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Harley Davidson SPORTSTER LK XL 1200CB 2016 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster XL 1200CB Year: 2016 Model Code: LK XL 1200CB Generation Sportster Generation: Evolution Engine Sportster Platform 👋 Introduction Market Position Vehicle Segment:...
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Type: Motorcycle
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Harley Davidson SPORTSTER LK XL 1200CB 2016 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
Sportster XL 1200CB
Year:
2016
Model Code:
LK XL 1200CB
Generation
Sportster Generation:
Evolution Engine Sportster Platform
👋 Introduction
Market Position
Vehicle Segment:
Cruiser Motorcycle, Mid-size Harley-Davidson offering
Target Audience:
Motorcyclists seeking a customizable and classic cruiser experience, DIY enthusiasts
Competitive Analysis
Key Competitors:
Indian Scout, Triumph Bonneville, Yamaha Bolt, Kawasaki Vulcan S
Key Features
Sportster Characteristics:
Iconic Harley-Davidson styling, accessible V-twin engine, customization potential, comfortable riding position for cruising
Cb Model Distinction:
Custom 'Bobber' styling, lower stance, drag handlebars, solo seat, blacked-out components
Manual Value Proposition
Comprehensiveness:
Enables owners to perform a wide range of maintenance and repair tasks, reducing reliance on dealership service
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Manual
Language:
English
Format:
Digital (likely PDF, as implied by 'explode......')
Page Count:
Estimated 500-700 pages (typical for a comprehensive service manual of this era)
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, diagnostics, tuning, fuel system, ignition system, lubrication, cooling (air-cooled)
Transmission:
Gearbox service, clutch operation, maintenance, troubleshooting, rebuild procedures
Electrical System:
Wiring diagrams, charging system (alternator, regulator/rectifier), starting system (starter motor, solenoid), ignition system, lighting, gauges, switches, battery maintenance
Chassis Components:
Frame inspection, steering head bearing service, front fork (suspension) overhaul and adjustment, rear shock absorber service, swingarm and bearings
Braking System:
Front and rear brake caliper service, master cylinder service, brake line replacement, bleeding procedures, rotor inspection and replacement
Fuel System:
Fuel tank service, fuel pump operation, fuel filter replacement, fuel injection system diagnostics (EFI)
Exhaust System:
Muffler and pipe inspection, gasket replacement
Bodywork And Trim:
Fenders, fuel tank, seat, handlebar, controls, and accessory mounting
Procedures Included
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, lubrication, tire pressure checks, brake pad inspection, belt tension adjustment
Troubleshooting:
Diagnostic flowcharts for common issues, symptom-based problem solving
Repair:
Step-by-step instructions for component replacement and repair, including detailed disassembly and reassembly sequences
Diagnostics:
Explains diagnostic trouble codes (DTCs), use of diagnostic tools (if applicable), and component testing
Rebuilds:
Comprehensive instructions for engine and transmission rebuilds, including torque specifications and clearances
Technical Depth
Depth Level:
Comprehensive (covers basic maintenance to complete engine and transmission overhauls)
Documentation Style:
Step-by-step instructions with exploded views and diagrams
📊 Manual Specifications
File Format
Digital Format:
PDF (assumed)
Searchability:
Likely text-searchable for efficient information retrieval
Print Quality
Diagram Resolution:
High-resolution for clear illustration of parts and procedures
Binding Type
Physical Binding:
N/A (digital format implied), but for a print version, likely coil or comb binding for lay-flat usability.
Paper Type
Physical Paper:
N/A (digital format implied), but ideally printed on durable, grease-resistant paper.
⚙️ Engine Specifications
Primary Engine
Engine Family:
Harley-Davidson Evolution (Sportster) V-twin
Displacement:
1200cc (73.4 cubic inches)
Bore X Stroke:
3.500 in x 3.812 in (88.9 mm x 96.8 mm)
Compression Ratio:
9.7:1
Engine Configuration:
Air-cooled, 45-degree V-twin
Valve Train:
Overhead valves (OHV), two valves per cylinder
Performance
Horsepower:
Approx. 67 HP @ 5750 RPM (estimated)
Torque:
Approx. 71 lb-ft @ 3500 RPM (estimated)
Fuel System
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded Gasoline, minimum 91 octane (AKI) recommended
Fuel Capacity:
3.3 US gallons (12.5 L)
Lubrication System
Oil Type:
Harley-Davidson 20W-50 Genuine Motorcycle Oil or equivalent API SG certified (check manual for exact spec)
Oil Capacity:
3.0 US quarts (2.8 L) with filter change
Ignition System
Ignition Type:
Spark Ignition, Electronic Ignition Module
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Primary Drive:
Duplex chain, oil bath enclosed
Final Drive:
Belt drive, 128-tooth, 0.500 in pitch
Features
Clutch Type:
Wet, multi-plate, diaphragm spring
Transmission Oil Type:
Harley-Davidson Hypoid Gear Oil SAE 85W-140 or equivalent
Transmission Oil Capacity:
2 US pints (0.95 L)
📐 Dimensions
Exterior
Length:
Approx. 88.0 in (2235 mm)
Width:
Approx. 32.5 in (825 mm)
Height:
Approx. 48.8 in (1240 mm)
Wheelbase:
60.0 in (1524 mm)
Ground Clearance:
Approx. 4.25 in (108 mm)
Seat Height:
Approx. 25.7 in (653 mm) (unladen)
Weights
Dry Weight:
Approx. 564 lb (256 kg)
Gross Vehicle Weight Rating:
Approx. 950 lb (431 kg)
Gvwr Payload Capacity:
Approx. 386 lb (175 kg)
🛡️ Safety Features
Ratings
Safety Certification:
Meets DOT/FMVSS standards for motorcycles
Active Features
Brakes:
Hydraulic disc brakes, front and rear
Lighting:
Halogen headlight, LED tail light, turn signals
Passive Features
Frame Construction:
Steel, welded frame and swingarm
Tires:
Dunlop Harley-Davidson Series Tires
Handlebar Design:
Drag-style handlebars promote an aggressive riding posture
💡 Technology Features
Infotainment
Instrument Cluster:
Analog speedometer with integrated LCD display for odometer, trip meter, clock, and gear indicator. Tachometer is often a separate gauge or integrated into the LCD.
Driver Assistance
ABS:
Available as an option on some 2016 Sportster models, including the XL1200CB.
Connectivity
Diagnostic Ports:
On-board diagnostics system accessible via specific tools/software (covered in the manual).
🔧 Maintenance
Service Intervals
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Services:
Every 5,000 miles (8,000 km) or 12 months thereafter (major service intervals for oil, filters, and checks)
Fluid Specifications
Engine Oil Viscosity:
20W-50
Transmission Oil Viscosity:
85W-140 Hypoid Gear Oil
Primary Chain Case Oil:
Harley-Davidson Primary Chain Lubricant (DOT 5.1 Brake Fluid is NOT used in the primary)
Brake Fluid:
DOT 4 (for ABS models, check manual, otherwise DOT 4)
Known Issues
Common Sportster Concerns:
Clutch adjustment, primary chain adjustment, occasional electrical gremlins, rear brake pad wear, carburetor (on earlier models, but this is EFI).
2016 Specific Concerns:
While generally reliable, specific EFI sensor issues or wiring harness wear can occur over time.
Filters
Oil Filter Part Number:
Harley-Davidson OEM: 63796-77A (may vary, check specific model fitment)
Air Filter Type:
High-flow aftermarket or stock paper element
📚 Vehicle History
Brand Heritage
Harley Davidson Legacy:
Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer known for its V-twin engines and cruiser lifestyle.
Model Evolution
Sportster Lineage:
The Sportster model line dates back to 1957, evolving significantly over decades while retaining its core identity.
2016 Sportster Updates:
2016 models featured improvements such as the electronic sequential port fuel injection (ESPFI) and updated suspension components.
Production
Manufacturing Location:
United States
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