Harley Davidson FLST Heritage Softail 2006 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLST Heritage Softail Year: 2006 Codes Model Code: FLST 👋 Introduction Market Position Market Segment: Cruiser Motorcycle Brand Recognition: Harley-Davidson is an iconic...

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

FLST Heritage Softail

Year:

Codes

Model Code:

👋 Introduction

Market Position

Market Segment:

Cruiser Motorcycle

Brand Recognition:

Harley-Davidson is an iconic American motorcycle brand renowned for its V-twin engines, custom styling, and heritage.

Competitive Analysis

Direct Competitors:

Competes with models from brands like Indian Motorcycle, Victory Motorcycles (discontinued), and custom-built choppers.

Key Features

Styling:

Classic retro styling, teardrop fuel tank, wide handlebars, whitewall tires, chrome accents, and fringed leather saddlebags (often optional or accessory).

Engine Type:

Harley-Davidson's signature air-cooled Twin Cam 88B V-twin engine, known for its torque and distinctive rumble.

Chassis Design:

Softail chassis, featuring hidden rear suspension to mimic the look of a rigid frame.

📋 Manual Details

Coverage Areas

Coverage Description:

Comprehensive repair and overhaul of the 2006 Harley-Davidson FLST Heritage Softail, including maintenance, troubleshooting, diagnostics, and component replacement for all major systems.

Page Count

Page Count:

Estimated 800-1000 pages (typical for a complete Harley-Davidson service manual of this era)

Manual Type

Manual Type:

Service Manual / Workshop Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

1450cc (88 cubic inch) Twin Cam 88B V-Twin engine overhaul, top-end and bottom-end assembly, ignition, fuel injection, exhaust systems.

Transmission:

5-speed Cruise Drive transmission disassembly, assembly, maintenance, lubrication, and troubleshooting.

Drivetrain:

Primary drive, clutch, final belt drive system inspection, adjustment, and replacement.

Suspension:

Front fork (including telescopic fork overhaul, fluid replacement, seals) and rear swingarm/shock absorber system inspection, adjustment, and replacement.

Brakes:

Front and rear hydraulic disc brake system service, including caliper overhaul, pad replacement, fluid bleeding, and master cylinder service.

Electrical:

Comprehensive electrical system diagnostics, including wiring diagrams, charging system (stator, regulator/rectifier), ignition system, lighting, starter, battery, and accessory circuits.

Fuel System:

Fuel injection system (EFI) diagnostics, injector service, fuel pump testing, and fuel tank maintenance.

Cooling System:

N/A (Air-cooled engine)

Bodywork And Frame:

Frame inspection, body panel removal/installation, fender service, fuel tank mounting, and seat assembly.

Wheels And Tires:

Wheel bearing service, tire replacement, and wheel balancing.

Controls:

Handlebar, levers, cables (throttle, clutch, brake), and foot controls adjustment and service.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, lubrication points, chain/belt inspection and adjustment.

Troubleshooting:

Diagnostic charts and procedures for identifying and resolving common and complex issues across all vehicle systems.

Engine Overhaul:

Detailed step-by-step instructions for complete engine disassembly, component inspection, measurement, and reassembly, including piston, rings, valves, camshafts, and crankshaft.

Transmission Rebuild:

Complete guide to gearbox disassembly, bearing replacement, gear inspection, and reassembly.

Brake System Repair:

Bleeding procedures, caliper seal replacement, rotor inspection, and master cylinder rebuild.

Electrical Diagnostics:

Using multimeters, oscilloscopes (implied), and diagnostic codes to pinpoint electrical faults.

Fuel Injection Service:

Injector cleaning, sensor testing (TPS, MAP, IAT), and idle speed control adjustments.

Suspension Fork Rebuild:

Replacement of fork seals, bushings, and damper rods.

Wiring Diagrams:

Color-coded and schematic diagrams for all electrical circuits.

Technical Depth

Depth Level:

Complete workshop level, suitable for professional technicians and advanced DIY mechanics.

Special Tools:

Lists of required special tools for specific procedures (e.g., engine disassembly, bearing presses, calibration tools).

Specifications And Tolerances:

Detailed torque values, clearances, measurements, and material specifications for all components.

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format)

Searchability:

Likely text-searchable, allowing for quick navigation to specific topics.

Print Quality

Print Quality:

Designed for clear reproduction of text, diagrams, and photographs.

Binding Type

Binding Type:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, Twin Cam 88B V-twin

Displacement:

1450cc (88 cubic inches)

Bore X Stroke:

3.75 in x 4.00 in (95.25 mm x 101.6 mm)

Compression Ratio:

8.8:1

Valve Train:

Overhead valves (OHV), two valves per cylinder, pushrod actuated.

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Ignition System:

Dual spark ignition, crank-triggered

Performance

Horsepower:

Approximately 65-70 HP (est. at crank, varies by source and tuning)

Torque:

Approximately 80-85 ft-lbs @ 3500 RPM (est. at crank, varies by source and tuning)

Fuel System

Fuel Type:

Unleaded Gasoline, 91 Octane (Recommended)

Fuel Tank Capacity:

4.8 US gallons (18.2 L)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Gear Ratios:

1st: 10.110, 2nd: 6.590, 3rd: 4.720, 4th: 3.920, 5th: 3.210 (Typical for Twin Cam 5-speed)

Final Drive:

Belt drive, 32/66 tooth sprockets (3.15:1 ratio)

Features

Clutch Type:

Wet, multi-plate, 9-plate

Transmission Oil Type:

Harley-Davidson Genuine Formula Plus (or equivalent V-twin transmission/primary lubricant)

Transmission Oil Capacity:

Approximately 2.8 US quarts (2.6 L)

📐 Dimensions

Exterior

Length:

93.3 inches (2370 mm)

Width:

38.6 inches (980 mm)

Height:

57.7 inches (1465 mm)

Wheelbase:

64.5 inches (1638 mm)

Weights

Dry Weight:

Approximately 650 lbs (295 kg)

Gross Vehicle Weight Rating Gvwr:

Approximately 1050 lbs (476 kg)

Payload Capacity:

Approximately 400 lbs (181 kg)

🛡️ Safety Features

Ratings

Safety Certifications:

Meets all applicable US federal motor vehicle safety standards (FMVSS) for motorcycles.

Active Features

Brakes:

Dual-piston front caliper with 292mm disc, single-piston rear caliper with 292mm disc.

Lighting:

Halogen headlamp, LED tail lamp and stop lamp, amber turn signals, auxiliary passing lamps (optional).

Passive Features

Frame Construction:

Steel, cradle frame

Front Suspension:

Telescopic fork with 41mm stanchions, air-assisted (variable)

Rear Suspension:

Horizontal, monoshock, swingarm with adjustable pre-load

💡 Technology Features

Infotainment

Audio System:

Optional accessory audio systems (e.g., radio, CD player, speakers) were available, often integrated into the fairing or handlebars.

Cruise Control:

Factory-installed cruise control was an option on many FLST models.

Driver Assistance

Anti-lock Braking System (ABS) was not standard on all 2006 models but was often an available option.

Connectivity

Diagnostics Port:

Diagnostic capabilities for engine management and fault codes, typically accessed via a specific data port and diagnostic tool.

🔧 Maintenance

Service Intervals

Initial Service:

First service typically at 1,000 miles (1,600 km) for engine oil and filter change, primary chain adjustment, and general inspection.

Routine Oil Change:

Every 5,000 miles (8,000 km) or 12 months, whichever comes first (engine oil).

Primary Chain Adjustment:

Check and adjust every 5,000 miles (8,000 km) or as needed.

Brake Fluid Change:

Every 2 years, regardless of mileage.

Spark Plug Replacement:

Typically every 10,000-15,000 miles (16,000-24,000 km).

Fluid Specifications

Engine Oil:

Harley-Davidson Genuine V-Twin Oil SAE 20W-50 (or equivalent SYN3/mineral API CI-4 or JASO MA rated oil)

Engine Oil Capacity:

Approximately 4.0 US quarts (3.8 L) with filter change.

Primary Drive Fluid:

Harley-Davidson Genuine Formula Plus (or equivalent primary lubricant).

Brake Fluid:

DOT 4 compatible Hydraulic Brake Fluid.

Fork Oil:

Harley-Davidson Genuine Fork Oil (Weight varies, typically 10W or 15W; consult specific manual section).

Known Issues

Cam Chain Tensioner Wear:

Early Twin Cam engines (prior to 2007) had hydraulic cam chain tensioners that could wear prematurely, requiring replacement with updated or aftermarket units.

Primary Bearing Issues:

Some models experienced primary drive bearing failures, often linked to oil pressure or load.

Crankshaft Runout:

While less common on the Twin Cam 88B, crankshaft runout issues can lead to primary and transmission component wear.

Fuel Line Leaks:

Occasional reports of fuel line leaks or hose degradation, necessitating inspection and replacement.

📚 Vehicle History

Brand Heritage

Founding:

Founded in 1903 in Milwaukee, Wisconsin.

Iconic Engines:

Known for its evolution of the V-twin engine, from the Knucklehead, Panhead, Shovelhead, Evolution, to the Twin Cam series.

Model Evolution

Heritage Softail Origin:

The Softail line debuted in 1983, offering a smoother ride with hidden rear suspension while retaining classic rigid frame aesthetics.

Twin Cam Introduction:

The Twin Cam 88 engine was introduced in 1999, replacing the Evolution Big Twin engine, and became the powerplant for most Harley-Davidson Big Twin models.

Flst Heritage Softail Development:

The Heritage Softail model has consistently represented Harley-Davidson's commitment to traditional styling and touring comfort.

Production

Manufacturing Location:

Primarily manufactured in York, Pennsylvania, and Milwaukee, Wisconsin, USA.

Model Year Coverage:

The FLST Heritage Softail model has been in continuous production with various updates since its introduction.

🏆 Awards & Recognition

Recognitions

Brand Awards:

Harley-Davidson motorcycles have consistently received accolades for design, engineering, and rider satisfaction within the cruiser segment.

Ratings

Consumer Ratings:

Highly regarded by owners for its styling, comfort, and the authentic Harley-Davidson riding experience.

Certifications

Certification Standard:

Certified to meet emissions and noise regulations for its model year.