🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster XL1200R Roadster

Year:

2006

Model Code:

XL1200R

👋 Introduction

Market Position:

The Harley-Davidson XL1200R Roadster was positioned as a classic, no-frills, performance-oriented cruiser within the Sportster line, appealing to riders seeking a more traditional and engaging riding experience.

Competitive Analysis:

Competed with other V-twin cruisers from American manufacturers and some Japanese brands offering similar displacement and styling, such as certain models from Indian Motorcycle and select offerings from Yamaha and Kawasaki, though Harley-Davidson's distinct V-twin rumble and brand heritage provided a unique selling proposition.

Key Features:

Iconic Evolution V-twin engine, classic styling cues, dual front disc brakes, raised fuel tank, sportier riding position compared to other Sportster models, emphasis on performance and handling for its class.

📋 Manual Details

Coverage Areas:

Full service, repair, troubleshooting, maintenance, and diagnostics for the 2006 Harley-Davidson Sportster XL1200R Roadster.

Page Count:

Estimated 600+ pages (typical for a comprehensive service manual).

Manual Type:

Service and Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Systems Covered:

Engine (V-Twin, air-cooled, Evolution), Fuel System (carbureted), Ignition System, Electrical System (wiring diagrams, charging, starting), Drivetrain (clutch, transmission, final drive belt), Brakes (hydraulic, front and rear), Suspension (front fork, rear shocks), Frame and Bodywork, Wheels and Tires, Controls, Exhaust System, Lubrication System, Cooling System (air), Emissions Control.

Procedures Included:

Routine maintenance (oil changes, filter replacement, chain adjustment), engine overhaul, transmission rebuild, carburetor tuning and repair, electrical system diagnostics, brake system bleeding and repair, suspension adjustments and component replacement, wheel and tire servicing, chassis component inspection and replacement, troubleshooting common problems, torque specifications, special tool usage, wiring schematics.

Technical Depth:

Comprehensive. Covers from basic maintenance tasks for the DIY owner to in-depth repair and diagnostic procedures suitable for professional mechanics. Includes detailed component disassembly, assembly, and specifications.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution, clear text and diagrams, suitable for printing.

Searchability:

Searchable text for quick information retrieval.

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Evolution V-Twin

Displacement:

1200cc (73.3 cubic inches)

Bore X Stroke:

3.496 in x 3.811 in (88.8 mm x 96.8 mm)

Cooling System:

Air-cooled

Compression Ratio:

9.0:1

Horsepower:

Approx. 65-70 HP (estimate, not officially published for this year/model)

Torque:

Approx. 70-75 lb-ft (estimate, not officially published for this year/model)

Fuel Delivery:

Carbureted (Keihin CV Carburetor)

Fuel Type:

Unleaded Gasoline, 91 Octane (RON+MON)/2)

Ignition System:

Electronic, single spark

🔧 Transmission

Transmission Type:

5-speed constant mesh

Gear Ratios:

1st: 3.000, 2nd: 2.105, 3rd: 1.600, 4th: 1.231, 5th: 1.000 (Typical ratios for Evolution 5-speed).

Primary Drive:

37/20 (1.85:1) Double-row, silent chain

Final Drive:

Belt drive, 32/61 (1.906:1)

Clutch:

Wet, multi-plate

Transmission Fluid Type:

Harley-Davidson SYN3 Transmission, Primary Chain Lubricant, or API GL-5, SAE 80W-90 (verify in manual).

📐 Dimensions

Length:

Approx. 88.2 inches (2240 mm)

Width:

Approx. 32.3 inches (820 mm)

Height:

Approx. 45.9 inches (1166 mm)

Wheelbase:

Approx. 60.0 inches (1524 mm)

Ground Clearance:

Approx. 4.7 inches (119 mm)

Dry Weight:

Approx. 543 lbs (246 kg)

Wet Weight:

Approx. 570 lbs (258 kg)

Fuel Capacity:

4.5 US gallons (17 Liters)

🛡️ Safety Features

Safety Ratings:

Motorcycles are not typically assigned crash test ratings like automobiles. Safety is achieved through design, braking systems, and rider awareness.

Active Safety Features:

Dual front disc brakes, responsive steering, stable chassis geometry.

Passive Safety Features:

Sturdy frame construction, rider-controlled systems.

💡 Technology Features

Infotainment System:

Basic analog instrumentation (speedometer, tachometer, fuel gauge, oil pressure warning lamp). No advanced infotainment system. Primarily focused on the riding experience.

Driver Assistance Features:

None. This era of motorcycle design did not incorporate electronic driver assistance systems.

Connectivity:

N/A. No Bluetooth, USB, or smart device integration.

Headlight:

Halogen bulb, sealed beam unit.

Taillight:

Incandescent bulb, standard tail/brake light assembly.

🔧 Maintenance

Initial Service Interval:

First service typically at 1,000 miles (1,600 km) for oil change, filter replacement, and inspection.

Regular Service Interval:

Oil and filter changes every 5,000 miles (8,000 km) or annually, whichever comes first. Further interval checks for transmission fluid, belt tension, spark plugs, and brake system.

Engine Oil Type:

Harley-Davidson SYN3 Full Synthetic Motorcycle Oil or equivalent SAE 20W-50 API CI-4 approved motorcycle oil.

Engine Oil Capacity:

3.0 US quarts (2.8 Liters) with filter change.

Primary Chain Lubricant Type:

Harley-Davidson SYN3 or SAE 85W-140 gear lubricant.

Primary Chain Lubricant Capacity:

Approx. 38 US fluid ounces (1.1 Liters).

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Common Issues:

Carburetor tuning can be sensitive to altitude and modifications, potential for oil leaks if gaskets are not properly maintained, wear on belt drive components, and occasional electrical gremlins common to older motorcycles without advanced diagnostics. Carburetor jets may require adjustment for optimal performance.

Spark Plug Part Number:

Harley-Davidson OEM: 32317-99 (or equivalent, check manual for specific application).

Oil Filter Part Number:

Harley-Davidson OEM: 63796-77A or 63731-99 (or equivalent, check manual for specific application).

📚 Vehicle History

Brand Heritage:

Harley-Davidson, founded in 1903, is synonymous with American motorcycling. The Sportster line, introduced in 1957, has a long and storied history, evolving through various iterations to become an iconic model.

Model Evolution:

The XL1200R Roadster represents a refinement of the Sportster platform, emphasizing performance with its larger 1200cc Evolution engine and a riding position more attuned to spirited riding, distinguishing it from more laid-back cruiser variants.

Production Years:

The XL1200R was produced for several years, with the 2006 model being part of this lineage. Sportster models continue to be manufactured.

Manufacturing Location:

United States (primarily Milwaukee, Wisconsin or Kansas City, Missouri for Harley-Davidson motorcycles during this era).

🏆 Awards & Recognition

Industry Recognition:

Harley-Davidson Sportster models have consistently received praise for their iconic styling, V-twin character, and enduring appeal as a customizable platform. Specific awards for the 2006 XL1200R model are not typically highlighted in consumer reviews but it contributed to the Sportster line's strong market presence.

📄 Manual Utility

Value For Owner:

This manual is invaluable for owners who wish to perform their own maintenance, diagnostics, and repairs, saving on labor costs and ensuring the motorcycle is kept in optimal condition. It empowers owners with the knowledge to understand their machine intimately.

Value For Mechanic:

Provides essential technical data, torque specifications, troubleshooting flowcharts, and detailed procedures that professional technicians rely on for efficient and accurate repairs on this specific model.

📄 Vehicle Specifications

Front Brakes:

Dual 11.5 inch (292 mm) hydraulic disc, 4-piston calipers.

Rear Brakes:

Single 11.5 inch (292 mm) hydraulic disc, 2-piston caliper.

Front Wheel Size:

19 inch

Rear Wheel Size:

16 inch

Front Tire Size:

100/90-19 (typically)

Rear Tire Size:

150/80-16 (typically)

Wheel Bolt Pattern:

N/A (Spoked wheels with hubs, no bolt pattern in the automotive sense)

Front Suspension Type:

Telescopic fork

Front Suspension Travel:

Approx. 4.6 inches (117 mm)

Rear Suspension Type:

Swingarm with dual shock absorbers

Rear Suspension Travel:

Approx. 3.1 inches (79 mm)

Frame Type:

Steel, cradle-type frame