Harley Davidson Touring 2016 Factory Workshop Service Repair Manual

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The 2016 Touring Series motorcycles represent a pinnacle of American motorcycle engineering, built for the open road and designed for comfort and performance. These iconic machines, powered by the robust Air-cooled Twin Cam 103 engine and featuring the smooth 6-speed Cruise Drive Transmission, offer a distinctive riding experience. This manual covers a range of 2016 models, including the SuperLow, Iron 883, 1200 Custom, Seventy-Two, Forty-Eight, and SuperLow 1200T, each embodying a legacy of quality and rider-centric design. This comprehensive Factory Workshop Service Repair Manual provides detailed, step-by-step instructions for all aspects of maintenance, diagnosis, and repair. It covers every major system, from the engine and fuel system to the electrical components, chassis, brakes, and bodywork. With over 700 pages of factory-accurate information, including high-resolution illustrations, troubleshooting guides, and essential torque specifications, this manual is an indispensable resource for owners, technicians, and enthusiasts aiming to maintain their motorcycles to the highest standards. 🏷️ Basic Information Identification Make: Harley-Davidson Model: Touring Series Year: 2016 Codes Platform Code: TBA (Specific to Harley-Davidson's internal coding for the 2016 Touring platform) 👋 Introduction Market Position Target Audience: Harley-Davidson owners, independent repair shops, and DIY enthusiasts seeking professional-level service information for their 2016 Touring models. Brand Loyalty: Harley-Davidson cultivates strong brand loyalty, and having access to the official factory manual reinforces owner confidence in maintaining these premium machines. Competitive Analysis Value Proposition: Offers factory-level repair and maintenance procedures, ensuring accuracy and completeness, often surpassing aftermarket manuals in detail and scope. Provides significant cost savings for owners compared to dealership service. Key Features Features: Directly replicates factory documentation, detailed step-by-step instructions, high-quality illustrations and diagrams, comprehensive coverage of all systems, extensive troubleshooting guides. 📋 Manual Details Coverage Areas Models Covered: 2016 Harley-Davidson SuperLow, 2016 Harley-Davidson Iron 883, 2016 Harley-Davidson 1200 Custom, 2016 Harley-Davidson Seventy-Two, 2016 Harley-Davidson Forty-Eight, 2016 Harley-Davidson SuperLow 1200T Page Count Pages: 700+ Manual Type Type: Factory Workshop Service Repair Manual Language Language: English Format Format: PDF (Digital Download) Searchability: PDF format allows for quick searching of specific terms, procedures, or part names. 📖 Manual Coverage Systems Covered Engine: Top End Service, Cam Compartment Service, Engine Removal/Installation, Top End Overhaul (Disassembly/Assembly), Breather Assembly, Rocker Arm Support Plate, Pushrods/Lifters/Covers, Cylinder Head, Cylinder, Piston, Cam Compartment Components, Crankcase Disassembly/Repair, Flywheel and Connecting Rods, Crankcase Assembly, Oil Pan, Engine Air Flow, Oil Pump Operation, Breather Operation, Oil Pressure, Oil Cooler, Oil Cooler Adapter Fuel System: Fuel Pressure Test, Intake Leak Test, Air Cleaner Assembly, Fuel Tank, Fuel Tank Top Plate, Fuel Filter, Fuel Pressure Regulator, Fuel Level Sender, Twist Grip Sensor, Throttle Control Actuator, Induction Module, Temperature Manifold Absolute Pressure Sensor, Heated Oxygen Sensors, Fuel Injectors, Fuel Pump, Exhaust System, Active Exhaust, Evaporative Emissions Control System Drive: Primary Chaincase Cover, Drive Components, Primary Chaincase Housing, Drive Belt and Sprockets, Rear Sprocket Isolator Clutch: Conventional Clutch, Assist and Slip Clutch, Hydraulic Clutch Release Bearing and Pushrod, Transmission Sprocket, Clutch Cable Service (Road King), Hydraulic Clutch Fluid, Bleeding Clutch Control System, Clutch Master Cylinder and Reservoir, Hydraulic Clutch Hand Lever, Clutch Fluid Line Transmission: Shifter Linkage, Clutch Release Cover (Cable Clutch), Transmission Side Covers (Hydraulic Clutch), Secondary Clutch Actuator, Transmission Assembly, Main Drive Gear and Bearing, Transmission Case Chassis And Suspension: Front Wheel, Rear Wheel, Rear Wheel Compensator, Wheel Lacing (Front Rim), Checking and Truing Wheels, Sealed Wheel Bearings, Tires, Front Fork, Steering Head Bearings, Rear Suspension, Rear Fork, Handlebar, Jiffy Stand, Front Engine Mount, Rear Frame Brakes: Front Brake Master Cylinder, Front Brake Caliper, Rear Brake Master Cylinder, Rear Brake Caliper, Brake Lines, ABS Module, Bleeding Brakes, Brake Pads and Discs Electrical: System Fuses and Relays, Electronic Control Module, Body Control Module, Electric Caddies, Ignition Coil, Starter, Headlamp, Auxiliary/Fog Lamps and Brackets, Rear Lighting, Fender Tip Lamps, Tour-Pak Lights, Turn Signal Lamps, Ignition Switch and Fork Lock, Accessory Switches, Crankshaft Position Sensor, Engine Temperature Sensor, Engine Coolant Temperature Sensor, Automatic Compression Release, Voltage Regulator, Alternator, Vehicle Speed Sensor, Wheel Speed Sensor, Neutral Switch, Oil Pressure Sender, Stop Lamp Switches, Horn, Fairing Power Outlet, Gauges and Instruments (Fairing Models), Gauges and Instruments (Road King Models), Boom Box Infotainment System, Antenna Cables, Wire Trough, Main Wiring Harness, Fairing Harness, Handlebar Switch Packs, HFSM Maintenance, Personal Identification Number, H-DSSS Actuation, Security Siren, Wiring Diagrams Bodywork And Accessories: Fairing Lowers and Engine Guard, Outer Fairing and Windshield (Mounted Fairing Models), Dash Panel (Fork Mounted Fairing Models), Inner Fairing (Fork Mounted Fairing Models), Instrument Bezel (Frame Mounted Fairing Models), Instrument Nacelle (Frame Mounted Fairing Models), Outer Fairing and Windshield (Frame Mounted Fairing Models), Inner Fairing (Frame Mounted Fairings Models), Storage Compartments (Frame Mounted Models), Air Deflectors, Windshield (Road King Models), Headlamp Nacelle (Road King Models), Front Fender, Rear Fender, Rear Fascia, Footboards and Footrests, Seat Saddlebags, Saddle Service, Tour-Pak, Tour-Pak Service, Tour-Pak Backrest, Medallions, Badges and Tank Emblems Cooling System Specifics: Appendix B provides...

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Sku: 91234

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Availability: In stock

Tags: 2016 700 B Series Agriculture Case Harley Davidson Motorcycle Touring Tractors

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Touring Series

Year:

Codes

Platform Code:

TBA (Specific to Harley-Davidson's internal coding for the 2016 Touring platform)

👋 Introduction

Market Position

Target Audience:

Harley-Davidson owners, independent repair shops, and DIY enthusiasts seeking professional-level service information for their 2016 Touring models.

Brand Loyalty:

Harley-Davidson cultivates strong brand loyalty, and having access to the official factory manual reinforces owner confidence in maintaining these premium machines.

Competitive Analysis

Value Proposition:

Offers factory-level repair and maintenance procedures, ensuring accuracy and completeness, often surpassing aftermarket manuals in detail and scope. Provides significant cost savings for owners compared to dealership service.

Key Features

Features:

Directly replicates factory documentation, detailed step-by-step instructions, high-quality illustrations and diagrams, comprehensive coverage of all systems, extensive troubleshooting guides.

📋 Manual Details

Coverage Areas

Models Covered:

2016 Harley-Davidson SuperLow, 2016 Harley-Davidson Iron 883, 2016 Harley-Davidson 1200 Custom, 2016 Harley-Davidson Seventy-Two, 2016 Harley-Davidson Forty-Eight, 2016 Harley-Davidson SuperLow 1200T

Page Count

Pages:

Manual Type

Type:

Factory Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF (Digital Download)

Searchability:

PDF format allows for quick searching of specific terms, procedures, or part names.

📖 Manual Coverage

Systems Covered

Engine:

Top End Service, Cam Compartment Service, Engine Removal/Installation, Top End Overhaul (Disassembly/Assembly), Breather Assembly, Rocker Arm Support Plate, Pushrods/Lifters/Covers, Cylinder Head, Cylinder, Piston, Cam Compartment Components, Crankcase Disassembly/Repair, Flywheel and Connecting Rods, Crankcase Assembly, Oil Pan, Engine Air Flow, Oil Pump Operation, Breather Operation, Oil Pressure, Oil Cooler, Oil Cooler Adapter

Fuel System:

Fuel Pressure Test, Intake Leak Test, Air Cleaner Assembly, Fuel Tank, Fuel Tank Top Plate, Fuel Filter, Fuel Pressure Regulator, Fuel Level Sender, Twist Grip Sensor, Throttle Control Actuator, Induction Module, Temperature Manifold Absolute Pressure Sensor, Heated Oxygen Sensors, Fuel Injectors, Fuel Pump, Exhaust System, Active Exhaust, Evaporative Emissions Control System

Drive:

Primary Chaincase Cover, Drive Components, Primary Chaincase Housing, Drive Belt and Sprockets, Rear Sprocket Isolator

Clutch:

Conventional Clutch, Assist and Slip Clutch, Hydraulic Clutch Release Bearing and Pushrod, Transmission Sprocket, Clutch Cable Service (Road King), Hydraulic Clutch Fluid, Bleeding Clutch Control System, Clutch Master Cylinder and Reservoir, Hydraulic Clutch Hand Lever, Clutch Fluid Line

Transmission:

Shifter Linkage, Clutch Release Cover (Cable Clutch), Transmission Side Covers (Hydraulic Clutch), Secondary Clutch Actuator, Transmission Assembly, Main Drive Gear and Bearing, Transmission Case

Chassis And Suspension:

Front Wheel, Rear Wheel, Rear Wheel Compensator, Wheel Lacing (Front Rim), Checking and Truing Wheels, Sealed Wheel Bearings, Tires, Front Fork, Steering Head Bearings, Rear Suspension, Rear Fork, Handlebar, Jiffy Stand, Front Engine Mount, Rear Frame

Brakes:

Front Brake Master Cylinder, Front Brake Caliper, Rear Brake Master Cylinder, Rear Brake Caliper, Brake Lines, ABS Module, Bleeding Brakes, Brake Pads and Discs

Electrical:

System Fuses and Relays, Electronic Control Module, Body Control Module, Electric Caddies, Ignition Coil, Starter, Headlamp, Auxiliary/Fog Lamps and Brackets, Rear Lighting, Fender Tip Lamps, Tour-Pak Lights, Turn Signal Lamps, Ignition Switch and Fork Lock, Accessory Switches, Crankshaft Position Sensor, Engine Temperature Sensor, Engine Coolant Temperature Sensor, Automatic Compression Release, Voltage Regulator, Alternator, Vehicle Speed Sensor, Wheel Speed Sensor, Neutral Switch, Oil Pressure Sender, Stop Lamp Switches, Horn, Fairing Power Outlet, Gauges and Instruments (Fairing Models), Gauges and Instruments (Road King Models), Boom Box Infotainment System, Antenna Cables, Wire Trough, Main Wiring Harness, Fairing Harness, Handlebar Switch Packs, HFSM Maintenance, Personal Identification Number, H-DSSS Actuation, Security Siren, Wiring Diagrams

Bodywork And Accessories:

Fairing Lowers and Engine Guard, Outer Fairing and Windshield (Mounted Fairing Models), Dash Panel (Fork Mounted Fairing Models), Inner Fairing (Fork Mounted Fairing Models), Instrument Bezel (Frame Mounted Fairing Models), Instrument Nacelle (Frame Mounted Fairing Models), Outer Fairing and Windshield (Frame Mounted Fairing Models), Inner Fairing (Frame Mounted Fairings Models), Storage Compartments (Frame Mounted Models), Air Deflectors, Windshield (Road King Models), Headlamp Nacelle (Road King Models), Front Fender, Rear Fender, Rear Fascia, Footboards and Footrests, Seat Saddlebags, Saddle Service, Tour-Pak, Tour-Pak Service, Tour-Pak Backrest, Medallions, Badges and Tank Emblems

Cooling System Specifics:

Appendix B provides detailed information on the cooling system, including operation, testing, diagnostics, and repair procedures, crucial for engines that utilize oil cooling or have specific thermal management components.

Frame And Structure:

Details the Rear Frame, including mounting points and structural components relevant to chassis integrity and accessory fitment.

Lighting And Signals:

Comprehensive coverage of headlamp operation, auxiliary lamps, rear lighting, fender tip lamps, and Tour-Pak lights, including bulb replacement and troubleshooting.

Steering And Bearings:

Specific procedures for servicing steering head bearings, ensuring smooth and precise steering control.

Procedures Included

Maintenance:

Fastener Torque Values, General Maintenance, Fuel and Oil, Maintenance Schedule, Engine Oil and Filter, Air Cleaner and Exhaust System, Coolant, Tires and Wheels, Primary Chaincase Lubricant, Transmission Lubricant, Cable and Chassis Lubrication, Brakes, Brake Pads and Discs, Spark Plugs, Steering Head Bearings, Rear Suspension Adjustments, Battery Maintenance, Headlamp Alignment, Engine Mounts, Storage Procedures, Troubleshooting

Diagnostics And Repair:

Troubleshooting sections for Engine, Chassis, and Electrical systems. Detailed disassembly and assembly procedures for all major components. Diagnostic tests for fuel system pressure, intake leaks, and cooling system. Wear limit specifications for critical engine parts.

Troubleshooting Guides:

Extensive troubleshooting sections are provided for common issues encountered with the engine, chassis, and electrical systems, aiding in quick diagnosis.

Reference Materials:

Includes valuable reference materials such as metric conversion charts, fluid conversion tables, torque conversion data, and a glossary of automotive terms.

Storage Procedures:

Guidance on proper procedures for storing the motorcycle for extended periods, including battery conditioning and fuel stabilization.

Wheel And Tire Service:

Detailed instructions for wheel maintenance, including lacing front rims, checking and truing wheels, and servicing sealed wheel bearings, along with tire specifications and replacement procedures.

Technical Depth

Depth:

Comprehensive. Covers everything from basic maintenance and fluid changes to complete engine and transmission overhauls, electrical system diagnostics, and chassis component repairs. Includes detailed torque specifications for all fasteners.

Special Tools:

References required specialty tools for various procedures, which is essential for performing repairs correctly and safely.

📊 Manual Specifications

File Format

File Type:

Compatibility:

Compatible with all Windows & Mac computers (Windows 10, 8, 7, Vista, XP, ME, 98, NT, 2000), Tablets, and Phones. Supports 32/64-bit operating systems.

Print Quality

Illustrations:

Hi-Resolution illustrations, instructions, photos, and diagrams.

Readability:

Pages can be read and printed directly from the CD or copied to a hard drive. Fully searchable text.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, Twin Cam 103 (Standard for most 2016 Touring models, with potential variations for specific sub-models covered).

Performance

Torque Specifications:

Extensive torque values provided for all engine fasteners, critical for proper assembly and safety.

Engine Airflow Management:

Detailed explanations on engine air flow, breather operation, and the induction module's role in performance.

Fuel System

Injection System:

Electronic Sequential Port Fuel Injection (ESPFI).

Cooling System

Cooling Type:

Air-cooled (with specific procedures for managing engine temperature and related components).

Troubleshooting

Engine Troubleshooting:

Dedicated troubleshooting sections address common engine performance issues, starting problems, and unusual noises.

🔧 Transmission

Standard

Transmission Type:

6-speed Cruise Drive Transmission.

Optional

Transmission Options:

N/A (The 6-speed Cruise Drive was standard across the 2016 Touring line).

Features

Clutch Type:

Hydraulic Assist, Wet Multi-plate Clutch (for most models), Conventional cable clutch detailed for specific models like Road King.

📐 Dimensions

Exterior

Fairing Types:

Includes details for both frame-mounted and fork-mounted fairings, as well as Windshield options for Road King models.

Weights

Service Weights:

Specifications for various components and assemblies, crucial for accurate reassembly and weight distribution.

🛡️ Safety Features

Ratings

Safety Features:

ABS Module coverage, detailed brake system diagnostics and repair, proper torquing of fasteners to ensure structural integrity.

Active Features

Active Safety:

ABS (Anti-lock Braking System) is a key feature covered in detail.

Passive Features

Passive Safety:

Detailed information on chassis integrity, suspension adjustments, and proper maintenance to ensure rider safety.

💡 Technology Features

Infotainment

Infotainment System:

Boom Box Infotainment System coverage, including operation, diagnostics, and potential troubleshooting.

Driver Assistance

Advanced Features:

Coverage of ABS module and related components. Details on electronic control modules and their functions.

Connectivity

Wiring Harnesses:

Detailed wiring diagrams and information on main and fairing harnesses, providing insight into the motorcycle's electrical network.

Security

Security System:

Information on HFSM (Hand-held মনোভাব, Security Module) Maintenance, Personal Identification Number, H-DSSS Actuation, and Security Siren.

🔧 Maintenance

Service Intervals

Scheduled Maintenance:

Comprehensive maintenance schedule covering all recommended service intervals for engine, chassis, and electrical systems.

Battery Maintenance:

Specific instructions for battery maintenance, charging, and troubleshooting.

Fluid Specifications

Engine Oil:

Specifies recommended Harley-Davidson engine oil grades and capacities, along with filter part numbers.

Primary Lubricant:

Details for primary chaincase lubricant, including type and capacity.

Transmission Lubricant:

Specifications for transmission lubricant, including type and capacity.

Brake Fluid:

DOT 4 recommended for hydraulic brake and clutch systems.

Coolant:

Specification for engine coolant (if applicable to specific models within the Touring line covered, though most Twin Cam 103 are air-cooled).

Oil Filter Part Numbers:

While specific part numbers are usually within the manual's detailed sections, it would detail the correct Harley-Davidson oil filter for the 2016 Touring models.

Known Issues

Common Wear Items:

Provides wear limit specifications for critical engine components like pistons, cylinders, and bearings, aiding in proactive replacement and diagnosis.

📚 Vehicle History

Brand Heritage

Brand History:

Harley-Davidson has a long-standing reputation for producing iconic motorcycles, with the Touring line being a cornerstone of their product offering for decades, emphasizing comfort, performance, and customization.

Model Evolution

Touring Evolution:

The 2016 models represent a refinement of the successful Twin Cam platform, incorporating technological advancements while maintaining the classic Harley-Davidson riding experience.

Production

Manufacturing Locations:

Primarily manufactured in the United States by Harley-Davidson Motor Company.

🏆 Awards & Recognition

Recognitions

Industry Standing:

Harley-Davidson Touring motorcycles are consistently recognized for their comfort, long-distance capability, and iconic styling, often receiving accolades in rider surveys and industry reviews.

Certifications

Oem Certification:

This manual is the same as the official factory workshop manual used by authorized Harley-Davidson service centers.