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Harley Davidson Sportster XL883 2006 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster XL883 Year: 2006 Codes Chassis Code: XL883 Engine Code: Evolution 👋 Introduction Market Position Segment: Entry-level to mid-range cruiser motorcycle, popular for...
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Harley Davidson Sportster XL883 2006 Factory Service Repair ManualHarley Davidson Sportster XL883 2006 Factory Service Repair ManualHarley Davidson Sportster XL883 2006 Factory Service Repair ManualHarley Davidson Sportster XL883 2006 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
Sportster XL883
Year:
2006
Codes
Chassis Code:
XL883
Engine Code:
Evolution
👋 Introduction
Market Position
Segment:
Entry-level to mid-range cruiser motorcycle, popular for customization.
Competitive Analysis
Competitors:
Competes with models from Indian, Honda, Yamaha, and Kawasaki in the cruiser segment.
Key Features
Platform:
Iconic Sportster platform known for its distinctive styling and V-twin rumble.
Customization:
Highly customizable platform, a significant draw for owners.
Target Audience
Audience:
Motorcyclists seeking classic styling, manageable performance, and a platform for personalization.
📋 Manual Details
Coverage Areas
Coverage:
Complete official full factory service repair manual
Page Count
Pages:
Hundreds
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed troubleshooting, repair, and overhaul procedures for the Evolution V-twin engine.
Fuel System:
Carburetor tuning, fuel pump, fuel lines, and tank maintenance.
Ignition System:
Ignition module, spark plugs, timing, and troubleshooting.
Transmission:
Servicing and repair of the 5-speed transmission, clutch, and primary drive.
Electrical System:
Wiring diagrams, component testing, battery, charging system, lighting, and starter.
Brakes:
Front and rear brake system maintenance, hydraulic components, and bleeding procedures.
Suspension:
Front fork servicing, rear shock absorber replacement, and adjustments.
Wheels And Tires:
Tire replacement, wheel balancing, bearing service, and spoke tensioning.
Frame And Bodywork:
Frame inspection, mounting points, fenders, fuel tank removal, and seat installation.
Exhaust System:
Exhaust component inspection, replacement, and gasket service.
Controls:
Handlebar controls, throttle cables, brake levers, and shifter linkages.
Procedures Included
Maintenance:
Scheduled maintenance, lubrication points, fluid changes, and filter replacements.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, including symptom-based troubleshooting guides.
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly.
Overhaul:
Complete engine and transmission overhaul procedures.
Diagnostics:
Detailed diagnostic flowcharts and electrical system diagnostics.
Specifications:
Torque specifications for all fasteners, clearances, and tolerances.
Technical Depth
Depth:
Comprehensive coverage from basic maintenance to advanced engine and transmission rebuilds.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
Designed for printing, allowing full hard copy reproduction.
Binding Type
Binding:
Digital (user printable and bindable)
Paper Type
Paper:
Digital PDF format, high-resolution for clear text and diagrams
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
883cc (53.7 cubic inches)
Bore X Stroke:
3.00 in x 3.56 in (76.2 mm x 90.4 mm)
Compression Ratio:
8.8:1
Valvetrain:
Overhead valves (OHV), 2 valves per cylinder
Performance
Horsepower:
Approx. 55 HP (at rear wheel, varies slightly)
Torque:
Approx. 50 ft-lbs (at rear wheel, varies slightly)
Fuel System
Carburetor:
Keihin CV (Constant Velocity) 40mm
Fuel Capacity:
3.1 gallons (11.7 liters)
Oil System
Oil Capacity:
2.5 US quarts (2.4 liters)
Oil Type:
Harley-Davidson Genuine V-Twin Synthetic or equivalent SAE 20W-50 motorcycle oil
🔧 Transmission
Standard
Type:
5-speed constant mesh
Primary Drive:
Duplex chain, 1.37:1 ratio
Final Drive:
Belt drive, 2.75:1 ratio
Features
Clutch:
Wet, multi-plate
Transmission Fluid Type:
Harley-Davidson Formula+ Transmission & Primary Chain Case Lubricant (or equivalent)
Transmission Fluid Capacity:
20-24 US fluid ounces (0.6-0.7 liters)
📐 Dimensions
Exterior
Length:
87.4 in (2220 mm)
Width:
32.0 in (813 mm)
Height:
48.0 in (1219 mm)
Wheelbase:
60.0 in (1524 mm)
Ground Clearance:
4.5 in (114 mm)
Weights
Dry Weight:
509 lbs (231 kg)
Gross Vehicle Weight Rating:
900 lbs (408 kg)
Dimensions
Seat Height:
28.0 in (711 mm)
🛡️ Safety Features
Ratings
Crash Test Results:
N/A (Motorcycle safety ratings differ from automobiles; emphasis on rider protection systems)
Active Features
Brakes:
Hydraulic front disc, hydraulic rear disc
Lighting:
Halogen headlight, LED tail light, incandescent turn signals.
Passive Features
Frame Construction:
Steel frame with integrated oil tank.
💡 Technology Features
Infotainment
Features:
Basic instrumentation: speedometer, odometer, trip meter, neutral indicator light, oil pressure light, turn signal indicators.
Driver Assistance
Features:
None (Standard for this model year and class of motorcycle).
Connectivity
Features:
None (Standard for this model year).
🔧 Maintenance
Service Intervals
Initial Service:
First service recommended at 1,000 miles (1,600 km).
Subsequent Intervals:
Subsequent services typically every 5,000 miles (8,000 km) or annually, whichever comes first, for oil changes and basic checks. Detailed schedule in manual.
Fluid Specifications
Engine Oil:
Harley-Davidson Genuine V-Twin Synthetic 20W-50
Primary Chain Case Oil:
Harley-Davidson Formula+ Transmission & Primary Chain Case Lubricant
Brake Fluid:
DOT 4
Fork Oil:
Refer to manual for specific type and viscosity (e.g., Harley-Davidson genuine or equivalent).
Known Issues
Carburetor Tuning:
CV carburetor can require periodic fine-tuning for optimal performance and idle stability.
Belt Tension:
Drive belt tension needs regular checking and adjustment to prevent premature wear.
Electrical Connections:
Ensuring all electrical connections are clean and tight is crucial for reliable operation.
Exhaust Leaks:
Exhaust header pipe gaskets can sometimes require replacement to prevent leaks.
📚 Vehicle History
Brand Heritage
Legacy:
Harley-Davidson, founded in 1903, has a rich history in motorcycling, with the Sportster line dating back to 1957.
Model Evolution
Sportster Line:
The Sportster has evolved from its original Ironhead to the Evolution engine, maintaining its core identity while incorporating modern technology.
Production
Manufacturing Location:
Milwaukee, Wisconsin, USA
🏆 Awards & Recognition
Recognitions
Awards:
While specific awards for the 2006 XL883 are not readily cataloged, the Sportster line has consistently been recognized for its iconic status and customizability within the motorcycling community.
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