Harley Davidson Sportster XLH 2006 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster XLH Year: 2006 Product Type: Full Service Repair Manual 👋 Introduction Market Position Segment: Cruiser Motorcycle Target Audience: Harley-Davidson Sportster owners seeking...

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UGS: 449983

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:

Product Type:

Full Service Repair Manual

👋 Introduction

Market Position

Segment:

Cruiser Motorcycle

Target Audience:

Harley-Davidson Sportster owners seeking to perform their own maintenance and repairs.

Competitive Analysis

Category Competitors:

Other aftermarket service manuals for Harley-Davidson Sportster models, factory service manuals.

Key Features

Value Proposition:

Provides detailed, actionable information for all major service and repair tasks, enabling cost savings and self-sufficiency for owners.

Usability:

Clear instructions, logical organization, and likely inclusion of diagrams and photographs.

📋 Manual Details

Coverage Areas

Engine Overhaul:

Complete

Transmission Repair:

Complete

Electrical System Diagnostics:

Comprehensive

Suspension And Steering:

Complete

Brake System Service:

Complete

Fuel System Maintenance:

Complete

Frame And Bodywork:

Complete

Scheduled Maintenance:

Detailed Intervals and Procedures

Troubleshooting Guides:

Extensive

Wiring Diagrams:

Included

Page Count

Estimated Pages:

Approximately 400-500 pages (typical for this type of manual)

Manual Type

Type:

Service & Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF likely, given description)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly/disassembly, cylinder heads, valves, pistons, connecting rods, crankshaft, camshafts, oil pump, timing.

Engine Fuel System:

Carburetor(s) (Keihin CV), fuel tank, fuel lines, fuel pump, fuel filter.

Ignition System:

Ignition module, spark plugs, ignition coil, wiring, timing.

Transmission And Drivetrain:

Clutch, primary drive, gearbox, shift mechanism, final drive belt, pulleys.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting (headlight, tail light, turn signals), ignition switch, fuses, relays, horn.

Suspension:

Front forks (assembly, seals, oil), rear shock absorbers, mounting hardware.

Steering:

Handlebars, risers, steering head bearings (adjustment, replacement).

Brakes:

Front and rear disc brakes, brake calipers, master cylinders, brake lines, brake pads, brake fluid specifications and bleeding procedures.

Wheels And Tires:

Wheel bearings, tire pressure, tire replacement, wheel balancing.

Chassis And Frame:

Frame inspection, engine mounting, body panels, fenders, seats, fuel tank mounting.

Exhaust System:

Exhaust pipes, mufflers, heat shields, mounting.

Procedures Included

Tune Up:

Spark plug replacement, carburetor adjustment, ignition timing check.

Engine Rebuild:

Complete top-end and bottom-end rebuild procedures, torque specifications for all fasteners.

Transmission Overhaul:

Gearbox disassembly, inspection of gears and bearings, reassembly.

Electrical Troubleshooting:

Diagnostic steps for common electrical faults, testing procedures for components.

Fork Seal Replacement:

Detailed step-by-step guide for front fork disassembly and seal replacement.

Brake Bleeding:

Proper procedures for bleeding hydraulic brake systems.

Carburetor Rebuild And Adjustment:

Jetting information, float level adjustment, idle mixture settings.

Clutch Adjustment And Replacement:

Clutch cable adjustment, primary chain adjustment, clutch plate replacement.

Wheel Bearing Replacement:

Procedure for repacking and replacing wheel bearings.

Diagnostic Procedures:

Systematic troubleshooting flowcharts and fault code interpretation (if applicable).

Technical Depth

Depth:

Comprehensive, covering routine maintenance to complete engine and transmission rebuilds. Suitable for experienced DIY mechanics and professional technicians.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable for easy keyword navigation.

Printability:

Printable pages for workshop use.

Print Quality

Image Resolution:

High resolution for clear diagrams and illustrations.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Evolution (Evo) V-Twin

Displacement Cc:

88 cubic inches (1449 cc) - Common for XLH models of this era, though a 1200cc variant also existed.

Bore X Stroke In:

3.437 in x 3.968 in (87.3 mm x 100.5 mm) for 1449cc

Compression Ratio:

9.0:1 (typical for this engine)

Engine Configuration:

Air-cooled, 45-degree V-twin

Valve Train:

Overhead valves (OHV), pushrod actuated

Performance

Horsepower Hp:

Approximately 65-70 HP (estimated, depending on tuning and specific model variant)

Torque Lb Ft:

Approximately 75-80 lb-ft (estimated, depending on tuning and specific model variant)

Fuel System

Fuel Delivery:

Carburetor (Keihin CV 40mm)

Fuel Type:

Unleaded gasoline, minimum 87 octane

🔧 Transmission

Standard

Type:

5-speed constant mesh

Clutch:

Wet, multi-plate

Features

Primary Drive:

Hyphoid gears

Final Drive:

Belt drive

📐 Dimensions

Exterior

Wheelbase In:

Approximately 60.0 inches (1524 mm)

Length In:

Approximately 88.0 inches (2235 mm)

Weights

Dry Weight Lb:

Approximately 535 lbs (243 kg)

Fuel Capacity Gal:

3.1 US gallons (11.7 L)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles typically do not have standardized crash test ratings like passenger cars).

Active Features

Braking System:

Dual disc front, single disc rear (hydraulic actuation)

Lighting:

Halogen headlight, LED tail light, amber turn signals.

Passive Features

Frame Construction:

Steel tube frame for rigidity and impact absorption.

💡 Technology Features

Infotainment

Features:

Basic instrumentation (speedometer, tachometer, odometer, trip meter, indicator lights). No integrated infotainment system in the modern sense.

Driver Assistance

Features:

None (Anti-lock Braking System (ABS) was not a standard or widely available option for Sportsters in 2006).

Connectivity

Features:

None.

🔧 Maintenance

Service Intervals

First Service:

1000 miles (1600 km) - Oil change, primary chain adjustment, inspection of critical fasteners, brake check.

Subsequent Services:

Every 5000 miles (8000 km) or annually - Oil change, primary chain adjustment, spark plug inspection/replacement, drive belt check, brake fluid check, general inspection.

Major Service:

Refer to manual for specific mileage/time intervals for valve adjustments, fork oil changes, and brake fluid replacement.

Fluid Specifications

Engine Oil Type:

Harley-Davidson SYN3 (Synthetic) 20W-50 or equivalent motorcycle-specific SAE 20W-50 oil meeting Harley-Davidson specifications.

Engine Oil Capacity Qt:

Approximately 3.0 US quarts (2.8 L) with filter change.

Primary Chain Case Oil Type:

Harley-Davidson Primary Chaincase Lubricant or equivalent motorcycle-specific primary lubricant.

Primary Chain Case Oil Capacity Qt:

Approximately 1.0 US quart (0.95 L).

Transmission Oil Type:

Harley-Davidson Transmission and Primary Chaincase Lubricant or equivalent motorcycle-specific transmission fluid (e.g., SAE 80W-90 gear oil).

Transmission Oil Capacity Qt:

Approximately 0.8 US quarts (0.75 L).

Brake Fluid Type:

DOT 4 specification hydraulic fluid.

Fork Oil Type:

Refer to manual, typically SAE 10W or 15W fork oil.

Known Issues

Common Wear Items:

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

Potential Electrical Issues:

Wiring harness degradation, regulator/rectifier failures, battery terminal corrosion (common on many motorcycles of this era).

Carburetor Tuning:

CV carburetors can require periodic adjustment for optimal performance and fuel economy.

📚 Vehicle History

Brand Heritage

Manufacturer:

Harley-Davidson Motor Company, established 1903, known for V-twin engines and cruiser motorcycles.

Model Evolution

Sportster Lineage:

The Sportster line has been in continuous production since 1957, evolving through various engine sizes and styling cues. The XLH designation typically refers to the standard or custom versions.

Production

Manufacturing Location:

United States (various Harley-Davidson plants)

Model Year Context:

2006 models often featured the 88 cubic inch Evolution engine and continued the Sportster's legacy as a versatile cruiser.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for the 2006 model might be scarce, the Sportster line itself is recognized for its enduring appeal and its contribution to motorcycle culture.

Ratings

Owner Satisfaction:

Generally high among owners who appreciate the classic styling and mechanical simplicity.