Segment:
Cruiser Motorcycle segment, entry-level to mid-range performance and style.
Key Competitors:
Indian Scout, Triumph Bonneville, Yamaha Bolt, Kawasaki Vulcan S.
Vehicle Appeal:
Iconic Harley-Davidson styling, accessible riding experience, customizable platform, V-twin engine character.
Benefit To Owner:
Empowers owners and independent mechanics to perform maintenance, diagnostics, and repairs confidently, saving time and money compared to dealership service.
Vehicle Variants Covered:
All 2016 Harley-Davidson Sportster models including Iron 883, SuperLow, 1200 Custom, Forty-Eight, Seventy-Two, and XR1200 (if applicable to US market)
Type:
Workshop Service Repair Manual
Digital Format:
PDF (Portable Document Format)
Powertrain:
Engine (Evolution V-Twin), Fuel System (Injection/Carburetion), Ignition System, Exhaust System, Transmission (5-Speed Cruise Drive)
Chassis:
Frame, Suspension (Front Fork, Rear Shocks), Steering, Wheels, Tires, Brakes (Front/Rear Disc)
Electrical:
Wiring Diagrams, Lighting, Instrumentation, Battery, Charging System, Starting System, Ignition, Security System (H-D Smart Security System)
Bodywork And Trim:
Body Panels, Fenders, Fuel Tank, Seat, Handlebars, Controls, Footpegs, Mirrors
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Chain Adjustment, Brake Pad Replacement, Spark Plug Replacement, Air Filter Service
Diagnostics And Troubleshooting:
Troubleshooting Guides by Symptom, Diagnostic Trouble Codes (DTCs), Electrical System Diagnostics, Fuel System Diagnostics
Repair And Overhaul:
Engine Rebuild Procedures, Transmission Overhaul, Fork Seal Replacement, Brake Caliper Rebuild, Clutch Adjustment and Replacement, Electrical Component Repair
Depth Of Information:
Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and torque specifications.
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
883cc (53.9 cu in) and 1200cc (73.2 cu in) variants
Bore X Stroke 883Cc:
76.2 mm x 96.8 mm (3.00 in x 3.81 in)
Bore X Stroke 1200Cc:
88.9 mm x 96.8 mm (3.50 in x 3.81 in)
Compression Ratio 883Cc:
9.0:1
Compression Ratio 1200Cc:
10.0:1
Horsepower 883Cc Approx:
50 HP @ 6000 RPM
Torque 883Cc Approx:
55 ft-lbs @ 3500 RPM
Horsepower 1200Cc Approx:
67 HP @ 6000 RPM
Torque 1200Cc Approx:
71 ft-lbs @ 3500 RPM
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI) for most models. Some international markets may have carbureted versions (Mikuni HSR42) for the 883cc.
Fuel Type:
Unleaded gasoline, minimum 91 octane (R+M)/2
Fuel Tank Capacity:
Approximately 3.3 US gallons (12.5 L)
Ignition System:
Electronic, Magneti Marelli electronic ignition with spark advance
Spark Plugs:
Specific plug type will be detailed in manual, typically a resistor-type plug (e.g., NGK DCPR7E or equivalent).
Transmission Type:
5-Speed Cruise Drive
Clutch Type:
Multi-plate wet clutch
Final Drive:
Belt Drive (45/72T)
Gear Ratios:
Specific ratios detailed in manual, typically: 1st: 10.370, 2nd: 7.266, 3rd: 5.369, 4th: 4.169, 5th: 3.310
Transmission Fluid Type:
Harley-Davidson 6-Speed Manual Transmission Fluid or Syn3 (for certain older models/recommendations, verify specific 2016 spec in manual) - typically SAE 75W-90
Crash Test Ratings:
N/A for motorcycles. Safety is primarily through rider control and vehicle stability.
Braking System:
Dual-piston front caliper with 300mm disc, single-piston rear caliper with 260mm disc. Optional ABS (Anti-lock Braking System) available on most models.
Suspension Stability:
Telescopic front forks (43mm diameter), rear emulsion shocks with pre-load adjustment.
Lighting:
Halogen headlamp, LED tail light, amber incandescent turn signals (front/rear).
Security:
Factory-installed H-D Smart Security System with integrated alarm and proximity fob.
Instrumentation:
Analog speedometer with integrated LCD display for tachometer, odometer, trip meter, clock, gear indicator, and fuel level. Some models may have a tachometer integrated or as a separate unit.
ABS Availability:
Optional on most 2016 Sportster models.
Communication Systems:
N/A (No built-in Bluetooth or smartphone integration beyond security fob)
First Service Mileage:
1,000 miles (1,600 km) or 6 months
Subsequent Service Mileage:
Every 5,000 miles (8,000 km) or 12 months thereafter (whichever comes first)
Engine Oil Type:
Harley-Davidson 20W-50 SYN3 or other Harley-Davidson approved synthetic motorcycle oil.
Engine Oil Capacity 883Cc:
Approximately 3.0 US quarts (2.8 L) with filter change.
Engine Oil Capacity 1200Cc:
Approximately 3.0 US quarts (2.8 L) with filter change.
Primary Chain Case Fluid:
Harley-Davidson Primary Chaincase Lubricant (SAE 50) or suitable equivalent.
Primary Chain Case Fluid Capacity:
Approximately 1 US quart (0.95 L)
Brake Fluid Type:
DOT 4 for all hydraulic brake systems.
Common Wear Items:
Clutch plates, brake pads, tires, fork seals, belt drive wear.
Potential Electrical Quirks:
Intermittent issues with sensors or starter solenoids can occur with age and mileage. Manual provides diagnostic steps.
Engine Vibration:
Characteristic of the V-twin engine; the manual will detail normal operating vibration levels and troubleshooting for excessive vibration.
Manufacturer Founding:
1903
Brand Identity:
Iconic American motorcycle manufacturer, known for V-twin engines and a distinct lifestyle.
Sportster Introduction:
The Sportster line dates back to 1957, making it one of the longest-running motorcycle nameplates in continuous production.
2016 Updates:
For 2016, key updates included improvements to the front braking system and the introduction of new paint schemes and styling cues across the range. The electronic fuel injection was standard on most US models.
Manufacturing Location:
United States (primarily Milwaukee, Wisconsin, and Kansas City, Missouri)
Industry Accolades:
Harley-Davidson Sportster models consistently receive positive reviews for their style, performance, and customization potential within the cruiser segment. Specific awards for the 2016 model year should be referenced from contemporary motorcycle publications.
Customer Satisfaction:
Generally high customer satisfaction due to brand loyalty and the Sportster's enduring appeal.
Emissions Compliance:
Meets EPA and California ARB emissions standards for the model year. Manual details specific requirements for emission-related components.
