2016 Harley-Davidson Touring Models Service Manual – Complete Workshop Repair Manual for FLHTCU FLHTK FLTRU FLHR FLHX

Description

This 2016 Harley-Davidson Touring Models Service Manual is the complete workshop repair manual covering all 2016 Touring models, including the FLHTCU, FLHTCUL, FLHTCU TC, FLHTCUL TC, FLHTK, FLHTKL, FLTRU, FLHR, FLHRC, FLHX, FLHXS, FLTRX, and FLTRXS. Whether you ride a Road King, Street Glide, Road Glide, Ultra Limited, or Electra Glide Ultra Classic, this 2016 Harley Touring service manual delivers the factory procedures, specifications, and diagnostic information needed to maintain and repair your motorcycle correctly.

File Details

• Manual Type: Complete Service Manual
• Brand: Harley-Davidson
• Models: 2016 Touring Models
• Document Number: 99483-16
• Publication Year: 2015
• Language: English
• Page Count: 686
• File Format: PDF

Chapters Covered

• Chapter 1: Maintenance — Fastener Torque Values, General Service Information, Fuel and Oil, Maintenance Schedule, Engine Oil and Filter, Air Cleaner and Exhaust System, Coolant, Tires and Wheels, Primary Chaincase Lubricant, Transmission Lubricant, Clutch Cable and Hydraulic Clutch Fluid, Drive Belt and Sprockets, Brakes, Brake Pads and Discs, Spark Plugs, Steering Head Bearings, Rear Suspension Adjustments, Battery Maintenance, Headlamp Alignment, Engine Mounts, Storage, Troubleshooting
• Chapter 2: Chassis — Fastener Torque Values, Specifications, Vehicle Identification Number (VIN), Front Wheel, Rear Wheel, Rear Wheel Compensator, Wheel Lacing, Checking and Truing Wheels, Sealed Wheel Bearings, Tires, Front Brake Master Cylinder, Front Brake Caliper, Rear Brake Master Cylinder, Rear Brake Caliper, Brake Lines, ABS Module, Bleeding Brakes, Front Fork, Steering Head Bearings, Rear Suspension, Rear Fork, Clutch Cable, Clutch Master Cylinder and Reservoir, Hydraulic Clutch Hand Lever, Clutch Fluid Line, Bleeding Clutch Control System, Handlebar, Mirrors, Seat, Saddlebags, Saddlebag Service, Tour-Pak, Tour-Pak Service, Tour-Pak Backrest, Fairing Lowers and Engine Guard, Outer Fairing and Windshield, Dash Panel, Inner Fairing, Instrument Bezel, Instrument Nacelle, Storage Compartments, Air Deflectors, Windshield, Headlamp Nacelle, Front Fender, Rear Fender, Rear Fascia, Rear Frame, Footboards and Footrests, Jiffy Stand, Front Engine Mount, Medallions and Badges
• Chapter 3: Engine — Fastener Torque Values, Specifications, Service Wear Limits, Engine Oil Flow, Oil Pump Operation, Breather Operation, Oil Pressure, Troubleshooting, Oil Cooler, Oil Cooler Adapter, Top End Service, Cam Compartment Service, Stripping Motorcycle for Service, Assembling Motorcycle After Service, Removing Engine From Chassis, Installing Engine in Chassis, Top End Overhaul: Disassembly, Breather Assembly, Rocker Arm Support Plate, Pushrods Lifters and Covers, Cylinder Head, Cylinder, Piston, Top End Overhaul: Assembly, Cam Compartment and Components, Oil Pump, Crankcase Disassembly and Repair, Flywheel and Connecting Rods, Crankcase Assembly, Oil Pan
• Chapter 4: Fuel System — Fastener Torque Values, Specifications, 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 (TGS), Throttle Control Actuator (TCA), Induction Module, Temperature Manifold Absolute Pressure Sensor (TMAP), Heated Oxygen Sensors (HO2), Fuel Injectors, Fuel Pump, Exhaust System, Active Exhaust HDI, Evaporative Emissions Control System
• Chapter 5: Drive — Fastener Torque Values, Specifications, Primary Chaincase Cover, Drive Components, Primary Chaincase Housing, Clutch: Conventional, Clutch: Assist and Slip, Hydraulic Clutch Release Bearing and Pushrod, Transmission Sprocket, Drive Belt
• Chapter 6: Transmission — Fastener Torque Values, Specifications, Transmission Power Flow, Shifter Linkage, Clutch Release Cover: Cable Clutch, Transmission Side Covers: Hydraulic Clutch, Secondary Clutch Actuator, Transmission Assembly, Main Drive Gear and Bearing, Transmission Case
• Chapter 7: Electrical — Fastener Torque Values, Specifications, System Fuses and Relays, Electronic Control Module (ECM), Body Control Module (BCM), Electrical 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 (CKP), Engine Temperature Sensor (ET), Engine Coolant Temperature Sensor (ECT), Automatic Compression Release (ACR), Voltage Regulator, Alternator, Vehicle Speed Sensor (VSS), Wheel Speed Sensors, Neutral Switch, Oil Pressure Sender, Stop Lamp Switches, Horn, Fairing Power Outlet, Gauges and Instruments, Indicator Lamps, BOOM! Box Infotainment System, Antenna Cables, Wire Trough, Main Wiring Harness, Fairing Harness, Handlebar Switch Packs, HFSM Maintenance, Personal Identification Number (PIN), H-DSSS Actuation, Security Siren
• Appendix A: Wiring — Connectors, Wiring Diagrams
• Appendix B: Cooling System — Fastener Torque Values, Specifications, Cooling System Operation, Testing and Diagnostics, Cooling System Repair
• Appendix C: Reference — Metric Conversion, Fluid Conversion, Torque Conversion, Glossary

This 2016 Harley-Davidson Touring service manual is not a generic overview — it is the complete factory workshop manual that a Harley-Davidson technician would use in the dealership. Every chapter is structured to take you from basic maintenance through full component overhaul. The Engine chapter alone spans more than 90 pages, covering the Twin Cam 103 in both air-cooled and Twin-Cooled configurations, including complete top-end and bottom-end teardown, cam compartment service, crankcase repair, flywheel inspection, and oil pump rebuild. The Chassis chapter walks through every wear item and adjustment on the motorcycle, from wheel bearing end play and brake disc runout to fork oil level and steering head swing-back. The Electrical chapter includes complete wiring diagrams, connector location tables, and diagnostic procedures for every sensor, module, and lighting circuit on the 2016 Touring platform.

The 2016 Harley Touring models covered in this manual include the Electra Glide Ultra Classic and Ultra Limited in both standard and Twin-Cooled versions, the Road Glide Ultra, Road Glide, Road Glide Special, Street Glide, Street Glide Special, Road King, and Road King Classic. Both the air-cooled High Output Twin Cam 103 and the Twin-Cooled High Output Twin Cam 103 are covered in full, with engine specifications, torque values, service wear limits, and fluid capacities listed throughout. Whether you are performing a routine 5,000-mile service, diagnosing a check engine light, replacing a clutch pack, rebuilding a front fork, or tracing an electrical fault through the main harness, the procedures in this 2016 Harley-Davidson Touring Models Service Manual are the same ones used by factory-trained technicians.

What This 2016 Harley-Davidson Touring Service Manual Enables You To Do

With this manual in hand, you can confidently tackle jobs that would otherwise require a dealer visit. Perform a complete engine oil and filter change with the correct torque values and capacity. Adjust drive belt deflection using the belt tension gauge procedure. Bleed the ABS brake system correctly, including the Digital Technician II step required on ABS-equipped models. Replace brake pads and discs while staying within service wear limits. Rebuild the front forks with the correct oil level and seal installation. Diagnose and repair electrical faults using the wiring diagrams and connector tables. Service the Twin-Cooled cooling system, including draining, filling, and bleeding the system. Replace the clutch pack on both conventional and Assist and Slipper clutches. Remove and reinstall the transmission, primary chaincase, and compensating sprocket. Rebuild the top end, including cylinder head valve work, piston and ring replacement, and camshaft service. The 2016 Harley Touring service manual covers all of this and considerably more.

Correct procedures and specifications matter. Using the wrong torque value can strip threads or cause a fastener to back out under vibration. Incorrect drive belt deflection can damage the transmission sprocket bearing or leave you stranded. Improper brake bleeding on an ABS-equipped Touring model can leave air in the system and compromise braking. The 2016 Harley-Davidson Touring Models Service Manual eliminates guesswork by giving you the exact factory specifications, sequences, and warnings for every procedure. Each chapter begins with a fastener torque value table so you never have to search for the correct specification. Step-by-step instructions are accompanied by detailed illustrations, exploded views, and wiring diagrams that show exactly how components fit together.

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This 2016 Harley Touring repair manual is delivered as an instant PDF download. There is no shipping, no waiting, and no physical book to store. The file works on any device — laptop, tablet, or smartphone — and every page is printable if you prefer a paper copy in the garage. Whether you are a professional Harley-Davidson technician, a dedicated home mechanic, or a Touring owner who wants to understand their motorcycle, this manual gives you the complete factory information in a convenient, searchable digital format.