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Harley Davidson Sportster XLH Motorcycle Complete Workshop Service Repair Manual 2006

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster XLH Year: 2006 Generation Generation Identifier: Evolution Engine Sportster Codes Engine Family Code: XL 👋 Introduction Market Position Market Segment: Cruiser/Sportbike Hybrid...
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Tipo: Motocicletas
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SKU: 469178
Harley Davidson Sportster XLH Motorcycle Complete Workshop Service Repair Manual 2006
🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
Sportster XLH
Year:
2006
Generation
Generation Identifier:
Evolution Engine Sportster
Codes
Engine Family Code:
XL
👋 Introduction
Market Position
Market Segment:
Cruiser/Sportbike Hybrid Motorcycle
Competitive Analysis
Key Competitors:
Varies by specific Sportster model variant (e.g., 883cc vs 1200cc), but generally competed with Japanese cruisers and other Harley-Davidson models.
Key Features
Powertrain:
Evolution V-twin engine, known for its torque and distinctive Harley-Davidson sound.
Chassis:
Relatively lightweight and nimble chassis compared to larger Harley-Davidson touring models.
Customization:
Highly popular platform for customization and personalization.
📋 Manual Details
Coverage Areas
Regions Covered:
Global (standard configurations applicable)
Page Count
Estimated Pages:
High (typically 500-800+ pages for a complete workshop manual)
Manual Type
Type:
Workshop Service and Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF (implied by product description)
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, troubleshooting, component inspection, tuning
Fuel System:
Carburetor (Keihin CV) or Electronic Fuel Injection (EFI) systems, fuel pump, lines, tank service
Ignition System:
Ignition module, coils, spark plugs, wiring
Transmission:
Clutch, gearbox, primary drive, final drive belt
Frame And Suspension:
Frame inspection, front fork overhaul, rear shock absorber service
Brakes:
Front and rear brake systems, hydraulic lines, calipers, master cylinders, rotor service
Electrical System:
Wiring diagrams, battery, charging system, lighting, starter, switches, diagnostic codes (if applicable)
Bodywork And Fittings:
Body panels, fenders, seat, handlebars, controls, exhaust system
Procedures Included
Maintenance:
Oil changes, filter replacements, chain/belt adjustment, brake fluid flush, spark plug replacement, tune-ups
Troubleshooting:
Diagnostic charts, symptom-based problem solving
Repair:
Component replacement, engine rebuilds, transmission overhauls, electrical repairs
Installation:
Accessory installation, component upgrades (where applicable)
Technical Depth
Depth:
Comprehensive (covers basic maintenance to full engine/transmission rebuilds and electrical diagnostics)
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text (typical for professionally produced PDFs)
Print Quality
Image Resolution:
High (includes detailed diagrams and photographs)
Binding Type
Binding:
Not Applicable (Downloadable Format)
Paper Type
Paper Quality:
Not Applicable (Downloadable Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 45-degree V-twin, Evolution engine
Engine Displacement:
Commonly 883cc (XLH883) or 1200cc (XLH1200) for the Sportster line. Specific XLH designation may refer to a base model or a specific variant, often 1200cc.
Bore X Stroke:
XLH1200: 3.50 in x 3.81 in (88.9 mm x 96.8 mm); XLH883: 3.00 in x 3.81 in (76.2 mm x 96.8 mm)
Compression Ratio:
Typically around 9.0:1 to 9.7:1 depending on the specific 1200cc variant.
Valve Train:
Overhead Valves (OHV), 2 valves per cylinder
Performance
Horsepower:
Approx. 65-70 HP for 1200cc models (at crankshaft, subject to specific configuration)
Torque:
Approx. 70-75 lb-ft for 1200cc models (at crankshaft, subject to specific configuration)
Fuel System
Carburetor Model:
Keihin CV (Constant Velocity) 40mm for most 2006 models, unless it's an early EFI variant. (Important to confirm exact model variant)
Fuel Capacity:
Typically 3.1 US gallons (11.7 liters) or 4.5 US gallons (17 liters) depending on the fuel tank style fitted.
Fuel Type:
Unleaded gasoline, minimum 87 octane (91 AKI)
🔧 Transmission
Standard
Type:
5-speed constant mesh
Primary Drive:
Duplex chain, 34/46 ratio
Final Drive:
Belt drive, 29/65 ratio (subject to model variant)
Optional
Optional Transmissions:
None standard for this model year/platform.
Features
Clutch:
Wet, multi-plate, manual engagement
📐 Dimensions
Exterior
Overall Length:
Varies by model variant (e.g., 88.4 in / 2245 mm for a typical 1200cc model)
Wheelbase:
Typically 60.0 in / 1524 mm
Ground Clearance:
Approximately 4.5 in / 114 mm
Weights
Dry Weight:
Around 525 lbs / 238 kg (varies by model variant)
Gvwr:
Not typically specified as a distinct figure, but payload capacity is important.
Payload Capacity:
Typically rated for rider and passenger up to a combined weight of around 350-400 lbs (159-181 kg), consult specific model details.
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycles are not subject to standardized crash test ratings like passenger cars).
Active Features
Braking System:
Hydraulic disc brakes front and rear. ABS was not standard or widely available on Sportsters in 2006.
Passive Features
Lighting:
Headlight, tail light, brake light, turn signals.
💡 Technology Features
Infotainment
Instrumentation:
Analog speedometer, tachometer (on some models), odometer, trip meter, indicator lights for turn signals, oil pressure, engine diagnostics, etc.
Driver Assistance
ABS:
ABS was not standard on 2006 Sportster models.
Connectivity
Bluetooth:
Not applicable for this model year.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 2,500-5,000 miles (4,000-8,000 km) or 6 months, whichever comes first. Consult manual for exact interval and oil type.
Primary Chain Tensioner Check:
Recommended check at regular intervals (e.g., 5,000-10,000 miles) as it's a known wear item.
Belt Tension Check:
Recommended check at regular intervals (e.g., 5,000 miles) and lubrication if specified.
Fluid Specifications
Engine Oil:
Harley-Davidson Genuine V-Twin Synthetic Motor Oil 20W-50, or equivalent SAE 20W-50 motorcycle-specific oil meeting Harley-Davidson specifications.
Primary Chain Case Oil:
Harley-Davidson Genuine Primary Chain Case Oil, or SAE 90W gear oil meeting API GL-4 specification.
Transmission Oil:
Harley-Davidson Genuine Formula + Transmission Oil, or SAE 80W-90 gear oil meeting API GL-5 specification (check manual for precise spec).
Brake Fluid:
DOT 4 brake fluid.
Known Issues
Primary Chain Tensioner:
The stock spring-loaded primary chain tensioner can wear out and cause noise or damage. Upgraded hydraulic tensioners are common replacements.
Carburetor Tuning:
Stock Keihin CV carburetors may require tuning for optimal performance, especially after modifications or at altitude.
Electrical Connectors:
Corrosion or loose connections on various electrical components can cause intermittent issues.
📚 Vehicle History
Brand Heritage
Brand Origins:
Harley-Davidson Motor Company, founded in 1903, is an iconic American motorcycle manufacturer.
Model Evolution
Sportster Lineage:
The Sportster line, introduced in 1957, has been a staple in Harley-Davidson's lineup, evolving from the Ironhead engine to the Evolution engine by 1986. The 2006 models represent a mature iteration of the Evolution Sportster.
Production
Manufacturing Location:
Milwaukee, Wisconsin, USA (and sometimes Kansas City, Missouri, USA for certain components/assembly).
🏆 Awards & Recognition
Recognitions
Industry Awards:
The Harley-Davidson Sportster line is consistently recognized for its iconic styling and customization potential, making it a perennial favorite in the cruiser market.
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