Market Segment:
Cruiser motorcycle, targeting riders seeking classic styling with modern performance and customization potential.
Competitors:
Indian Chief, Triumph Bonneville, Kawasaki Vulcan, Honda Shadow, Yamaha Bolt.
Vehicle Highlights:
Iconic Harley-Davidson styling, V-twin engine character, comfortable riding position, extensive customization options.
Manual Benefit:
Empowers owners to perform routine maintenance, diagnose issues, and undertake repairs, saving on dealership costs and maximizing motorcycle lifespan.
Systems Covered:
Engine, Fuel System, Ignition, Transmission, Drivetrain, Chassis, Suspension, Brakes, Electrical System, Lighting, Instrumentation, Controls, Bodywork, Frame, Maintenance, Troubleshooting, Diagnostics, Specifications.
Page Count:
Hundreds of pages
Manual Type:
Factory Service Repair Manual
Engine Mechanical:
Complete overhaul, internal component inspection and replacement (pistons, rings, valves, camshafts), cylinder head service, timing procedures.
Fuel System:
Fuel injection system (EFI), throttle body, injectors, fuel pump, fuel filter, fuel tank maintenance, emissions control systems.
Ignition System:
Spark plugs, ignition coils, crankshaft position sensor, engine control module (ECM) diagnostics.
Transmission And Drivetrain:
Clutch operation and service, gear shifting mechanisms, primary drive system, final drive (belt drive) inspection and adjustment, transmission fluid service.
Chassis And Suspension:
Front fork service (oil change, seal replacement), rear shock absorber maintenance, steering head bearing service, wheel bearing inspection.
Braking System:
Front and rear brake caliper service, hydraulic system bleeding, brake pad replacement, rotor inspection.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting circuits, horn, switches, fuses, relays.
Instrumentation And Controls:
Speedometer, tachometer, indicator lights, throttle and clutch controls, brake levers, handlebar adjustments.
Bodywork And Frame:
Fender removal and installation, fuel tank removal and installation, seat maintenance, frame inspection.
Preventative Maintenance:
Scheduled maintenance tasks, lubrication points, fluid level checks and changes, filter replacement, belt inspection and tensioning.
Troubleshooting:
Diagnostic flowcharts for common problems, symptom-based troubleshooting guides, fault code interpretation (if applicable).
Repair And Rebuild:
Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly for all major vehicle systems.
Diagnostic Procedures:
Engine performance analysis, electrical system testing, fuel system pressure testing, troubleshooting using diagnostic tools.
Depth Of Coverage:
Comprehensive, suitable for professional technicians and experienced DIY mechanics. Covers detailed specifications, torque values, and specialized procedures.
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
1202 cc (73.2 cubic inches)
Bore X Stroke:
3.000 in x 3.500 in (76.2 mm x 88.9 mm)
Valve Train:
Overhead valves (OHV), 2 valves per cylinder, pushrod actuated
Horsepower Est:
Approximately 65-70 hp (rated at crankshaft)
Torque Est:
Approximately 70-75 lb-ft (rated at crankshaft)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Premium unleaded gasoline, minimum 91 octane recommended
Oil Type Specification:
Harley-Davidson SYN3 Full Synthetic Motorcycle Oil (or equivalent SAE 20W-50)
Oil Capacity:
3.0 US quarts (2.8 liters) with filter change
Safety Certification:
Meets all applicable safety standards for motorcycles in the U.S. and Canada.
Braking System Type:
Hydraulic Disc, Front and Rear
Anti Lock Braking System:
Optional (Check specific vehicle configuration)
Lighting:
Halogen headlamp, LED tail lamp, amber incandescent front turn signals, clear incandescent rear turn signals.
Instrument Cluster:
Analog speedometer with integrated digital tachometer, odometer, trip meter, and fuel level indicator.
Audio System:
Not typically standard on this model; aftermarket audio integration is common.
Cruise Control:
Not standard on the 2016 1200 Custom; available as an accessory/option.
Diagnostics Port:
CAN bus diagnostic connector for use with Harley-Davidson diagnostic tools (e.g., Digital Technician).
First Service:
1,000 miles (1,600 km) or 6 months, whichever comes first.
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months for routine checks and fluid changes.
Engine Oil Change Interval:
Every 5,000 miles (8,000 km) or 12 months.
Transmission Primary Chaincase Oil Change Interval:
Every 5,000 miles (8,000 km) or 12 months.
Spark Plug Replacement Interval:
Every 10,000 miles (16,000 km)
Front Fork Oil Type:
Harley-Davidson Type E or Type H Motorcycle Fork Oil (viscosity may vary based on preference and condition; consult manual)
Front Fork Oil Quantity:
Approx. 11.6 US fl oz (343 ml) per leg (verify in manual)
Common Wear Items:
Clutch plates, brake pads, tires, fork seals, battery. Belt drive requires periodic tension adjustment and inspection.
Potential Electrical Concerns:
Intermittent issues with charging system components (regulator/rectifier) or grounds are not uncommon on older models, but less prevalent on 2016 models.
