Target Audience:
DIY mechanics, Harley-Davidson enthusiasts, independent repair shops.
Product Value Proposition:
The most comprehensive and detailed resource for maintaining and repairing the 2016 Harley-Davidson Sportster 1200 Custom Limited B, enabling owners to perform a wide range of tasks themselves.
Manual Completeness:
Direct competitor to factory service manuals and other aftermarket manuals, offering thorough coverage.
Step By Step Instructions:
Clear, sequential steps for each repair and maintenance procedure.
Detailed Diagrams:
Includes exploded views, wiring diagrams, and component illustrations.
Troubleshooting Guides:
Essential for diagnosing and resolving issues efficiently.
Engine Mechanical:
Detailed disassembly, assembly, inspection, and repair of the Evolution 1200cc V-Twin engine (cylinder heads, cylinders, pistons, crankshaft, connecting rods, camshafts, valve train).
Fuel System:
Fuel injection system diagnostics and repair (throttle body, injectors, fuel pump, pressure regulator), fuel tank, fuel lines, and filter service.
Ignition System:
Ignition coil service, spark plug replacement, ignition module diagnostics, and timing adjustment procedures.
Transmission:
Clutch service (operation, adjustment, replacement), gearbox disassembly and assembly (all gears, shafts, bearings), primary drive system maintenance.
Electrical System:
Wiring diagrams for all circuits, starter system service, charging system (alternator, regulator), lighting systems (headlight, taillight, turn signals), battery maintenance and testing, fuse and relay identification.
Braking System:
Front and rear brake system service (hydraulic lines, master cylinders, calipers, brake pads, rotors), brake fluid replacement and bleeding procedures.
Suspension System:
Front fork service (oil replacement, seal replacement, spring inspection), rear shock absorber inspection and replacement, swingarm and pivot bearing service.
Wheel And Tires:
Wheel bearing service, tire inspection and replacement, tubeless tire repair, wheel alignment checks.
Frame And Body:
Frame inspection, fairing and body panel removal/installation, seat service, handlebar and control lever adjustments.
Exhaust System:
Exhaust pipe and muffler inspection, replacement, and gasket service.
Diagnostics:
Troubleshooting guides for common performance issues, error code interpretation (if applicable for the era's electronics).
Preventative Maintenance:
Regular scheduled maintenance tasks, fluid checks and changes, filter replacements, lubrication points.
Tune Up:
Engine tuning procedures, spark plug gap and replacement, air filter cleaning/replacement, idle speed adjustments.
Component Replacement:
Step-by-step guides for replacing major and minor components across all systems.
Rebuilds:
Comprehensive instructions for engine and transmission rebuilds.
Troubleshooting Charts:
Detailed charts linking symptoms to potential causes and corrective actions.
Diagnostic Level:
Advanced diagnostics, including electrical system troubleshooting and component testing.
Repair Scope:
Covers everything from basic maintenance to complete engine and transmission overhauls.
Special Tools:
Lists and descriptions of specialized tools required for specific procedures.
Torque Specifications:
Precise torque values for all fasteners and critical components.
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
1200 cc (73.3 cubic inches)
Bore X Stroke:
3.500 in. x 3.800 in. (88.9 mm x 96.8 mm)
Horsepower:
Approx. 67-70 HP (depending on specific tuning and source, typically around 5500 RPM)
Torque:
Approx. 71 ft-lb (96 Nm) at around 3500 RPM
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane (R+M)/2 (95 RON)
Fuel Tank Capacity:
3.3 gallons (12.5 L)
First Service:
1000 miles (1600 km) or 6 months (whichever comes first) for initial oil change, inspection, and adjustments.
Subsequent Service:
Every 5000 miles (8000 km) or 12 months for routine maintenance, including oil and filter changes, primary fluid checks, spark plug replacement, and inspections.
Engine Oil:
Harley-Davidson SYN3 (SAE 20W50) or equivalent API SG or higher, JASO FD certified motorcycle oil. Capacity: 3.0 US qt (2.8 L) with filter change.
Primary Chain Case Fluid:
Harley-Davidson Primary Fluid or Syn3 (SAE 20W-50). Capacity: 2.8 US qt (2.6 L).
Transmission Fluid:
Harley-Davidson Transmission Lubricant (SAE 85W-140). Capacity: 0.7 US qt (0.65 L).
Brake Fluid:
DOT 4 recommended.
Fork Oil:
Harley-Davidson Factory Fork Oil (weight and quantity will be specified in manual).
Common Wear Items:
Clutch plates, brake pads, tires, wheel bearings, spark plugs, fork seals.
Potential Performance Issues:
Carbon buildup in combustion chambers, fuel system cleaning needs, charging system component wear (regulator/stator) are typical for older models but also applicable for routine maintenance.
