Positioning:
Essential resource for Harley-Davidson Sportster owners and independent repair shops seeking to maintain and repair their 2016 models.
Competitors:
Factory service manuals (FSMs) are the gold standard. This aftermarket manual aims to replicate or exceed the FSM's utility for DIY mechanics.
Features:
Comprehensive coverage, step-by-step instructions, visual aids (illustrations, photos, diagrams), troubleshooting guides, maintenance schedules.
Engine Mechanical:
Engine assembly, disassembly, inspection, cylinder heads, cylinders, pistons, crankshaft, camshaft, valve train, oil pump, lubrication system.
Engine Performance:
Fuel injection system, throttle body, injectors, fuel pump, fuel filter, exhaust system, emissions controls, engine tuning, diagnostics.
Transmission Drivetrain:
Clutch, transmission gears, shift drum, primary drive, final drive (belt/chain), gearcase, maintenance, and repair.
Electrical System:
Ignition system, starting system, charging system, lighting system (headlight, taillight, turn signals), battery, wiring diagrams, fuses, relays, sensors, ECUs.
Brakes Suspension:
Front and rear brake systems (calipers, master cylinders, lines, pads, rotors), ABS (if equipped), front forks (disassembly, service, fluid changes), rear shock absorbers, swingarm, wheel bearings.
Chassis Frame:
Frame inspection, steering head, handlebars, triple clamps, foot controls, seat assembly, bodywork removal and installation.
Maintenance:
Routine maintenance schedules, oil changes, filter replacements, brake fluid changes, clutch adjustments, chain lubrication/adjustment, fork oil changes.
Troubleshooting:
Diagnostic charts for common symptoms, identifying and resolving electrical issues, engine performance problems, starting difficulties.
Repair:
Step-by-step instructions for major component disassembly, rebuilding, and reassembly of engine, transmission, suspension, and electrical systems.
Diagnostics:
Diagnostic trouble codes (DTCs), sensor testing, data stream interpretation (if applicable to diagnostics tools mentioned).
Depth:
Comprehensive. Covers everything from basic owner maintenance to full engine and transmission rebuilds. Includes torque specifications, clearances, and detailed procedures.
File Type:
Likely PDF (Portable Document Format)
Searchability:
High (assuming text-based PDF, allowing for keyword searches)
Printability:
Printable, with individual pages or the entire document.
Illustrations:
High-quality, detailed illustrations, photos, and diagrams.
Binding:
Not applicable for digital format (if printed, would be spiral-bound or comb-bound for lay-flat use).
Paper Quality:
Not applicable for digital format (if printed, expect durable paper suitable for workshop use).
Engine Type:
Air-cooled, Evolution V-Twin
Engine Displacement:
Available in 883cc (53.9 cu in) and 1200cc (73.4 cu in) variants.
Bore Stroke 883Cc:
3.000 in x 3.8125 in (76.2 mm x 96.8 mm)
Bore Stroke 1200Cc:
3.498 in x 4.125 in (88.9 mm x 104.8 mm)
Compression Ratio 883Cc:
9.0:1
Compression Ratio 1200Cc:
10.0:1
Valve Train:
Overhead valves (OHV), two valves per cylinder
Fuel System:
Electronic Sequential Port Fuel Injection (ESPFI)
Horsepower 883Cc:
Approximately 50-55 HP (est.)
Torque 883Cc:
Approximately 55-60 lb-ft (est.)
Horsepower 1200Cc:
Approximately 65-70 HP (est.)
Torque 1200Cc:
Approximately 70-75 lb-ft (est.)
Initial Service:
Break-in service typically recommended at 1,000 miles (1,600 km).
Routine Oil Change:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first.
Belt Tension Check:
Check and adjust belt tension every 5,000 miles (8,000 km).
Spark Plug Replacement:
Typically recommended every 10,000-15,000 miles (16,000-24,000 km).
Engine Oil Type:
Harley-Davidson 20W50 SYN3 (Full Synthetic) or equivalent API CI-4 or better.
Engine Oil Capacity:
Approximately 3 US quarts (2.8 L) with filter change.
Transmission Primary Chain Case Oil Type:
Harley-Davidson Formula+ (or equivalent primary lubricant).
Transmission Primary Chain Case Oil Capacity:
Approximately 2.7 US quarts (2.5 L).
Brake Fluid Type:
DOT 4 (for ABS models, consult specific manual for confirmation).
Common Complaints:
Stalling at idle, engine vibration at certain RPMs, clutch drag, potential for primary chain tensioner wear (though addressed in later revisions).
Electrical Quirks:
Occasional issues with battery charging system or intermittent electrical connections.
Brand Origin:
Harley-Davidson Motor Company, founded in 1903 in Milwaukee, Wisconsin.
Sportster Lineage:
The Sportster line has been in continuous production since 1957, evolving from early OHV designs to the modern Evolution engine.
Manufacturing Location:
United States (primarily York, Pennsylvania, and Milwaukee, Wisconsin for final assembly)
