Harley Davidson Sportster XLH 2006 Repair Service Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster XLH Year: 2006 Sub Model: XLH Series Codes Vin Prefix: 1HD 👋 Introduction Market Position Segment: Cruiser / Performance Cruiser Target Audience:...

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Taper: Motorcycle

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UGS: 479269

Mots clés: 2006 Harley Davidson Misc Motorcycle Motorcycles Sportster XLH

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Sportster XLH

Year:

Sub Model:

XLH Series

Codes

Vin Prefix:

👋 Introduction

Market Position

Segment:

Cruiser / Performance Cruiser

Target Audience:

Enthusiast riders, independent repair shops, and professional motorcycle technicians.

Competitive Analysis

Competitors 2006:

Other V-twin cruisers from manufacturers like Indian, Honda, Yamaha, Suzuki, and Kawasaki.

Key Features

Sportster Legacy:

The Sportster line represents one of Harley-Davidson's longest continuous production model lines, known for its accessible performance and customizability.

Xlh Platform:

The XLH designation typically refers to models with the Evolution engine, a staple of the Sportster range.

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive repair and service for the 2006 Harley-Davidson Sportster XLH models.

Engine Coverage:

Engine disassembly, assembly, tuning, and troubleshooting.

Drivetrain Coverage:

Transmission, clutch, and final drive systems.

Chassis Coverage:

Frame, suspension (front and rear), steering, and wheels.

Electrical Coverage:

Wiring diagrams, ignition system, lighting, charging system, and accessories.

Braking Coverage:

Front and rear brake systems, including hydraulic components and bleeding procedures.

Fuel System Coverage:

Carburetor (if applicable), fuel delivery, and tank components.

Exhaust Coverage:

Exhaust system components and maintenance.

Bodywork Coverage:

Body panels, fenders, seat, and fuel tank removal/installation.

Page Count

Estimated Pages:

~400-600 (typical for this model and format)

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF (Downloadable)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Cylinder head, cylinders, pistons, connecting rods, crankshaft, camshaft, valve train, oil pump, timing.

Engine Management:

Ignition timing, carburetor adjustment (CV Carburetor), fuel delivery diagnosis.

Transmission Mechanical:

Gearbox disassembly and assembly, shift mechanism, primary drive, clutch assembly.

Electrical System:

Battery, charging system (alternator, regulator/rectifier), starter motor, ignition coil, spark plugs, lighting circuits, horn, instrument cluster.

Suspension System:

Front fork service (oil change, seal replacement), rear shock absorber removal and installation.

Braking System:

Hydraulic brake system components, caliper service, master cylinder service, brake fluid specifications and bleeding.

Fuel Delivery:

Carburetor (Keihin CV 40), fuel lines, fuel filter, fuel tank servicing.

Exhaust System:

Muffler replacement, exhaust pipe sealing.

Wheel Hub Bearing:

Wheel bearing inspection and replacement.

Frame Body:

Frame inspection, mounting points, body panel removal and installation.

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, spark plug service, drive belt inspection/adjustment, brake fluid replacement.

Diagnostic Procedures:

Troubleshooting common issues, electrical system diagnostics, engine performance analysis.

Engine Overhaul:

Complete engine teardown, inspection, part replacement, and reassembly.

Transmission Repair:

Clutch replacement, gear inspection, bearing replacement, and transmission reassembly.

Electrical Repairs:

Wiring harness repair, component testing and replacement (e.g., stator, regulator, starter solenoid).

Suspension Servicing:

Fork seal replacement, fork oil replacement, rear shock absorber servicing.

Brake System Maintenance:

Brake pad replacement, brake fluid flush and bleed, caliper and master cylinder service.

Carburetor Adjustment And Rebuild:

CV carburetor tuning, jetting, idle speed adjustment, float bowl service.

Wheel Tire Service:

Tire replacement, wheel balancing, spoke tensioning (if applicable).

Frame And Body Repair:

Body panel alignment, fairing repair (if applicable), mounting hardware checks.

Technical Depth

Depth:

Complete Professional-Level Diagnostic and Repair

Detail Level:

Step-by-step instructions with torque specifications, clearances, and detailed diagrams.

Diagnostic Tools:

Mentions specific tools and techniques for effective troubleshooting.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF for quick information retrieval.

Print Quality

Resolution:

High resolution, suitable for printing key sections or the entire manual.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Evolution V-Twin (Air-Cooled)

Displacement:

1200cc (likely, also 883cc variants exist for the Sportster line)

Bore X Stroke:

3.50 in x 3.81 in (for 1200cc, approximate)

Compression Ratio:

9.0:1 (typical for 1200cc Evolution)

Valve Train:

Overhead Valve (OHV), 2 valves per cylinder

Performance

Horsepower:

~65-70 HP (estimated for 1200cc)

Torque:

~70-75 ft-lbs (estimated for 1200cc)

Fuel System

Fuel Delivery:

Keihin 40mm Constant Velocity (CV) Carburetor

Fuel Type:

Unleaded Gasoline, 91 octane (minimum recommended)

Oil System

Oil Capacity:

~2.7 US qt (3.0 L) with filter change (check manual for exact)

Oil Type:

Harley-Davidson SYN3 Full Synthetic Motorcycle Oil or equivalent V-twin specific engine oil.

Ignition

Ignition System:

Electronic Ignition

Spark Plugs:

Typically NGK DCPR8E or equivalent (refer to manual for specific)

🔧 Transmission

Standard

Transmission Type:

5-Speed Constant Mesh

Primary Drive:

Duplex Chain

Final Drive:

Belt Drive (25mm width)

Features

Clutch Type:

Wet, Multi-plate

Transmission Fluid Capacity:

~1 US qt (0.95 L) (check manual for exact)

Transmission Fluid Type:

Harley-Davidson Formula+ Transmission Fluid or equivalent V-twin specific transmission oil.

📐 Dimensions

Exterior

Length:

~88.0 inches (2235 mm) (approximate, varies by model)

Width:

~30.9 inches (785 mm) (approximate)

Height:

~48.0 inches (1219 mm) (approximate)

Wheelbase:

~60.0 inches (1524 mm)

Weights

Dry Weight:

~500 lbs (227 kg) (approximate)

Gross Vehicle Weight Rating:

930 lbs (422 kg) (typical)

Fuel Capacity:

3.0 US gallons (11.4 L) (typical for XLH models)

Oil Capacity:

2.7 US quarts (3.0 L) (as noted in engine specs)

Wheels Tires

Front Tire Size:

100/90-19 57H (typical)

Rear Tire Size:

150/80B16 71H (typical)

Front Wheel:

19-inch

Rear Wheel:

16-inch

Wheel Bolt Pattern:

N/A (Hub-mounted, spoke wheels or cast wheels)

🛡️ Safety Features

Ratings

Crash Test Results:

Motorcycles are not typically subjected to standardized crash testing like automobiles. Safety is inherent in design and rider skill.

Active Features

Braking System:

Hydraulic disc brakes front and rear. ABS was not standard or widely available on 2006 Sportster models.

Lighting:

Headlight, taillight, brake light, turn signals.

Passive Features

Frame Construction:

Steel frame providing structural integrity.

Ergonomics:

Rider controls and seating position designed for rider comfort and control.

💡 Technology Features

Infotainment

Standard Features:

Basic analogue instrumentation (speedometer, tachometer, fuel gauge, indicator lights). No advanced infotainment systems typical of modern vehicles.

Driver Assistance

Features:

No electronic driver assistance systems common in cars. Relies on rider skill and mechanical systems.

Connectivity

Features:

No integrated connectivity features (Bluetooth, Wi-Fi, smartphone integration).

🔧 Maintenance

Service Intervals

Initial Service:

500 miles (800 km) for break-in service (oil change, belt adjustment, inspection).

Regular Oil Change:

Every 5,000 miles (8,000 km) or annually, whichever comes first.

Drive Belt Inspection:

Inspect tension at 2,500 miles (4,000 km) and 7,500 miles (12,000 km).

Brake Fluid Flush:

Every 2 years, regardless of mileage.

Spark Plug Replacement:

Refer to manual, typically around 10,000-15,000 miles.

Fluid Specifications

Engine Oil Spec:

Harley-Davidson SYN3 or SAE 20W-50 Motorcycle Oil meeting Harley-Davidson specifications.

Transmission Fluid Spec:

Harley-Davidson Formula+ or equivalent V-twin transmission oil.

Primary Chain Case Oil:

Harley-Davidson Formula+ or equivalent V-twin transmission oil (shared with transmission).

Brake Fluid Spec:

DOT 4 Hydraulic Brake Fluid.

Fork Oil Type:

Harley-Davidson Type E or equivalent SAE 10W fork oil (refer to manual for specific grade and quantity).

Known Issues

Carburetor Tuning:

CV carburetor can sometimes require adjustment for optimal performance, especially at altitude or with modifications.

Electrical Connections:

Occasional issues with corrosion or looseness in electrical connectors, particularly on older models. Manual covers inspection and cleaning.

Clutch Adjustment:

Clutch lever free play adjustment is important for smooth operation and longevity.

Wheel Bearings:

Routine inspection and potential replacement as part of scheduled maintenance.

Drive Belt Wear:

Proper tension and alignment are crucial for belt life; manual details inspection and adjustment.

📚 Vehicle History

Brand Heritage

Harley Davidson Founding:

Founded in 1903, Harley-Davidson is one of the oldest motorcycle manufacturers in the world.

Model Evolution

Sportster Introduction:

The Sportster line was introduced in 1957 as a performance-oriented motorcycle.

Evolution Engine Debut:

The Evolution engine ('Evo') was introduced in 1984, marking a significant update to the Sportster platform.

Production

Manufacturing Location:

United States (primarily Milwaukee, Wisconsin for this era)

🏆 Awards & Recognition

Recognitions

Sportster Status:

The Sportster has consistently been recognized as an iconic motorcycle, a symbol of American freedom and customization.

Ratings

Reliability:

Generally considered reliable with proper maintenance. The Evolution engine is known for its robustness.

Certifications

Manual Quality:

Prepared by professionals for professional use, indicating a high standard of technical accuracy and comprehensiveness.