Harley Davidson Sportster XLH 2006 WSM Service Manual Repair

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster XLH Year: 2006 Codes Engine Family Code: XL Generation Sportster Generation: Evolution Engine Sportster (9th Generation) 👋 Introduction Market Position Segment: Cruiser...

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Type: Motorcycle

Vendor:

Sku: 458636

Tags: 2006 Harley Davidson Misc Motorcycle Motorcycles Sportster XLH

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Sportster XLH

Year:

Codes

Engine Family Code:

Generation

Sportster Generation:

Evolution Engine Sportster (9th Generation)

👋 Introduction

Market Position

Segment:

Cruiser Motorcycle

Target Audience:

Riders seeking classic styling, customization potential, and the Harley-Davidson experience.

Competitive Analysis

Competitors 2006:

Yamaha V-Star series, Honda Shadow series, Kawasaki Vulcan series, Indian Chief.

Key Features

Engine Platform:

Evolution Engine, a hallmark of Harley-Davidson's Sportster line for decades.

Customization:

Renowned for its vast aftermarket support and customization potential.

Brand Heritage

Brand Legacy:

Harley-Davidson's long-standing heritage of V-twin motorcycles, offering distinctive sound, feel, and style.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Service and Repair for Harley-Davidson Sportster XLH 2006 models

Page Count

Estimated Page Count:

Manual Type

Type:

Factory Service Manual (WSM - Workshop Manual)

Language

Language:

English

Format

Format:

Digital (Likely PDF, downloadable)

📖 Manual Coverage

Systems Covered

Engine:

1200cc Evolution V-Twin (Air-cooled), Carbureted and Fuel Injection variants (specific to 2006 model year)

Transmission:

5-speed constant mesh, clutch, drive chain, primary drive system

Fuel System:

Carburetor (Keihin CV type) or Electronic Fuel Injection (EFI) systems, fuel pump, fuel lines, fuel tank service

Electrical System:

Ignition system, lighting, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), battery, wiring diagrams, ECM/ECU diagnosis

Suspension:

Front forks (telescopic, cartridge/emulsion), rear shock absorbers (twin, adjustable/non-adjustable), fork seals, fork oil replacement, rear shock mounting and adjustment

Brakes:

Front and rear disc brakes, hydraulic system, brake fluid specifications, caliper service, master cylinder overhaul, brake pad replacement, bleeding procedures

Chassis And Frame:

Frame inspection, steering head bearing service, swingarm and pivot bearings, wheel bearings, chassis alignment

Bodywork And Trim:

Fenders, fuel tank, seat, handlebars, controls, fairings (if applicable), mounting hardware

Exhaust System:

Exhaust pipes, mufflers, mounting hardware, gasket replacement

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements (oil, air), spark plug replacement, lubrication points, chain adjustment and lubrication, brake fluid flush

Repair:

Engine rebuilds (top-end and bottom-end), transmission overhaul, clutch replacement, fork seal replacement, brake caliper rebuild, starter motor repair, carburetor/EFI tuning and repair

Diagnostics:

Troubleshooting guides for common issues, diagnostic trouble codes (DTCs) for EFI models, electrical system diagnostics, performance tuning advice

Specifications:

Torque values for critical fasteners, engine clearances, fluid capacities, electrical component specifications, performance data

Wiring Diagrams:

Detailed, color-coded wiring schematics for all electrical systems

Technical Depth

Depth:

Comprehensive, suitable for professional technicians and experienced DIY mechanics. Covers everything from basic checks to complete engine and transmission overhauls.

📊 Manual Specifications

File Format

Digital Format:

Print Quality

Image Resolution:

High-resolution scans for clarity of diagrams and text.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

Searchability

Text Search:

Searchable text for quick information retrieval.

Usability

Navigation:

Likely includes internal links/bookmarks for easy navigation between sections.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, 45-degree V-twin, Evolution engine

Displacement:

1200cc (73.7 cubic inches)

Bore X Stroke:

3.496 in. x 4.000 in. (88.8 mm x 101.6 mm)

Compression Ratio:

9.0:1 (typical for 2006 XLH 1200)

Valvetrain:

OHV (Overhead Valve), 2 valves per cylinder, operated by pushrods and rocker arms

Ignition System:

Electronic Ignition (Distributorless for some models, SE ignition for others)

Performance

Horsepower:

Approx. 65-70 HP (varies slightly by model and tuning)

Torque:

Approx. 70-75 lb-ft @ 3500 RPM (varies slightly by model and tuning)

Fuel System

Carburetor Type:

Keihin CV (Constant Velocity) 40mm

Fuel Injection Type:

Single-port, throttle body EFI (if applicable to specific 2006 XLH variant)

Lubrication

Oil Type:

Harley-Davidson 20W50 V-Twin Oil or equivalent API SG/SH/SJ/SL rated motorcycle oil

Oil Capacity:

3.0 US quarts (2.8 liters) without filter change, 3.5 US quarts (3.3 liters) with filter change

Oil Filter Part Number:

Harley-Davidson 63796-77A (or equivalent aftermarket)

🔧 Transmission

Standard

Transmission Type:

5-speed, constant mesh, manual gearbox

Primary Drive:

Chain, 34/49 tooth (typical)

Secondary Drive:

Belt drive, 32/65 tooth (typical)

Features

Clutch Type:

Multi-plate, wet clutch, cable-actuated

Transmission Fluid Type:

Harley-Davidson primary chaincase lubricant or equivalent Harley-Davidson transmission oil

Transmission Fluid Capacity:

Approx. 1.0 US quart (0.95 liters)

📐 Dimensions

Exterior

Wheelbase:

Approx. 59.6 inches (1514 mm)

Length:

Approx. 88.0 inches (2235 mm)

Weights

Dry Weight:

Approx. 500-520 lbs (227-236 kg)

Gross Vehicle Weight Rating:

Approx. 930 lbs (422 kg)

Cargo

Fuel Tank Capacity:

3.1 US gallons (11.7 liters)

Wheels And Tires

Front Tire Size:

MT90B16 (or 130/90-16)

Rear Tire Size:

150/80B16

Wheel Type:

Spoked or Cast Aluminum (depending on specific model variant)

🛡️ Safety Features

Ratings

Crash Safety Ratings:

N/A (Motorcycle safety is assessed differently than automobiles, focus on rider safety features and design)

Active Features

Braking System:

Dual-disc front braking, single-disc rear braking (hydraulic)

Passive Features

Lighting:

Halogen headlight, LED taillight, incandescent turn signals

Frame Construction:

Steel frame designed for stability and handling

💡 Technology Features

Infotainment

Audio System:

Generally no integrated infotainment system on base models; aftermarket options are common.

Driver Assistance

Anti-lock Braking System (ABS) was an optional feature, not standard on all 2006 models. Check specific vehicle build.

Connectivity

Usb Port:

Not standard. Aftermarket solutions available.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 2,500-5,000 miles or 6 months, whichever comes first (consult manual for specifics)

Primary Chain Adjustment:

Every 2,500-5,000 miles

Spark Plug Replacement:

Every 7,500-10,000 miles (depending on plug type)

Brake Fluid Flush:

Every 12-24 months or as needed based on condition

Fluid Specifications

Front Fork Oil:

Harley-Davidson Type HD 20W or equivalent motorcycle fork oil

Front Fork Oil Capacity:

Approx. 10.0 US fl oz (296 ml) per fork leg (check manual for exact specification)

Known Issues

Cam Chain Tensioners:

Early Evolution engines (prior to 2007) had cam chain tensioner pads that could wear. 2006 is on the cusp, manual will guide inspection.

Carburetor Tuning:

CV carburetor may require occasional adjustment for optimal performance and idle.

Starter Solenoid:

Solenoid can sometimes fail, leading to starting issues.

📚 Vehicle History

Brand Heritage

Founding:

Founded in 1903 by William S. Harley and Arthur Davidson.

Iconic Models:

Electra Glide, Fat Boy, V-Rod, Sportster

Model Evolution

Sportster Introduction:

The Sportster line was introduced in 1957.

Evolution Engine Debut:

The Evolution engine debuted in 1984.

2006 Updates:

2006 saw the continued refinement of the Evolution engine Sportster, with potential minor styling and component updates over earlier years.

Production

Manufacturing Location:

Milwaukee, Wisconsin, USA (primarily)

🏆 Awards & Recognition

Recognitions

Brand Awards:

Harley-Davidson is consistently recognized for its brand loyalty and cultural impact.

Ratings

Motorcycle Reviews:

The Sportster line is a perennial favorite among motorcycle reviewers for its classic feel and handling.