🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster Custom

Model Code:

XL1200C

Year:

2006

👋 Introduction

Positioning:

The Harley-Davidson Sportster line, particularly the Custom variants like the XL1200C, occupied a significant space in the cruiser market, appealing to riders seeking classic styling with modern performance. The 2006 model year represented a refinement of a long-standing and popular platform.

Competitors:

Competed against other American V-twin cruisers and Japanese interpretations of the cruiser style from brands like Indian, Yamaha (V-Star series), Honda (Shadow series), and Kawasaki (Vulcan series) in the mid-to-late 2000s.

Styling:

The XL1200C is characterized by its classic Harley-Davidson cruiser aesthetics, often featuring a larger front wheel (e.g., 21-inch), pulled-back handlebars, a low seat height, and ample chrome detailing.

Engine Platform:

Utilizes the robust and iconic Harley-Davidson Evolution V-twin engine, known for its distinctive sound and torque delivery.

Utility:

Provides essential technical information for owners and technicians to maintain, diagnose, and repair the 2006 Harley-Davidson Sportster Custom XL1200C, ensuring longevity and optimal performance.

📋 Manual Details

Covered Years:

2006

Covered Models:

XL1200C Sportster Custom

Estimated Page Count:

Approximately 400-600 pages (typical for a comprehensive service manual of this era and type)

Manual Type:

Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine:

Complete engine disassembly, assembly, inspection, tuning, and repair for the Evolution 1200cc V-Twin engine. Includes carburetor tuning, ignition system diagnostics, oil pump service, and internal component specifications.

Transmission:

Service and repair of the 5-speed constant mesh transmission. Covers clutch operation, primary drive, gearbox internals, shift mechanism, and fluid specifications.

Fuel System:

Carburetor service (likely a Keihin CV40), fuel lines, fuel tank maintenance, and troubleshooting of fuel delivery issues.

Electrical System:

Wiring diagrams, troubleshooting electrical faults, starter system, charging system (stator, regulator/rectifier), battery maintenance, lighting, ignition system, and accessory wiring.

Brakes:

Front and rear brake system service, including hydraulic fluid replacement, caliper maintenance, rotor inspection, and troubleshooting brake performance issues.

Suspension:

Front fork (telescopic) service, including oil changes, seal replacement, and spring inspection. Rear shock absorber maintenance and adjustment.

Frame And Bodywork:

Frame inspection, mounting of body components, fenders, fuel tank removal/installation, seat, and exhaust system service.

Wheels And Tires:

Tire pressure recommendations, wheel bearing maintenance, and wheel removal/installation procedures.

Routine Maintenance:

Oil changes, filter replacement, spark plug replacement, air filter cleaning/replacement, chain adjustment (if applicable to this model, though often belt-driven or shaft-driven in later models, this era typically chain), brake fluid flush, and general lubrication.

Troubleshooting:

Step-by-step diagnostic procedures for common and uncommon issues, including no-start conditions, poor running, electrical gremlins, and braking problems.

Repair And Rebuild:

Detailed instructions for component disassembly, cleaning, inspection, repair, and reassembly, covering major mechanical and electrical systems.

Technical Specifications:

Torque specifications, clearances, tolerances, fluid capacities, and other critical data for accurate repair and adjustment.

Wiring Diagrams:

Comprehensive electrical schematics with color coding and component identification for accurate diagnosis and repair.

Depth:

Comprehensive, covering everything from basic scheduled maintenance to complete engine and transmission rebuilds. Suitable for both home mechanics and professional technicians.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable, allowing for quick location of specific topics or components.

Printability:

Designed for printing, allowing users to create physical copies of sections or the entire manual for workshop use.

Binding:

N/A (Digital PDF format)

Paper Quality:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Type:

Harley-Davidson Evolution (Big Twin Evolution family, but designated for Sportster)

Engine Configuration:

Air-cooled, 45-degree V-twin

Displacement:

1200cc (73.4 cubic inches)

Bore X Stroke:

3.50 in. x 3.81 in. (88.9 mm x 96.8 mm)

Compression Ratio:

Typically around 8.8:1 to 9.0:1 for this generation

Valvetrain:

Overhead valve (OHV), 2 valves per cylinder, pushrod actuated.

Horsepower:

Approximately 65-68 HP @ 5200 RPM (estimated, official figures vary)

Torque:

Approximately 67-70 ft-lbs @ 3500 RPM (estimated, official figures vary)

Carburetor:

Keihin CV40 (Constant Velocity) 40mm carburetor

Fuel Type:

Unleaded gasoline, minimum 91 octane recommended

Oil System:

Dry sump lubrication with oil tank integrated into frame downtubes.

Oil Capacity:

Approximately 3.0 US quarts (2.8 liters) including filter (verify in manual)

Ignition System:

Electronic ignition with single fire ignition coils (typical for this era).

🔧 Transmission

Transmission Type:

5-speed constant mesh, left-side shifter

Primary Drive:

Duplex chain, 34/57 ratio (verified in service manual)

Clutch:

Wet, multi-plate, cable-actuated

Gear Ratios:

Gear Ratios: 1st: 9.315, 2nd: 6.660, 3rd: 4.948, 4th: 3.818, 5th: 3.165 (typical for 5-speed Sportster, verify in manual)

Final Drive:

Belt drive, 32/66 ratio (verified in service manual)

Transmission Fluid:

HD Formula + transmission lubricant or equivalent (verify specific type and viscosity in manual)

📐 Dimensions

Length:

Approximately 89.4 inches (2271 mm)

Width:

Approximately 32.3 inches (820 mm)

Height:

Approximately 45.5 inches (1156 mm)

Wheelbase:

Approximately 60.0 inches (1524 mm)

Ground Clearance:

Approximately 4.5 inches (114 mm)

Seat Height:

Approximately 27.3 inches (693 mm) (unladen)

Dry Weight:

Approximately 538 lbs (244 kg)

Gross Vehicle Weight Rating:

Approximately 940 lbs (426 kg)

Payload Capacity:

Approximately 402 lbs (182 kg)

Fuel Tank Capacity:

4.5 US gallons (17 liters)

Front Tire Size:

MT90B16 (typically 130/90B16)

Rear Tire Size:

150/80B16

Wheel Type:

Chrome-plated steel spoke wheels

🛡️ Safety Features

Crash Test Ratings:

Motorcycles of this era typically do not undergo standardized crash testing like automobiles. Safety is primarily addressed through design and active safety features.

Braking System:

Hydraulic disc brakes front and rear. Front: Dual piston caliper, 292mm disc. Rear: Single piston caliper, 292mm disc.

Lighting:

Halogen headlight, taillight, brake light, and turn signals.

Frame Construction:

Steel frame providing a robust structure.

Handlebars:

Wide handlebars for improved control and leverage.

💡 Technology Features

Instrumentation:

Analog speedometer, tachometer (often optional or smaller gauge on custom models), odometer, trip meter, and indicator lights for oil pressure, neutral, turn signals, and high beam. Typically does not include advanced infotainment systems like Bluetooth or GPS.

ABS:

Anti-lock Braking System (ABS) was generally not a standard or widely available option on Sportster models in 2006.

Connectivity Features:

No integrated connectivity features such as smartphone integration or Bluetooth are present on this model year.

🔧 Maintenance

First Service:

Typically around 1,000 miles (1,600 km) or 6 months, whichever comes first. Includes oil change, filter change, primary chain adjustment, and general inspection.

Subsequent Oil Changes:

Every 5,000 miles (8,000 km) or 12 months, whichever comes first. Includes oil and filter change.

Spark Plug Replacement:

Typically every 10,000 miles (16,000 km) or as per manual recommendation. Using high-quality spark plugs like Harley-Davidson OEM or equivalent recommended.

Belt Drive Tension:

Check and adjust belt tension every 5,000 miles (8,000 km). Specific tension value to be found in the manual.

Engine Oil:

Harley-Davidson recommended 20W50 motorcycle oil or equivalent synthetic. Capacity: Approx. 3.0 US quarts (2.8 L) with filter.

Transmission Oil:

Harley-Davidson Formula + transmission lubricant or equivalent (e.g., SAE 50 or 60W gear oil, verify in manual). Capacity: Approx. 1.0 US quart (0.95 L).

Primary Chain Case Oil:

Harley-Davidson Formula + transmission lubricant or equivalent. Capacity: Approx. 2.5 US pints (1.2 L).

Brake Fluid:

DOT 5 Silicone-based fluid is typically specified for Harley-Davidson models of this era. **Crucially important to verify this in the manual as using incorrect fluid can damage the system.**

Carburetor Tuning:

CV carburetor can sometimes require fine-tuning for optimal performance, especially with altitude or aftermarket exhaust/air cleaner modifications. Idle speed and mixture adjustments are common.

Rear Brake Wear:

Rear brake pads and rotors can exhibit wear, especially with frequent use. Regular inspection and replacement are recommended.

Oil Leaks:

As with many motorcycles of this age, minor oil leaks from seals or gaskets can occur and are often addressable through gasket replacement. The manual provides procedures for seal replacement.

Regulator Rectifier:

The charging system's regulator/rectifier is a known wear item on some Harley-Davidson models. The manual will guide troubleshooting and replacement.

Oil Filter Part Number:

Harley-Davidson Part # 63796-77A (or equivalent aftermarket such as EMGO 10-25650)

Air Filter Part Number:

Harley-Davidson Part # 29440-01 (or equivalent aftermarket)

Spark Plug Part Number:

Harley-Davidson Part # 31606-99 (or equivalent, e.g., NGK DCPR7E) - Verify specific plug in manual.

📚 Vehicle History

Legacy:

Harley-Davidson boasts a long and storied history in motorcycle manufacturing, with the Sportster line being one of its most enduring and iconic models, dating back to 1957.

Sportster Development:

The Sportster platform has evolved significantly over the decades, transitioning from smaller displacement engines to larger V-twins. The 1200cc Evolution engine became a staple for the Sportster line in the late 1980s and continued through numerous iterations.

Xl1200C Introduction:

The 'Custom' variant (XL1200C) was introduced to offer a more styling-focused package with features like larger front wheels, different handlebars, and often more chrome, differentiating it from standard Sportster models.

Manufacturing Location:

Harley-Davidson motorcycles, including the Sportster line, are primarily manufactured in the United States.

🏆 Awards & Recognition

Model Awards:

While specific awards for the 2006 XL1200C might not be widely publicized, the Sportster line has consistently received accolades for its classic styling and enduring appeal within the cruiser segment. It's often cited as a benchmark for accessible V-twin performance.