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Harley Davidson FLHTCU Electra Glide Ultra Classic Motorcycle 2016 Service Repair Workshop Manual Pdf
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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHTCU Electra Glide Ultra Classic Year: 2016 Codes Product Code Identifier: FLHTCU 👋 Introduction Market Position Segment: Full-dresser touring motorcycle, flagship model in...
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🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FLHTCU Electra Glide Ultra Classic
Year:
2016
Codes
Product Code Identifier:
FLHTCU
👋 Introduction
Market Position
Segment:
Full-dresser touring motorcycle, flagship model in Harley-Davidson's lineup.
Target Audience:
Long-distance touring riders, individuals seeking maximum comfort, features, and luggage capacity.
Competitive Analysis
Key Competitors:
Indian Roadmaster, Honda Gold Wing, BMW R1200RT, Yamaha Star Venture.
Key Features
Touring Amenities:
Full fairings with integrated windshield, spacious saddlebags and tour-pak, comfortable rider and passenger seating, premium infotainment system.
Engine Type:
Air-cooled, Twin Cam 103 High Output V-twin engine.
Suspension Type:
Telescopic front forks with dual-rate springs and air-assist rear shocks.
Braking System Type:
Linked, four-piston, four-caliper disc brakes with standard ABS.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Workshop Manual
Language:
English
Format:
PDF Download
Page Count
Estimated Page Count:
Approximately 800-1000+
File Format
File Type:
Portable Document Format (PDF)
Searchability:
Text-searchable content for quick information retrieval.
Print Quality
Printability:
Printable for physical use, with clear diagrams and text.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
📖 Manual Coverage
Systems Covered
Engine System:
Comprehensive coverage of the Twin Cam 103 High Output engine, including disassembly, assembly, troubleshooting, and diagnostics.
Transmission System:
Detailed procedures for the Cruise Drive 6-speed transmission, including clutch, primary drive, and internal components.
Fuel System:
In-depth coverage of the Electronic Sequential Port Fuel Injection (ESPFI), fuel pump, injectors, and throttle body.
Electrical System:
Extensive wiring diagrams, diagnostic procedures for the electrical system, ignition, lighting, charging system, and accessories.
Braking System:
Service procedures for hydraulic brake systems, including ABS components, brake lines, calipers, and master cylinders.
Suspension System:
Front fork service (cartridge/air assist) and rear shock absorber maintenance and replacement procedures.
Chassis Frame Bodywork:
Procedures for fairing removal/installation, body panel servicing, chassis inspection, and frame alignment checks.
Heating Cooling System:
While primarily air-cooled, covers any related cooling components or systems if applicable to the model variant.
Exhaust System:
Information on exhaust system removal, installation, and common service points.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug service, drive belt inspection and adjustment, lubrication points.
Troubleshooting Diagnostics:
Systematic troubleshooting guides for common malfunctions and diagnostic codes.
Engine Overhaul:
Complete engine tear-down, component inspection, repair, and reassembly instructions.
Transmission Repair:
Detailed steps for clutch replacement, gear set servicing, and transmission rebuilds.
Electrical Component Testing:
Testing and replacement procedures for starter motor, alternator, battery, lights, and electronic control modules (ECM).
Suspension Adjustment Repair:
Fork oil changes, seal replacement, and rear shock adjustment/replacement.
Brake System Service:
Bleeding procedures, caliper overhaul, master cylinder replacement, and ABS system bleeding.
Wheel Tire Service:
Wheel bearing replacement, tire mounting/balancing, and spoke tensioning (if applicable).
Bodywork Fairing Repair:
Instructions for removing, repairing, and reinstalling fairings and body panels.
Technical Depth
Depth Of Coverage:
Comprehensive, factory-level detail suitable for professional technicians and advanced DIY enthusiasts.
Diagnostic Capability:
Includes diagnostic procedures, fault code interpretation, and testing methods for various electronic systems.
Rebuild Capability:
Provides full rebuild procedures for major mechanical components like the engine and transmission.
⚙️ Engine Specifications
Primary Engine
Engine Family:
Twin Cam
Engine Configuration:
V-twin, 45-degree cylinder angle
Displacement:
1690 cc (103 cubic inches)
Bore X Stroke:
3.875 in. x 4.375 in. (98.4 mm x 111.1 mm)
Compression Ratio:
9.6:1
Performance
Horsepower:
Approximately 75-80 HP (at crankshaft, estimated for 2016 model)
Torque:
104.7 ft-lbs @ 3,250 RPM (rated by manufacturer)
Fuel System
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane (R+M)/2
Valvetrain
Valve Train:
Pushrod actuated, overhead valves with two valves per cylinder
🔧 Transmission
Standard
Transmission Type:
Cruise Drive, 6-speed constant mesh
Clutch Type:
Hydraulically actuated, 9-plate, wet clutch
Final Drive:
Carbon belt, 2.200:1 ratio
Features
Overdrive Gear:
Includes an overdrive gear for relaxed highway cruising.
📐 Dimensions
Exterior
Length:
103.1 in. (2619 mm)
Width:
37.6 in. (955 mm)
Height:
53.7 in. (1364 mm)
Wheelbase:
64.5 in. (1638 mm)
Ground Clearance:
5.1 in. (130 mm)
Weights
Dry Weight:
849 lbs (385 kg)
Curb Weight:
899 lbs (408 kg)
Gvwr:
1360 lbs (617 kg)
Payload Capacity:
461 lbs (209 kg)
Cargo
Saddlebag Capacity:
2.3 cu ft (65 L)
Tour Pak Capacity:
4.4 cu ft (125 L)
Capacities
Fuel Tank Capacity:
6.0 gallons (22.7 L)
Oil Capacity:
4.0 quarts (3.8 L)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not applicable for motorcycles in the same manner as automobiles; focuses on engineering robustness and rider protection features.
Active Features
ABS:
Standard Antilock Braking System (ABS)
Linked Braking:
Linked braking system (front and rear brakes are partially actuated together).
Passive Features
Lighting System:
Halogen headlight, integrated front and rear turn signals, auxiliary passing lamps, tour-pak brake/tail lights.
Wind Protection:
Full-coverage Batwing fairing and windshield designed for rider comfort and protection.
Ergonomics:
Designed for long-distance comfort with rider backrest and spacious passenger accommodations.
💡 Technology Features
Infotainment
Head Unit Type:
Boom! Box 6.5GT Infotainment System
Display Size:
6.5-inch color touchscreen
Features:
AM/FM radio, CB/Intercom, SiriusXM Satellite Radio, USB/SD card/Bluetooth media playback, GPS navigation, voice recognition.
Driver Assistance
Cruise Control:
Electronic cruise control
Security System:
Factory integrated security system with immobilizer
Connectivity
Bluetooth:
Bluetooth connectivity for audio streaming and hands-free calling.
Usb Port:
USB port for media playback and device charging.
🔧 Maintenance
Service Intervals
First Service:
1,000 miles (1,600 km) or 6 months, whichever comes first (includes oil/filter change, primary chain tension adjustment, inspection).
Subsequent Oil Change:
Every 5,000 miles (8,000 km) or 12 months.
Drive Belt Inspection:
Inspect every 10,000 miles (16,000 km); check for wear, damage, and proper tension.
Spark Plug Replacement:
Inspect at 10,000 miles (16,000 km); replace as needed or at recommended intervals.
Brake Fluid Flush:
Every 24 months or as indicated by fluid condition.
Fluid Specifications
Engine Oil:
Harley-Davidson SYN3 (Synthetic) SAE 20W50, or equivalent API CI-4 rated synthetic motorcycle oil.
Primary Chain Case Oil:
Harley-Davidson Primary Chain Case Lubricant (Formula +), or SAE 80W-90 Hypoid Gear Oil.
Transmission Oil:
Harley-Davidson SYN3 (Synthetic) SAE 20W-50, or SAE 80W-90 Hypoid Gear Oil.
Brake Fluid:
DOT 4 Harley-Davidson Premium Motorcycle Brake Fluid.
Fork Oil:
Refer to manual for specific weight and quantity; typically SAE 15W or equivalent.
Known Issues
Primary Chain Tensioner:
Early Twin Cam models were prone to cam chain tensioner wear; updated hydraulic tensioners were introduced, but inspection remains prudent.
Exhaust Flaking:
Some owners report chrome flaking on exhaust components over time; addressed via proper care and potential replacement.
Infotainment Glitches:
Occasional software glitches or connectivity issues with the infotainment system, often resolvable with software updates.
📚 Vehicle History
Brand Heritage
Brand Origin:
Founded in 1903 in Milwaukee, Wisconsin, USA.
Brand Philosophy:
Known for its V-twin engines, distinctive styling, and emphasis on the riding experience and community.
Model Evolution
Electra Glide Origin:
The Electra Glide line dates back to the 1960s, evolving from the Duo Glide. The 'Ultra' designation signifies the most equipped touring model.
Twin Cam Introduction:
The Twin Cam engine platform was introduced in 1999, with the 'High Output' variant offering increased displacement and torque for later models.
Production
Production Location:
Primarily assembled in York, Pennsylvania, USA.
Model Updates 2016:
The 2016 model benefited from refinements in the Twin Cam 103 engine, infotainment system updates, and chassis improvements.
🏆 Awards & Recognition
Recognitions
Model Type Recognition:
Consistently recognized as a benchmark for long-distance touring comfort and features by motorcycle publications and rider surveys.
Ratings
Consumer Satisfaction:
Generally high consumer satisfaction ratings for comfort, performance, and touring capability.