🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster XL883

Year:

2006

Sub Model:

XL883

Generation Identifier:

XL Evolution (2004-2010)

Engine Code:

Evolution V-Twin

👋 Introduction

Market Segment:

Entry-level to mid-range cruiser motorcycle.

Target Audience:

New riders, experienced riders seeking a nimble and accessible Harley-Davidson experience, customizers.

Key Competitors:

Indian Scout, Yamaha Bolt, Honda Shadow, Kawasaki Vulcan.

Competitive Advantage:

Iconic Harley-Davidson brand heritage, accessible V-twin rumble, customizable platform, strong aftermarket support.

Engine Architecture:

Air-cooled, 45-degree V-twin Evolution engine.

Driving Experience:

Torquey power delivery, characteristic Harley-Davidson sound and feel, comfortable riding posture.

Customization Potential:

Extensive aftermarket parts and accessories available for personalization.

📋 Manual Details

Primary Coverage:

Workshop Service and Repair

Secondary Coverage:

Maintenance, Diagnostics, Troubleshooting, Overhaul

Estimated Pages:

Hundreds (as per description)

Type:

Factory Service Manual (FSM) / Workshop Manual

Language:

English

Format:

Downloadable digital format (implied PDF)

📖 Manual Coverage

Engine Systems:

Engine disassembly, assembly, lubrication, cooling, fuel delivery (carburetor), ignition system, exhaust system, internal components (pistons, rings, valves, camshafts, crankshaft).

Transmission Drivetrain:

Clutch, primary drive, transmission gears, shift mechanism, final drive (belt drive system), lubrication.

Chassis Suspension:

Frame, front fork (suspension, seals, adjustments), rear shock absorbers, swingarm, wheel bearings, steering head bearings.

Brake System:

Front and rear brake calipers, master cylinders, brake lines, brake pads, brake fluid flush and bleed procedures, rotor inspection.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting system (headlight, taillight, turn signals), ignition switch, electrical connectors, wiring diagrams, fuses, relays.

Fuel System:

Carburetor (Keihin CV type) disassembly, cleaning, adjustment, jetting, fuel tank, fuel lines, fuel filter.

Bodywork Fittings:

Fender removal/installation, seat, fuel tank mounting, handlebars, controls, instrument cluster, mirrors.

Maintenance Procedures:

Oil changes, filter replacements, spark plug replacement, air filter cleaning/replacement, brake fluid checks and changes, chain adjustment (if applicable, though 2006 Sportster is belt-driven), tire pressure checks.

Repair Procedures:

Engine top-end rebuild, transmission gear replacement, clutch service, fork seal replacement, wheel bearing replacement, brake caliper rebuild, starter motor service.

Troubleshooting Diagnostics:

Systematic fault finding for starting issues, running problems, electrical faults, braking concerns. Includes diagnostic charts and symptom-based troubleshooting.

Depth:

Comprehensive. Covers routine maintenance to full engine and transmission rebuilds. Includes detailed specifications and tolerances.

Diagnostic Capabilities:

Detailed guidance on identifying and resolving mechanical and electrical issues using standard tools and procedures.

📊 Manual Specifications

File Type:

PDF (Portable Document Format) - typical for downloadable manuals.

Searchability:

Likely text-searchable for easy information retrieval.

Printability:

Designed to be printable, allowing users to create a physical copy for garage use.

Recommended Binding:

Coil-bound or three-ring binder for lay-flat usability in a workshop environment.

Recommended Paper:

Durable, laminated pages for resistance to grease and shop fluids.

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-twin

Displacement:

883cc (53.7 cubic inches)

Bore X Stroke:

3.00 in x 3.5625 in (76.2 mm x 90.4875 mm)

Compression Ratio:

8.8:1

Valve Train:

Overhead valves (OHV), 2 valves per cylinder

Ignition System:

Electronic ignition

Horsepower Estimate:

Approximately 50-55 HP (at crankshaft, unconfirmed without exact spec sheet)

Torque Estimate:

Approximately 54-57 ft-lbs (at crankshaft, unconfirmed without exact spec sheet)

Fuel Delivery:

Keihin CV 34mm (Constant Velocity) Carburetor

Fuel Type:

Unleaded gasoline, minimum 91 octane (AKI) recommended.

🔧 Transmission

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-plate

Optional Transmission:

N/A for this model year and variant.

Final Drive:

Belt drive, 29/51 ratio

📐 Dimensions

Length:

88.3 in (2243 mm)

Width:

32.1 in (815 mm)

Height:

47.1 in (1196 mm)

Wheelbase:

60.0 in (1524 mm)

Ground Clearance:

4.25 in (108 mm)

Seat Height:

27.3 in (693 mm)

Dry Weight:

Approximately 545 lbs (247 kg)

Gvwr:

930 lbs (422 kg)

Fuel Capacity:

4.0 US gal (15.1 L)

🛡️ Safety Features

Safety Ratings:

Motorcycles typically do not undergo standardized crash testing like automobiles. Safety relies on rider skill and adherence to traffic laws.

Active Safety Features:

Disc brakes (front and rear), stable chassis geometry, responsive handling.

Passive Safety Features:

Headlight, taillight, brake light, turn signals, handlebar-mounted mirrors.

💡 Technology Features

Infotainment System:

Basic. Typically features analog speedometer and tachometer. No integrated infotainment system as found on modern touring models.

Driver Assistance Features:

N/A. This model predates most advanced rider assistance systems.

Connectivity Features:

N/A.

🔧 Maintenance

Oil Change Interval:

Every 5,000 miles (8,000 km) or annually, whichever comes first (refer to manual for precise Harley-Davidson recommendation).

Primary Chain Case Oil Change:

Every 10,000 miles (16,000 km) or annually.

Transmission Drive Gear Oil Change:

Every 10,000 miles (16,000 km) or annually.

Spark Plug Replacement:

Recommended every 10,000 miles (16,000 km) or as needed based on inspection.

Belt Inspection Tension:

Check belt tension and condition at every service, adjust as per manual specifications.

Engine Oil Type:

Harley-Davidson Genuine V-Twin 20W-50 (or equivalent SAE 50W Motorcycle Oil meeting Harley-Davidson specifications).

Engine Oil Capacity:

3.0 US qt (2.8 L) with filter change.

Primary Chain Case Oil Type:

Harley-Davidson Genuine Primary Chain Lubricant (or equivalent SAE 85W-140 Gear Oil).

Primary Chain Case Oil Capacity:

20-24 US fl oz (591-710 ml).

Transmission Drive Gear Oil Type:

Harley-Davidson Genuine Formula + (or equivalent SAE 85W-140 Gear Oil).

Transmission Drive Gear Oil Capacity:

28-30 US fl oz (828-887 ml).

Brake Fluid Type:

DOT 4 Hydraulic Fluid (Harley-Davidson recommends their own brand).

Common Wear Items:

Clutch plates, brake pads, fork seals, drive belt, wheel bearings, carburetor diaphragm.

Potential Electrical Faults:

Voltage regulator failure, stator issues, loose electrical connections.

Carburetor Tuning:

Some models may require carburetor re-jetting or adjustment for optimal performance, especially after modifications or at altitude.

Belt Tension Adjustment:

Incorrect drive belt tension can lead to premature wear or failure.

📚 Vehicle History

Brand Legacy:

Harley-Davidson is an iconic American motorcycle manufacturer with a rich history dating back to 1903, known for its distinctive V-twin engines and cruiser styling.

Sportster Lineage:

The Sportster line has been in continuous production since 1957, evolving significantly over the decades while retaining its core identity as a sporty, accessible Harley-Davidson.

2006 Model Context:

The 2006 Sportster XL883 is part of the Evolution Sportster platform that saw a major update in 2004 with frame and suspension improvements. It represents a refined version of the classic Sportster formula.

Manufacturing Location:

United States (Milwaukee, Wisconsin and York, Pennsylvania)

🏆 Awards & Recognition

Market Awards:

The Sportster line has consistently been praised for its accessibility, style, and the classic Harley-Davidson experience. Specific awards for the 2006 XL883 may vary but the model is generally well-regarded within its segment.

Reliability Ratings:

Reliability is generally good when properly maintained, with the Evolution engine known for its durability. Common issues are typically related to routine wear and tear or electrical components.

Emissions Compliance:

Complies with EPA and California ARB emissions standards for the 2006 model year.