Positioning:
Premium long-distance touring motorcycles, popular for their V-twin engines, comfortable ride, and extensive customization options.
Competitors:
Indian Motorcycles (Chief, Roadmaster), Victory Motorcycles (Cross Country, Vision), Honda Gold Wing, BMW R 1200 RT, Kawasaki Vulcan Voyager.
Design Philosophy:
Focus on rider comfort, cargo capacity, and distinctive Harley-Davidson styling and V-twin sound.
Engine Heritage:
Continuation of the iconic Harley-Davidson V-twin engine architecture, updated for performance and emissions.
Utility:
Essential resource for maintaining, diagnosing, and repairing these complex machines, ensuring longevity and optimal performance.
Primary Coverage:
Comprehensive service, repair, and maintenance for 2006 Harley-Davidson FLHX, FLHT, FLHR, and FLTR Touring models.
Secondary Coverage:
Includes troubleshooting, diagnostics, specifications, and procedures for all major vehicle systems.
Estimated Page Count:
~800-1000+ pages (typical for comprehensive workshop manuals)
Type:
Workshop Repair Service Manual
Format:
Digital Download (PDF)
Powertrain:
Engine (Twin Cam 96), fuel system, ignition system, exhaust system, transmission (5-speed Cruise Drive), primary drive, final drive.
Chassis:
Frame, suspension (front forks, rear shocks), steering, wheels, tires, brakes (front and rear hydraulic disc), clutch.
Electrical:
Battery, charging system (alternator, regulator), starting system (starter, solenoid), lighting (headlight, taillight, turn signals), instrumentation, ignition, EFI, sensors, wiring diagrams.
Bodywork And Accessories:
Fairings, saddlebags, tour-pak (optional), seating, body panels, fuel tank, fenders, controls, accessories.
Maintenance:
Routine service, oil changes, filter replacements, spark plug service, brake fluid flush, belt inspection/tensioning, fork oil change.
Troubleshooting:
Diagnostic procedures, common problems, fault code interpretation, electrical system troubleshooting, engine performance issues.
Repair And Overhaul:
Engine disassembly/reassembly, transmission overhaul, brake caliper rebuild, suspension component replacement, electrical component repair.
Special Tools:
Identification and usage instructions for specialized Harley-Davidson tools required for various procedures.
Depth:
Highly detailed, suitable for professional technicians and experienced DIY mechanics. Covers full disassembly, component-level repair, and diagnostic procedures.
Engine Type:
Air-cooled, Twin Cam 96 V-twin
Displacement:
96 cubic inches (1584 cc)
Bore X Stroke:
3.75 in. x 4.38 in. (95.25 mm x 111.25 mm)
Compression Ratio:
8.9:1 (typical for Twin Cam 96)
Horsepower Estimated:
~65-70 HP @ 5200 RPM (stock)
Torque Estimated:
~86-90 lb-ft @ 3500 RPM (stock)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Ignition Type:
Dual spark plugs, electronic ignition
Type:
5-speed Cruise Drive
Gear Ratios:
1st: 9.59:1, 2nd: 6.65:1, 3rd: 4.94:1, 4th: 3.81:1, 5th: 3.17:1
Final Drive:
Belt drive, 32/66 ratio
Clutch Type:
Cable-actuated, multi-plate wet clutch
Transmission Oil:
Harley-Davidson Transmission Lubricant, SAE 75W-90, or API GL-5 rated synthetic gear oil. Capacity: 24-26 fl. oz. (710-770 mL).
Primary Chain Case Oil:
Harley-Davidson Primary Chaincase Lubricant, SAE 20W-50, or API SG or SH rated motorcycle oil. Capacity: 2.75 US qt (2.6 L).
Length:
Approx. 93.5 in. (2375 mm) for FLHT/FLHX; varies slightly for FLHR/FLTR
Seat Height:
Approx. 27.0 in. (686 mm) unladen
Ground Clearance:
Approx. 4.8 in. (122 mm)
Dry Weight Estimated:
Approx. 700-750 lbs (318-340 kg) depending on model
Gross Vehicle Weight Rating Gvwr:
1260 lbs (572 kg) typical
Saddlebag Capacity:
Approx. 2.2 cu ft per saddlebag (integrated, lockable)
Tour Pak Capacity:
Optional, adds significant cargo space
Crash Test Ratings:
Motorcycles are not subjected to traditional automotive crash testing standards.
Braking System:
Dual front and single rear hydraulic disc brakes with dual-piston calipers.
Lighting:
Halogen headlight, LED taillight and brake light, amber front and rear turn signals.
Frame Construction:
Steel, double-cradle frame designed for stability and load carrying.
Ergonomics:
Designed for rider comfort during long rides, with adjustable controls and seating positions.
Audio System:
Factory-installed CB radio and intercom system, AM/FM stereo with cassette or CD player (model dependent).
Display:
Analog gauges for speedometer, tachometer, fuel level, oil pressure, and voltage. Also includes indicator lamps.
Cruise Control:
Electronic cruise control is a standard or optional feature on most 2006 Touring models.
Diagnostic Ports:
Includes proprietary diagnostic connectors for use with Harley-Davidson diagnostic tools (e.g., Digital Technician).
Initial Service:
First service typically at 1,000 miles (1600 km) or 6 months.
Routine Oil Change:
Every 5,000 miles (8000 km) or 12 months, whichever comes first. Engine oil capacity: 4.0 US qt (3.8 L).
Transmission Fluid Change:
Every 10,000 miles (16000 km).
Primary Fluid Change:
Every 10,000 miles (16000 km).
Spark Plug Replacement:
Every 10,000 miles (16000 km) (dual plugs per cylinder).
Engine Oil:
Harley-Davidson V-Twin Synthetic 20W-50 or Syn3. Check owner's manual for specific API rating and temperature recommendations.
Brake Fluid:
DOT 4 brake fluid (non-silicone based). Fluid flush recommended every 2 years.
Coolant:
Not applicable for air-cooled engines. Some models may have oil coolers requiring specific oil.
Cam Chain Tensioners:
Early Twin Cam models (pre-2007) used plastic cam chain tensioners that could wear out. This manual will cover inspection and replacement procedures.
Crankcase Bearings:
Intermittent issues with crankcase bearings (e.g., pinion bearing) have been reported on some Twin Cam engines. Manual provides diagnostic steps.
Regulator Rectifier:
Can be a failure point; manual covers testing and replacement.
Founding:
Founded in 1903, Milwaukee, Wisconsin. One of the two oldest motorcycle manufacturers.
Iconic Engines:
Known for its V-twin engine designs, evolving through Flathead, Knucklehead, Panhead, Shovelhead, Evolution, and Twin Cam eras.
Touring Lineage:
Touring models have a long history dating back to the Hydra-Glide and Electra-Glide series, evolving with technological advancements while maintaining core design elements.
Twin Cam Introduction:
The Twin Cam engine was introduced in 1999, becoming the standard for Harley-Davidson Big Twins and replacing the Evolution engine.
Manufacturing Location:
Primary manufacturing in York, Pennsylvania, and Milwaukee, Wisconsin, USA.
Brand Awards:
Harley-Davidson frequently recognized for brand loyalty, design, and V-twin engine performance by motorcycle publications.
Customer Satisfaction:
Consistently high customer satisfaction ratings among cruiser and touring motorcycle segments.
Emissions Compliance:
Meets EPA and California Air Resources Board (CARB) emissions standards for its model year.
