🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster XLH

Year:

2006

Chassis Code:

XLH

👋 Introduction

Segment:

Cruiser Motorcycle

Target Audience:

Harley-Davidson Sportster XLH 2006 owners, independent motorcycle mechanics, and enthusiasts looking for in-depth service information.

Competitors:

Primarily other American V-twin motorcycles from brands like Indian, as well as Japanese cruisers from Yamaha (V-Star), Honda (Shadow), and Kawasaki (Vulcan) from the same era.

Sportster Identity:

Known for its approachable size, classic styling, and strong V-twin performance, often considered a gateway to Harley-Davidson ownership.

Manual Value Proposition:

Provides authoritative, factory-backed repair procedures, diagnostic techniques, and specifications essential for maintaining the longevity and performance of the 2006 Sportster XLH.

📋 Manual Details

Primary Coverage:

Harley-Davidson Sportster XLH 2006

Estimated Pages:

Estimated 600-800 pages (typical for factory service manuals of this era)

Type:

Factory Service Repair Manual

Language:

English

Format:

Digital (likely PDF, based on common sales practice for older manuals)

📖 Manual Coverage

Engine Systems:

Engine disassembly, assembly, diagnostics, tuning, cooling system (air-cooled specific considerations), lubrication system, fuel delivery (carburetor or EFI depending on specific XLH variant), ignition system.

Transmission Drivetrain:

Clutch operation and adjustment, gearbox disassembly and assembly, final drive belt inspection and adjustment, transmission fluid specifications and change intervals.

Electrical System:

Wiring diagrams, battery maintenance and testing, charging system (stator, regulator/rectifier), ignition system components, lighting system troubleshooting, starter motor, fuse box and circuit protection.

Chassis Suspension:

Front fork disassembly, rebuilding, and fluid specifications, rear shock absorber removal, inspection, and replacement, wheel bearing maintenance, steering head bearing adjustment.

Braking System:

Front and rear brake caliper service, hydraulic system bleeding, brake pad replacement, master cylinder and slave cylinder service, brake fluid specifications.

Fuel System:

Carburetor (Keihin CV recommended for 2006 XLH models) disassembly, cleaning, jetting, and adjustment; fuel tank removal, cleaning, and inspection; fuel line replacement.

Exhaust System:

Exhaust pipe removal, installation, and gasket replacement; muffler servicing.

Bodywork Fittings:

Fender removal and installation, fuel tank mounting, seat removal, electrical component access panels, handlebar and control lever adjustments.

Preventative Maintenance:

Routine maintenance checks, lubrication points and schedules, oil and filter change procedures, drive belt tensioning, spark plug replacement.

Troubleshooting:

Diagnostic flowcharts for common running issues, electrical faults, and starting problems; symptom-based troubleshooting guides.

Repair Rebuild:

Detailed step-by-step instructions for major component disassembly, overhaul, and reassembly (e.g., engine, transmission, forks).

Adjustment Calibration:

Carburetor idle speed and mixture adjustment, ignition timing checks (if applicable), clutch and brake lever free play adjustments, suspension sag settings.

Special Tool Requirements:

Identification and usage instructions for specialized Harley-Davidson tools required for specific repair procedures.

Depth:

Comprehensive, ranging from basic owner maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures.

📊 Manual Specifications

Digital Format:

PDF (Portable Document Format) is the most common for this type of manual. Searchable text and image clarity are key quality indicators.

Image Resolution:

High-resolution images and clear diagrams are expected for accurate service work. Text clarity is paramount for reading specifications and instructions.

Physical Binding:

Not applicable for digital format. For a physical manual, expected binding would be professional perfect binding or spiral binding for ease of use in a workshop.

Physical Paper:

Not applicable for digital format. Physical manuals typically use durable, glossy paper to withstand workshop conditions and prevent ink bleed.

⚙️ Engine Specifications

Engine Type:

Air-cooled, 45-degree V-twin, Evolution Engine

Engine Displacement:

Typically 883cc (XLH883) or 1200cc (XLH1200) for the 2006 model year. The manual would cover specific variants.

Bore X Stroke:

883cc: 3.00 in. x 3.56 in. (76.2 mm x 90.4 mm); 1200cc: 3.498 in. x 4.25 in. (88.8 mm x 108.0 mm)

Compression Ratio:

Typically around 9.0:1 for 883cc and 9.7:1 for 1200cc models (check manual for exact figures).

Horsepower:

Approx. 50-55 HP for 883cc, 65-70 HP for 1200cc (at crank, estimates vary).

Torque:

Approx. 50-55 ft-lbs for 883cc, 65-70 ft-lbs for 1200cc (at crank, estimates vary).

Fuel Delivery:

Typically a Keihin CV (Constant Velocity) 40mm carburetor for 2006 models, though some international markets or specific variants might have Electronic Fuel Injection (EFI). Manual would detail specific system.

Fuel Type:

Unleaded gasoline, 91-octane (95 RON) or higher recommended.

Oil Capacity:

Approximately 3 quarts (2.8 Liters) with filter change (check manual for precise capacity).

Oil Type:

Harley-Davidson 20W-50 SYN3 (Synthetic) or equivalent motorcycle-specific oil meeting Harley-Davidson specifications (e.g., H-D 63796-77).

Ignition Type:

Electronic Ignition (Solid State).

Spark Plugs:

H-D part number 32305-06 or equivalent (e.g., NGK DCPR7E). Check manual for correct plug and gap specification.

🔧 Transmission

Transmission Type:

5-speed constant mesh, manual transmission.

Optional Transmission:

None typically offered for this model year.

Clutch Type:

Wet, multi-plate, diaphragm spring.

Gear Ratios:

Specific ratios provided in the manual, typically with lower first gear for acceleration and higher gears for cruising.

Transmission Fluid:

H-D Formula+, or a synthertic 75W-90 gear oil meeting API GL-5 specifications.

Transmission Fluid Capacity:

Approximately 2.5 U.S. quarts (2.4 L) (check manual for precise capacity).

Final Drive:

Belt drive.

📐 Dimensions

Length:

Typically around 88-90 inches (2235-2286 mm) depending on the specific Sportster model (e.g., Custom, Roadster).

Width:

Approximately 32-35 inches (813-889 mm) at handlebars.

Height:

Approximately 45-48 inches (1143-1219 mm) to the top of the handlebars.

Seat Height:

Around 26-28 inches (660-711 mm) depending on model and suspension.

Dry Weight:

Typically around 540-570 lbs (245-259 kg) for 883cc and 1200cc models.

Gross Vehicle Weight Rating Gvwr:

Typically around 930-960 lbs (422-435 kg).

Payload Capacity:

Calculated by GVWR minus dry weight and rider/passenger weight.

Cargo Capacity:

Minimal integrated cargo capacity; requires optional saddlebags or luggage racks.

Front Tire Size:

Commonly 100/90-19 or 110/90-19, depending on specific model.

Rear Tire Size:

Commonly 150/80-16, depending on specific model.

Wheelbase:

Approximately 59.6 inches (1514 mm).

Front Wheel Type:

Typically 19-inch spoke or cast aluminum wheel.

Rear Wheel Type:

Typically 16-inch spoke or cast aluminum wheel.

Wheel Bolt Pattern:

N/A for most motorcycles; wheels attach via axle.

🛡️ Safety Features

Crash Test Ratings:

Motorcycles are not subjected to standardized crash testing like automobiles. Safety is primarily based on design and rider skill.

Braking System:

Hydraulic disc brakes front and rear. ABS was not standard on most 2006 Sportster models, but might have been an option on higher trims or later models. Manual would confirm.

Lighting:

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

Frame Construction:

Steel cradle frame designed for stability and rider feedback.

Handlebars:

Handlebar design contributes to rider control and ergonomics.

Rider Position:

Forward foot controls and typically mid-rise handlebars offer a commanding yet relaxed riding posture.

💡 Technology Features

Infotainment System:

Basic; typically no integrated infotainment system. Primarily analog gauges (speedometer, tachometer if equipped), odometer, trip meter, and indicator lights.

Driver Assistance Features:

None applicable for motorcycles of this era.

Connectivity Features:

None applicable.

Headlight Type:

Halogen.

Charging System Type:

Stator and regulator/rectifier system.

🔧 Maintenance

Initial Service:

Typically at 1,000 miles (1600 km) for the first major service (oil change, filter, clutch/throttle cable check, belt check).

Regular Oil Change:

Every 5,000 miles (8,000 km) or annually, whichever comes first, for synthetic oil. Check manual for specific intervals and oil type.

Drive Belt Check:

Inspect belt tension and condition at every service interval. Adjustment as needed.

Spark Plug Replacement:

Typically every 10,000-15,000 miles (16,000-24,000 km) or as recommended by the manual.

Brake Fluid Flush:

Every 2 years, regardless of mileage, to prevent moisture contamination.

Fork Oil Change:

Recommended every 20,000-30,000 miles (32,000-48,000 km) or if performance degrades.

Engine Oil:

Harley-Davidson 20W-50 SYN3 (Synthetic) or equivalent meeting H-D 63796-77.

Transmission Fluid:

Harley-Davidson Formula+ or synthetic 75W-90 gear oil meeting API GL-5.

Primary Chain Case Oil:

Same as transmission fluid (H-D Formula+ or synthetic 75W-90).

Brake Fluid:

DOT 4 hydraulic brake fluid.

Fork Oil:

Refer to manual for specific viscosity (e.g., Harley-Davidson Type 'E' or equivalent).

Cam Chain Tensioners:

Early Evolution engines (pre-2007) are known to have hydraulic cam chain tensioners that can wear out, leading to noise and potential failure. Manual would cover inspection and replacement.

Carburetor Adjustment:

Keihin CV carburetors can require periodic adjustments for optimal performance, especially after modifications or mileage accumulation. Manual will detail tuning procedures.

Oil Leaks:

Common areas for minor leaks can include primary cover, transmission, and crankcase seals. Manual will guide on seal replacement.

Electrical Connectors:

Corrosion or loose connections can cause intermittent electrical issues. Manual provides wiring diagrams for diagnosis.

📚 Vehicle History

Harley Davidson Legacy:

Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer with a rich history of V-twin engines and cruiser motorcycles.

Sportster Lineage:

The Sportster line, introduced in 1957, is one of Harley-Davidson's longest-running models, evolving from a lightweight sport bike to a versatile cruiser. The XLH designation typically refers to the Evolution engine Sportsters.

Production Era:

The Evolution engine (known as the 'Evo') was introduced to the Sportster line in 1986, replacing the Shovelhead engine. The 2006 model is part of the Evolution era Sportsters.

Manufacturing Location:

Harley-Davidson motorcycles are primarily manufactured in the United States.

🏆 Awards & Recognition

Sportster Reputation:

The Sportster line is consistently recognized for its iconic styling, accessible performance, and strong community following. It's often praised as a customizable platform and a classic American motorcycle experience.