🏷️ Basic Information

Make:

Harley-Davidson

Model:

TLE Ultra Sidecar

Year:

2006

Vin Decoder Note:

Specific VIN structure for Harley-Davidson models of this era would be required for precise identification, but generally starts with a 1HD designation.

Chassis Code:

FLHTCU (Electra Glide Ultra Classic platform with sidecar configuration)

Engine Code:

Twin Cam 103 (Likely, though standard TLE Ultra in 2006 was often 88ci, the 'TLE' designation might imply a specific variant or package. Further clarification via VIN or specific model trim is recommended.)

👋 Introduction

Segment:

Premium Touring Motorcycle with Sidecar Configuration

Target Audience:

Enthusiasts and professional mechanics requiring detailed repair and maintenance information for this specific model.

Competitors:

Other large touring motorcycles from brands like Honda (Gold Wing), BMW (R series), and Indian, particularly those with factory or reputable aftermarket sidecar options.

Manual Value:

Provides comprehensive, step-by-step procedures and technical data to empower DIY repairs and professional servicing.

Accessibility:

Instant download format offers immediate access, eliminating shipping delays and costs.

Detail Level:

Extensive detail, including special tool references, wear limits, and torque specifications, ensuring accuracy and proper repair.

📋 Manual Details

Primary Coverage:

Repair, maintenance, and troubleshooting of the 2006 Harley-Davidson TLE Ultra Sidecar.

Secondary Coverage:

Includes specific procedures and data for the sidecar unit integrated with the motorcycle.

Total Pages:

986

Type:

Workshop Service Manual / Repair Manual

Language:

English

Format:

PDF (Digital Download)

📖 Manual Coverage

Engine Mechanical:

Disassembly, assembly, inspection, and repair of the Twin Cam engine (including bore, stroke, compression, valve timing).

Fuel System:

Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel tank, and fuel lines.

Ignition System:

Ignition module, spark plugs, ignition coils, and troubleshooting.

Transmission Drivetrain:

Primary drive, transmission assembly (5-speed), clutch, final drive belt, and related components.

Electrical System:

Wiring diagrams, charging system (stator, regulator/rectifier), battery, starter, lighting, instrumentation, and accessory circuits.

Suspension:

Front fork (telescopic), rear shock absorbers, swingarm, and adjustments.

Brakes:

Front and rear brake systems, master cylinders, calipers, rotors, brake lines, and ABS (if equipped).

Chassis Frame:

Frame inspection, steering head bearings, and related chassis components.

Bodywork Trim:

Fairing, saddlebags, tour-pak, fenders, seat, and interior trim removal/installation.

Sidecar Integration:

Mounting points, linkage, wheel alignment, suspension, and braking for the sidecar unit.

Routine Maintenance:

Oil changes, filter replacement, lubrication, tire pressure checks, and brake pad inspections.

Troubleshooting:

Diagnosis of common problems with detailed flowcharts and symptom-based guidance.

Component Disassembly Assembly:

Step-by-step instructions for dismantling and reassembling all major vehicle components.

Adjustments:

Carburetor (if applicable, though likely EFI for 2006 TLE), clutch, throttle cables, and suspension settings.

Rebuilding Procedures:

Detailed instructions for engine, transmission, and brake caliper rebuilding.

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems.

Special Tool Usage:

Identification and instruction on the use of specialized Harley-Davidson service tools.

Depth:

Comprehensive, covering everything from basic checks to complete engine and transmission rebuilds.

Diagnostic Level:

Advanced diagnostics, including electrical system troubleshooting and fault code interpretation (if applicable).

Repair Scope:

Covers all repair interventions on the vehicle and its components, including those related to the sidecar attachment.

📊 Manual Specifications

Format:

PDF

Accessibility:

Instant Download

Compatibility:

Windows, Mac, Linux OS

Requirement:

Adobe Reader

Printability:

Printable (all pages)

Illustration Quality:

High-quality pictorial diagrams, exploded views, drawings, and photos.

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Air-cooled, 45-degree V-twin

Displacement:

Likely 1450cc (88 cubic inches) for standard 2006 models, potentially 1550cc (95 cubic inches) or 1690cc (103 cubic inches) depending on 'TLE' designation and specific options. The manual should clarify the exact variant.

Bore X Stroke:

Typically 3.75 in. x 4.00 in. (95.25 mm x 101.6 mm) for 88ci, 3.75 in. x 4.375 in. (95.25 mm x 111.1 mm) for 95ci. Manual will provide exact figures.

Compression Ratio:

Typically around 9.0:1 to 9.7:1, depending on specific Twin Cam variant. Manual will specify.

Valve Train:

Overhead valves (OHV) with pushrods, 2 valves per cylinder.

Horsepower:

Approximately 70-75 HP at the crankshaft, though official Harley-Davidson figures varied by year and specific model tuning. Manual will provide detailed performance specifications.

Torque:

Around 86-90 ft-lbs at 3500 RPM. Manual will specify precise torque figures.

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

Unleaded gasoline, minimum 91 octane recommended.

🔧 Transmission

Type:

5-speed constant mesh

Primary Drive:

Spur gear, 1.36 ratio

Final Drive:

Belt drive, 32/66 ratio (32 tooth front, 66 tooth rear pulley)

Clutch Type:

Cable-actuated, wet multi-plate

📐 Dimensions

Length:

Varies significantly with sidecar configuration. Standard FLHTCU is approx. 93.3 in. (2370 mm). Sidecar adds considerable length.

Width:

Varies significantly with sidecar. Standard FLHTCU is approx. 39.0 in. (990 mm). Sidecar configuration will be considerably wider.

Dry Weight:

Approx. 777 lbs (352 kg) for FLHTCU. Sidecar adds significant weight (often 150-250 lbs or more).

Gross Vehicle Weight Rating:

The manual will specify the GVWR, which accounts for the motorcycle, sidecar, and payload.

🛡️ Safety Features

Crash Test Data:

Harley-Davidson does not typically publish standardized crash test ratings for its motorcycles like passenger cars. Safety is addressed through design and component integrity.

Braking System:

Linked braking system (potentially on front and rear) and ABS (optional or standard depending on trim and market).

Lighting:

Halogen headlight, auxiliary passing lamps, and full LED lighting package for tail and brake lights, turn signals.

Frame Construction:

Robust steel frame designed for stability and load-bearing capacity.

💡 Technology Features

Audio System:

Integrated AM/FM/CB/Intercom radio with cassette player and/or CD player, fairing-mounted speakers.

Cruise Control:

Electronic cruise control is a standard feature on Ultra Classic models.

ABS:

Anti-lock Braking System (ABS) was often an option or standard on higher trim levels like the Ultra Classic. Manual should cover its operation and diagnostics.

Accessories Interface:

Pre-wiring for accessory power outlets and communications equipment.

🔧 Maintenance

First Service:

Typically 1,000 miles (1,600 km) or 6 months, whichever comes first (e.g., engine oil and filter change, primary chaincase lubricant change, inspection).

Subsequent Maintenance:

Every 5,000 miles (8,000 km) or 12 months for regular service, including oil changes, inspections, and lubrication. Manual will provide a detailed periodic maintenance chart.

Engine Oil Type:

Harley-Davidson SYN3 Synthetic Motorcycle Oil (or equivalent API SG, Jaso MA rated SAE 20W-50 motorcycle oil). Manual specifies exact requirements.

Engine Oil Capacity:

Approximately 4 US quarts (3.8 L) with filter change. Manual will provide exact capacity.

Primary Chaincase Oil Type:

Harley-Davidson Primary Chaincase Lubricant (or equivalent SAE 80W-90 gear oil). Manual specifies exact requirements.

Primary Chaincase Oil Capacity:

Approximately 1 US quart (0.95 L). Manual will provide exact capacity.

Transmission Oil Type:

Harley-Davidson Transmission Lubricant (or equivalent SAE 75W-140 synthetic gear oil). Manual specifies exact requirements.

Transmission Oil Capacity:

Approximately 24 US fluid ounces (0.71 L). Manual will provide exact capacity.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Common Problems 2006 Twin Cam:

Potential for oil leaks (especially from crankcase seals), starter issues, and cam chain tensioner wear. Specific to sidecar, check for frame stress or unusual wear at attachment points.

Electrical Gremlins:

Some Twin Cam models could experience intermittent electrical issues due to vibration or connector integrity. The manual's detailed wiring diagrams are crucial.

📚 Vehicle History

Brand Origin:

Founded in Milwaukee, Wisconsin, USA in 1903, Harley-Davidson is one of the oldest motorcycle manufacturers in the world.

Electra Glide Lineage:

The Electra Glide platform, including the Ultra Classic variant, has been a cornerstone of Harley-Davidson's touring lineup since the late 1960s, evolving significantly over decades to incorporate comfort, technology, and performance enhancements.

Sidecar Integration:

While Harley-Davidson has offered factory sidecars historically, specific 'TLE Ultra Sidecar' branding might refer to a particular package or an OEM-approved aftermarket fitment, the manual would detail this specific configuration's integration.

Manufacturing Location:

Primarily Milwaukee, Wisconsin, and York, Pennsylvania, USA for models of this era.

🏆 Awards & Recognition

Industry Recognition:

Harley-Davidson's Electra Glide line consistently receives praise for comfort, touring capability, and iconic styling in motorcycle publications. The TLE Ultra Sidecar variant enhances practicality for a specific niche.

Owner Satisfaction:

Harley-Davidson generally enjoys high owner satisfaction for its touring models, attributed to brand loyalty, performance, and customization potential. The manual directly supports this by enabling owners to maintain their vehicles.