Target Audience:
Professional motorcycle technicians and experienced DIY enthusiasts seeking to perform maintenance, repairs, and diagnostics on the Harley Davidson Sportster Roadster XL1200R 2006.
Value Proposition:
Provides highly detailed, step-by-step instructions with extensive diagrams, covering virtually every aspect of the vehicle for efficient and accurate service, offering significant cost savings over dealership service.
Content Focus:
Emphasizes accuracy, clarity, and comprehensiveness with 'bumper to bumper' coverage, including special notes, important points, service data, and precautions for optimal repair outcomes.
Engine:
Engine disassembly, assembly, diagnosis, repair, troubleshooting, internal components
Fuel System:
Fuel delivery, carburetor tuning and repair (likely Keihin CV carb for this era), fuel tank, fuel lines
Ignition System:
Ignition module, spark plugs, wiring, timing
Transmission:
Gearbox inspection, repair, lubrication, clutch operation
Drivetrain:
Belt drive system, rear pulley, compensating sprocket
Brakes:
Front and rear brake system inspection, repair, fluid replacement, caliper service
Suspension:
Front fork service, rear shock absorber adjustment and replacement
Electrical System:
Wiring diagrams, battery, charging system, lighting, starter motor, switches
Chassis Frame:
Frame inspection, bodywork repair, mounting points
Wheels Tires:
Wheel bearing inspection, tire mounting and balancing, rim specifications
Controls:
Handlebars, levers, footpegs, throttle control
Exhaust System:
Exhaust pipe inspection, muffler replacement
Maintenance:
Scheduled maintenance, lubrication, adjustments, fluid changes
Troubleshooting:
Diagnostic procedures, common fault identification, solutions
Disassembly Assembly:
Step-by-step instructions for component removal and installation
Repair:
Detailed repair procedures for all major components and systems
Technical Specifications:
Torque specifications, measurement values, tolerances, wear limits
Special Tools:
Identification and usage of required special service tools
Depth:
Comprehensive, from basic maintenance to in-depth engine and transmission rebuilds, including detailed diagnostics and troubleshooting.
Quality:
High-resolution PDF, allowing for clear viewing and printing of all diagrams and text.
Printability:
Fully printable, allowing users to print specific sections or the entire manual.
Binding:
N/A (Digital PDF format)
Paper Type:
N/A (Digital PDF format)
Operating Systems:
Compatible with Windows, Mac, and Linux OS, requiring Adobe Reader.
Engine Type:
Evolution V-Twin, Air-Cooled
Displacement:
1200cc (73.3 cubic inches)
Bore X Stroke:
3.50 in x 3.81 in (88.9 mm x 96.8 mm) - typical for 1200cc Evolution Sportster
Compression Ratio:
9.0:1 (typical for this model/year)
Carburetor:
Keihin CV (Constant Velocity) 40mm
Fuel Tank Capacity:
3.7 US gallons (14.0 liters) - typical for Sportster Roadster
Oil Change:
Recommended every 2,500-5,000 miles or 6 months, whichever comes first (refer to manual for exact spec).
Primary Chain Case Oil Change:
Recommended every 5,000-10,000 miles (refer to manual for exact spec).
Engine Oil Type:
Harley-Davidson recommends 20W50 motorcycle oil (e.g., Harley-Davidson SYN3 or equivalent mineral/synthetic oil meeting specifications like API SG or higher).
Primary Chain Case Fluid:
Harley-Davidson Primary Chaincase Lubricant or equivalent (e.g., Spectro Primary Oil).
Transmission Fluid:
Harley-Davidson Transmission Oil or equivalent (e.g., Spectro HD Transmission Oil).
Brake Fluid:
DOT 4 or DOT 5.1 (check manual for specific recommendation, DOT 5 is silicone-based and not typically mixed with DOT 3/4/5.1).
Carburetor Tuning:
CV carburetor can sometimes require adjustments for optimal performance, especially with aftermarket exhaust or air cleaner modifications. The manual will detail proper tuning procedures.
Belt Tension:
Proper primary and final drive belt tension is crucial for longevity and performance; the manual provides specifications and adjustment procedures.
Electrical Connections:
As with many motorcycles of this era, ensuring clean and tight electrical connections is vital for reliable operation. The manual's wiring diagrams are invaluable.
Fork Seals:
Fork seal leaks can occur over time; the manual provides procedures for fork seal replacement and oil changes.
Heritage:
Harley-Davidson is synonymous with American motorcycle culture, known for its V-twin engines and distinctive styling.
Sportster Lineage:
The Sportster line, introduced in 1957, is Harley-Davidson's longest-running model. The Roadster variant typically features a sportier riding posture and suspension compared to other Sportster models.
Manufacturing Location:
USA (Milwaukee, Wisconsin or Kansas City, Missouri)
