🏷️ Basic Information

Make:

Harley-Davidson

Model:

XLH Sportster

Model Variant:

XLH (likely indicates the 883cc or 1200cc engine configuration, often XLH883 or XLH1200 depending on specific sub-model)

Year:

2006

Chassis Code Prefix:

1HD1

Engine Family Code:

Evolution (Big Twin and Sportster variants)

👋 Introduction

Positioning:

The Harley-Davidson Sportster line, particularly the 2006 models, represented a blend of classic styling and evolutionary engineering, appealing to riders seeking a versatile cruiser with iconic American heritage.

Competitors:

Competed with other V-twin cruisers from brands like Indian, Triumph (America series), and custom builders, as well as some Japanese cruisers in terms of performance and rider experience.

Features 2006:

The 2006 Sportster models continued the evolution of the platform, likely featuring electronic fuel injection (EFI) on some variants, improved braking systems, and refinements to the Evolution engine. Key selling points were its distinctive Harley-Davidson character, exhaust note, and customization potential.

Value:

This manual is essential for owners and technicians to maintain, diagnose, and repair the 2006 XLH Sportster effectively, ensuring longevity and optimal performance of this classic motorcycle.

📋 Manual Details

Scope:

Comprehensive factory service and repair coverage for the 2006 Harley-Davidson XLH Sportster motorcycle.

Count:

Typically 500-700+ pages for a full factory service manual.

Type:

Factory Service Manual / Workshop Manual / Repair Manual

Language:

English

Format:

Print

📖 Manual Coverage

Engine:

Detailed diagnostics, disassembly, assembly, inspection, and repair for the Evolution V-Twin engine (including 883cc and 1200cc variants).

Transmission:

Inspection, maintenance, and repair of the 5-speed constant mesh transmission and primary drive system.

Fuel System:

Carburetor (likely Keihin CV) or early fuel injection system diagnosis, adjustment, and repair; fuel tank, lines, and pump servicing.

Electrical System:

Complete wiring diagrams, component testing, ignition system, charging system (stator, regulator/rectifier), lighting, starting system, and accessory circuits.

Brakes:

Front and rear brake system inspection, service, hydraulic component replacement (calipers, master cylinder, lines), and bleeding procedures.

Suspension:

Front fork (telescopic) and rear shock absorber inspection, service, and rebuild procedures; steering head bearing maintenance.

Frame And Bodywork:

Frame inspection, mounting hardware torque specifications, body panel removal/installation, and general chassis components.

Wheels And Tires:

Wheel bearing service, tire maintenance, and wheel removal/installation.

Exhaust System:

Exhaust component inspection and replacement.

Maintenance:

Regular scheduled maintenance, oil changes, filter replacements, spark plug service, belt tension checks, brake fluid flushes.

Troubleshooting:

Systematic diagnostic procedures for common issues, fault finding charts, and diagnostic codes (if applicable to EFI models).

Repair:

Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly.

Technical Specifications:

Torque specifications for all fasteners, engine clearances, fluid capacities, electrical system parameters, and dimensional data.

Depth:

In-depth, covering complete engine rebuilds, transmission overhauls, and detailed electrical system diagnostics, suitable for professional mechanics and advanced DIY enthusiasts.

📊 Manual Specifications

Format Details:

Typically a professionally printed book with high-quality paper for durability in a workshop environment.

Quality:

High-resolution images, clear diagrams, and legible text, designed for workshop use.

Binding:

Often spiral-bound or lay-flat binding to allow the manual to remain open on a workbench.

Paper:

Durable, glossy, or semi-gloss paper stock suitable for frequent handling and exposure to shop environments.

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-twin, pushrod-actuated overhead valves

Displacement Variants:

Typically 883cc (53.9 cu in) or 1200cc (73.2 cu in) for the XLH designation.

Bore Stroke 883:

3.00 in x 3.8125 in (76.2 mm x 96.8 mm)

Bore Stroke 1200:

3.50 in x 3.8125 in (88.9 mm x 96.8 mm)

Horsepower 883 Est:

~53 hp @ 6000 rpm

Torque 883 Est:

~48 lb-ft @ 3500 rpm

Horsepower 1200 Est:

~65 hp @ 6000 rpm

Torque 1200 Est:

~72 lb-ft @ 3500 rpm

Fuel Delivery:

Keihin CV 40mm Carburetor (likely standard for many 2006 models) or Electronic Fuel Injection (EFI) on select variants.

Fuel Type:

Unleaded gasoline, 91 octane (R+M)/2 or higher recommended.

Ignition System:

Electronic, solid-state with knock sensor (if EFI).

Cooling System:

Air-cooled

Exhaust Type:

Dual exhaust system

🔧 Transmission

Transmission Type:

5-speed, constant mesh, helical gear

Primary Drive:

Primary chain drive to clutch, enclosed in a separate oil bath.

Clutch Type:

Wet, multi-plate

Gear Ratios:

Specific ratios detailed in the manual, typically ranging from around 2.79:1 in first gear to 0.86:1 in fifth gear for overdrive.

📐 Dimensions

Length Est:

~89 inches (2260 mm)

Width Est:

~32 inches (813 mm)

Height Est:

~47 inches (1194 mm)

Dry Weight Est:

~500-520 lbs (227-236 kg)

Gross Vehicle Weight Rating Gvw Est:

~930 lbs (422 kg)

Fuel Capacity:

3.1 US gallons (11.7 L)

Oil Capacity Engine Primary:

3.0 US quarts (2.8 L)

Oil Capacity Transmission Secondary:

1 US quart (0.95 L)

Front Tire Size Common:

MT90-16 72H

Rear Tire Size Common:

130/90-16 73H

Wheel Type:

Spoke wheels or solid cast aluminum wheels, depending on trim level.

Wheelbase:

~59.6 inches (1514 mm)

Rake Trail Est:

30 degrees rake, ~4.1 inches trail

🛡️ Safety Features

NHTSA Rating:

Motorcycles are generally not subject to the same crash test ratings as passenger cars. Safety is primarily determined by rider skill and adherence to road safety.

Braking System:

Dual-piston front caliper with 11.5-inch disc; Dual-piston rear caliper with 11.5-inch disc. (ABS was not common on Sportsters of this era).

Lighting:

Halogen headlight, LED tail light, standard front and rear turn signals.

Frame Construction:

Steel cradle frame designed for stability and rider feedback.

Ergonomics:

Mid-mount controls and handlebar position designed for a comfortable riding posture.

💡 Technology Features

Audio System:

Base models typically did not include factory audio systems. Accessory audio systems were available.

ABS Availability:

ABS was not a standard or widely available option on 2006 Sportster models. This manual will not cover ABS diagnostics or repair.

Connectivity Features:

No integrated smartphone connectivity or advanced digital interfaces typical of modern motorcycles. Focus is on mechanical and electrical system operation.

Gauge Cluster:

Analog speedometer, tachometer (on some models), fuel gauge (in some tanks), and indicator lights for oil pressure, turn signals, and high beam.

🔧 Maintenance

Initial Service:

First service typically at 1,000 miles (1600 km) for oil change, filter change, primary chain adjustment, and comprehensive inspection.

Subsequent Oil Change:

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

Spark Plug Replacement:

Typically every 10,000-15,000 miles (16,000-24,000 km), depending on plug type and condition.

Drive Belt Inspection:

Inspect belt tension and condition at every 5,000-mile service. Replacement typically at 40,000-60,000 miles, depending on riding conditions.

Engine Oil Spec:

Harley-Davidson SYN3 (SAE 20W-50 Synthetic) or equivalent API CG-4 or higher rated V-twin motorcycle oil.

Primary Chain Case Oil Spec:

Harley-Davidson primary chaincase lubricant or SAE 50 motorcycle transmission oil.

Transmission Oil Spec:

Harley-Davidson transmission oil (e.g., SAE 85W-140) or a compatible motorcycle-specific 75W-90 synthetic gear oil.

Brake Fluid Spec:

DOT 4 hydraulic brake fluid.

Fork Oil Spec:

Harley-Davidson Type E (20W) Fork Oil or equivalent SAE 15W fork oil. Check manual for specific grade and quantity.

Common Wear Items:

Clutch plates, drive belts, wheel bearings, steering head bearings, fork seals, and exhaust gaskets.

Electrical Connections:

Corrosion in connectors, particularly on older models, can lead to intermittent electrical issues. Regular inspection and dielectric grease application is recommended.

Carburetor Tuning:

CV carburetors may require periodic adjustment or cleaning, especially if modified or exposed to varying fuel quality.

Primary Chain Tension:

Improper primary chain tension can lead to premature wear on clutch components and chain. The manual details the correct adjustment procedure.

📚 Vehicle History

Heritage:

Harley-Davidson is an iconic American motorcycle manufacturer with a history dating back to 1903, renowned for its V-twin engines and custom culture.

Sportster Lineage:

The Sportster model line was introduced in 1957 and has evolved significantly over the decades. The 2006 models represent the evolution of the Sportster into a more modern, yet still characterful, machine.

Manufacturing Location:

York, Pennsylvania, USA; Milwaukee, Wisconsin, USA (for engine assembly and other components).

Model Significance 2006:

The 2006 model year was a significant year for Harley-Davidson as they continued to integrate EFI and other modern technologies while maintaining the Sportster's classic appeal and robust engineering.

🏆 Awards & Recognition

Model Recognition:

The Sportster line has historically received accolades for its styling, handling, and customization potential, earning it a dedicated following among motorcycle enthusiasts.

Reliability Reputation:

Generally regarded as reliable when properly maintained. The Evolution engine is known for its durability.

Manual Quality Certification:

As a factory-produced service manual, it adheres to Harley-Davidson's internal technical documentation standards, ensuring accuracy and comprehensiveness.