Drive belt and shifter shaft removal/install with alignment procedures
• Crankcase bearing service and detent assembly handling
• Shift drum and fork synchronization and tolerances

Fuel & Exhaust Systems

• EFI diagnostics, fuel pump replacement, pressure testing, and venting checks
• Induction module, TMAP sensor, idle air control, and oxygen sensor service
• Charcoal canister and purge valve (California emissions) inspection
• Muffler and full exhaust system disassembly and leak test

Cooling System & Diagnostics

• Coolant routing, thermostat housing replacement, and overflow tank checks
• Pressure cap test, freeze point diagnostics, and dye leak detection methods
• Cooling fan, hoses, radiator core inspection, and ECT sensor service

Electrical Systems & Wiring

• Fuses, relays, ignition control, and ECM module location and servicing
• Starter motor, alternator, battery tray, and wire harness layout
• Handlebar switch housing, horn, turn signals, and speedometer replacement
• Complete connector repair guide and color-coded wiring diagrams

The Harley Davidson 2016 Street Service Manual is your workshop-level guide to accurately servicing every system of your Street 500 or Street 750. Built for those who demand factory precision and deep mechanical understanding.