🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster XLH

Year:

2006

Chassis Code:

XLH

Engine Code:

XL Evolution

👋 Introduction

Target Audience:

Harley-Davidson Sportster XLH 2006 owners and independent motorcycle mechanics.

Value Proposition:

Empowers owners to perform their own maintenance and repairs, ensuring quality and saving money compared to dealership services. Essential tool for understanding and maintaining the complex systems of the Sportster.

Comparison To Alternatives:

Provides more detailed and accurate information than generic repair guides or online forums. Factory-sourced or equivalent data ensures correctness for specific model year components and procedures.

Features:

Detailed schematics, step-by-step repair instructions, torque specifications, wiring diagrams, troubleshooting charts, and maintenance schedules.

📋 Manual Details

Coverage Scope:

All service and repair

Estimated Pages:

700+

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Downloadable Digital Format (PDF)

📖 Manual Coverage

Engine Systems:

Engine assembly, disassembly, diagnosis, performance tuning, oil system, cooling system (air-cooled), fuel system (carburetor and EFI variants if applicable for the year), ignition system, exhaust system, lubrication.

Drivetrain Systems:

Clutch, primary drive, transmission (5-speed or 6-speed based on specific model variant), final drive (belt or chain), drive sprocket, wheel bearings.

Chassis Systems:

Frame inspection and repair, front suspension (forks, triple clamps, steering head bearings), rear suspension (shocks, swingarm, pivot bearings), wheels and tires, braking system (front and rear calipers, master cylinders, lines, rotors), electrical system (wiring diagrams, battery, charging system, lighting, starting system, ignition switch, security system).

Bodywork And Trim:

Fender replacement, fuel tank removal and installation, seat mounting, handlebar and control lever adjustments, fairings and body panels (if applicable), lighting components, instrument cluster.

Routine Maintenance:

Oil and filter changes, spark plug replacement, air filter cleaning/replacement, drive belt inspection and tensioning, brake pad replacement, chain lubrication and adjustment (if applicable), tire pressure checks, battery maintenance.

Repair And Rebuild:

Engine rebuilds (top-end and bottom-end), transmission overhauls, brake system bleeding and component replacement, suspension fork seal replacement, electrical component troubleshooting and replacement, carburetor/fuel injection system tuning and repair.

Troubleshooting:

Diagnostic procedures for common starting, running, and electrical issues. Use of diagnostic codes (if applicable for the model year).

Depth:

Comprehensive. Covers everything from basic rider maintenance to complete engine and transmission overhauls. Includes detailed diagnostic procedures and specifications for expert-level repairs.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text content for quick information retrieval.

Printability:

Printable pages for on-demand access in a workshop environment.

Image Resolution:

High-resolution diagrams and illustrations suitable for printing.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-Twin

Displacement:

88 cubic inches (1442 cc) for many XLH models, though 1200cc variants (XL1200) were also common. The manual likely covers both if applicable to the XLH designation.

Bore X Stroke:

Varies by specific engine size (e.g., 3.50 in x 4.47 in for 88ci).

Compression Ratio:

Typically around 9.0:1 to 9.7:1 depending on specific model and configuration.

Horsepower:

Approx. 65-70 HP (varies by specific engine and tuning).

Torque:

Approx. 70-75 ft-lbs (varies by specific engine and tuning).

Fuel Delivery:

Carbureted (e.g., Keihin CV 40mm) or Electronic Fuel Injection (EFI) depending on the specific Sportster model variant within the XLH designation for 2006.

Fuel Type:

Unleaded gasoline, octane rating typically 91 or higher.

Ignition Type:

Electronic ignition with single spark plug per cylinder.

🔧 Transmission

Transmission Type:

5-speed constant mesh transmission (common for 2006 Sportster models).

Optional Transmission:

N/A for this model year, 5-speed was standard.

Clutch Type:

Wet, multi-plate clutch.

Primary Drive:

Duplex chain, 1.371:1 ratio.

Final Drive:

Belt drive, 2.75:1 ratio.

Transmission Fluid:

Harley-Davidson Formula+ Transmission Lubricant (or equivalent SAE 50 motorcycle gear oil).

📐 Dimensions

Length:

Approx. 88.8 inches (2255 mm).

Width:

Approx. 32.1 inches (815 mm).

Height:

Approx. 47.5 inches (1207 mm) to handlebars.

Seat Height:

Approx. 26.5 inches (673 mm) unladen.

Ground Clearance:

Approx. 4.2 inches (107 mm).

Dry Weight:

Approx. 550-570 lbs (250-260 kg), depending on specific model variant.

Gross Vehicle Weight Rating:

Typically around 900-950 lbs (408-431 kg).

Fuel Capacity:

Approx. 3.7 gallons (14.0 L).

Oil Capacity:

Approx. 3.0 quarts (2.8 L) with filter change.

Front Tire:

3.00-19 4PR (or similar specification like 100/90-19).

Rear Tire:

130/90-16 73H (or similar).

Wheel Type:

Spoked or Mag wheels depending on trim.

Wheelbase:

Approx. 59.6 inches (1514 mm).

🛡️ Safety Features

Safety Ratings:

Motorcycles are not typically subject to formal crash test ratings like automobiles. Safety relies on design and rider skill.

Braking System:

Dual disc front brakes, single disc rear brake. Hydraulic actuation.

Suspension System:

Telescopic front forks (e.g., 39mm), adjustable rear shock absorbers.

Lighting:

Halogen headlight, taillight, brake light, front and rear turn signals.

Security:

Optional factory security system with alarm and immobilizer.

💡 Technology Features

Infotainment Systems:

Typically minimal for this era of Sportster. Basic analog speedometer, tachometer (optional), odometer, trip meter, and indicator lights. No advanced infotainment systems are standard.

Driver Assistance Features:

N/A. Motorcycles of this era do not feature electronic driver assistance systems like ABS or traction control unless specifically noted as an aftermarket addition.

Connectivity Features:

N/A. No Bluetooth or smartphone connectivity.

Wiring Diagrams:

Comprehensive, color-coded wiring diagrams included for all electrical circuits, enabling detailed troubleshooting.

🔧 Maintenance

Initial Service:

First service typically at 1,000 miles (1600 km): oil change, primary chain case inspection, drive belt check, inspection of all fasteners, clutch and brake operation check, throttle and idle speed adjustment, air filter inspection.

Subsequent Service:

Subsequent services typically every 5,000 miles (8000 km) or annually, whichever comes first. This includes oil and filter changes, primary and transmission fluid checks/changes, spark plug replacement (e.g., every 10,000 miles), air filter cleaning/replacement, brake fluid checks, and thorough inspections.

Belt Tension Check:

Check drive belt tension every 2,500 miles (4,000 km).

Engine Oil:

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

Primary Chain Case Fluid:

Harley-Davidson Formula+ Transmission Lubricant (or equivalent SAE 50 motorcycle gear oil).

Transmission Fluid:

Harley-Davidson Formula+ Transmission Lubricant (or equivalent SAE 50 motorcycle gear oil).

Brake Fluid:

DOT 4 brake fluid.

Fork Oil:

Typically Harley-Davidson Type E or similar weight (e.g., 10W).

Common Wear Items:

Clutch plates, drive belt, brake pads, fork seals, wheel bearings, spark plugs, battery.

Potential Performance Issues:

Carburetor tuning drift, starter solenoid issues, charging system (stator/regulator) failures, oil leaks from engine seals.

Engine Mount Torque:

Specific torque values for engine mounting bolts are critical and detailed in the manual.

Wheel Axle Torque:

Specific torque values for front and rear axle nuts/bolts are provided.

📚 Vehicle History

Heritage:

Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and cruiser-style motorcycles.

Sportster Lineage:

The Sportster line, introduced in 1957, is Harley-Davidson's longest-running model. It evolved from earlier models, becoming a platform for performance and customization.

2006 Sportster Updates:

2006 saw continued refinement of the Evolution engine and chassis. Key updates often included fuel system changes (transitioning towards EFI on some models, though carburetors remained prevalent), improved suspension, and updated styling elements. The XLH designation typically referred to the standard Sportster models, often featuring the larger displacement Evolution engines.

Manufacturing Location:

United States (primarily Milwaukee, Wisconsin, and Kansas City, Missouri).

🏆 Awards & Recognition

Model Recognition:

The Harley-Davidson Sportster platform has consistently been recognized for its iconic styling, V-twin rumble, and customizable nature, making it a favorite among riders.

Reliability Ratings:

While subject to individual maintenance, the Evolution engine is known for its durability when properly cared for. The manual assists in maintaining this reliability.

Manual Certification:

While not a formal certification, the manual provides factory-equivalent technical data, ensuring accuracy and adherence to manufacturer specifications.