Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson Sportster XLH owners and independent repair shops seeking detailed technical information.
Manual Value:
Provides a highly detailed and authoritative resource for servicing the 2006 Sportster XLH models, essential for DIY mechanics and professionals alike.
Detail Level:
Hundreds of pages of detailed instructions, diagrams, and specifications.
Scope:
Covers the full spectrum of maintenance, repair, and restoration tasks.
Powertrain:
Engine, Transmission, Primary Drive, Final Drive
Chassis:
Frame, Suspension (Front & Rear), Wheels, Tires, Brakes (Front & Rear), Steering
Electrical:
Ignition System, Lighting System, Charging System, Starting System, Instrumentation, Wiring Diagrams, Fault Diagnosis
Fuel And Exhaust:
Fuel Tank, Fuel Lines, Carburetor (or Fuel Injection System, if applicable), Exhaust System
Components:
Body Panels, Fenders, Seat, Handlebars, Controls, Footpegs
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacement, Chain Adjustment, Spark Plug Service, Brake Fluid Flush
Repair And Rebuild:
Engine Rebuild, Transmission Overhaul, Suspension Component Replacement, Brake System Repair, Electrical Component Diagnosis and Replacement
Troubleshooting:
Diagnostic Procedures, Symptom-Based Troubleshooting, Fault Code Interpretation
Disassembly And Assembly:
Component-Level Disassembly and Reassembly Instructions
Level:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds)
PDF Quality:
High-resolution, searchable text for easy navigation and printing.
Scannability:
Designed for clarity and readability when printed.
Digital Format Advantage:
Instant access, easily shareable, searchable content.
N/A:
N/A (Digital Format)
Type:
Air-cooled, Evolution V-Twin (Pushrod OHV)
Displacements:
883cc (53.9 cu in) and 1200cc (73.2 cu in)
Bore Stroke 883:
3.00 in x 3.8125 in (76.2 mm x 96.8 mm)
Bore Stroke 1200:
3.50 in x 3.8125 in (88.9 mm x 96.8 mm)
Compression Ratio 883:
8.8:1 (Typical)
Compression Ratio 1200:
9.0:1 (Typical)
Horsepower 883:
Approx. 55 HP @ 6000 RPM (Estimate, varies slightly)
Torque 883:
Approx. 65 lb-ft @ 3500 RPM (Estimate, varies slightly)
Horsepower 1200:
Approx. 65 HP @ 6000 RPM (Estimate, varies slightly)
Torque 1200:
Approx. 70 lb-ft @ 3500 RPM (Estimate, varies slightly)
Induction:
Keihin CV (Constant Velocity) Carburetor, 40mm (Standard on most 2006 models).
Fuel Type:
Unleaded gasoline, 91-95 octane (RON+MON)/2 (AKI) recommended.
Fuel Tank Capacity:
Typically 3.1 US gallons (11.7 L) or 4.1 US gallons (15.5 L) depending on model variant (e.g., standard vs. custom with larger tank).
Type:
5-speed Manual Constant Mesh
Primary Drive:
Multi-plate wet clutch, chain drive to transmission.
Clutch Operation:
Cable-actuated
Gear Ratios:
Specific ratios detailed in the manual, crucial for performance tuning and troubleshooting.
Transmission Fluid:
Harley-Davidson transmission lubricant or equivalent API GL-5 rated gear oil.
Wheelbase:
Approx. 59.8 in (1519 mm)
Length:
Approx. 83.5 in (2121 mm)
Seat Height:
Approx. 26.0 in (660 mm) (Unladen)
Dry Weight:
Approx. 480 lbs (218 kg) - Varies slightly by model/configuration.
Gross Vehicle Weight Rating:
Typically around 860 lbs (390 kg).
Payload Capacity:
Approx. 380 lbs (172 kg).
N/A:
Motorcycles are not typically rated by formal safety bodies like NHTSA or Euro NCAP. Safety relies on design and rider execution.
Braking System:
Dual-piston calipers front and rear, hydraulic actuation. Specifics on disc size and rotor type provided in manual.
Suspension:
Telescopic front forks (e.g., 39mm Showa), Rear shock absorbers with adjustable preload.
Lighting:
Headlight, Taillight, Stop Light, Turn Signals.
Frame:
Steel, tubular frame designed for rigidity and stability.
Features:
Basic instrumentation includes speedometer, odometer, trip meter, and indicator lights. No advanced infotainment systems are standard.
Features:
No electronic driver assistance systems (e.g., ABS, traction control) were standard on 2006 Sportster models.
Features:
No factory Bluetooth or smartphone connectivity features.
Oil Change:
Every 2,500-5,000 miles (4,000-8,000 km) or 6 months, whichever comes first (consult manual for specific engine oil type and capacity).
Primary Chain Adjustment:
Check every 2,500 miles (4,000 km).
Spark Plugs:
Inspect/replace per manual, typically around 7,500-10,000 miles (12,000-16,000 km).
Belt Tension:
Check every 5,000 miles (8,000 km).
Engine Oil:
Harley-Davidson SYN3 (20W50) or other recommended motorcycle-specific oil meeting Harley-Davidson specifications.
Transmission Oil:
Harley-Davidson Transmission Oil (SAE 80W-90, API GL-5) or equivalent.
Primary Chain Case Oil:
Harley-Davidson Primary Chain Case Oil (Formula+, SAE 20W-50) or equivalent.
Brake Fluid:
DOT 4 or DOT 5.1 fluid (check manual for precise specification).
Carburetor Tuning:
CV carburetors can require occasional adjustment or rebuild for optimal performance. Manual provides detailed tuning procedures.
Cam Chain Tensioner:
Earlier Evolution engines had plastic cam chain tensioners that could wear. Later models (including some variations of 2006) may have upgraded hydraulic tensioners. Manual details inspection and replacement.
Electrical Gremlins:
As with many motorcycles of this era, electrical connections and grounds can be a source of intermittent issues. Detailed wiring diagrams in the manual are crucial.
Legacy:
Harley-Davidson is an iconic American motorcycle manufacturer with a history dating back to 1903.
Sportster Lineage:
The Sportster line, introduced in 1957, is one of Harley-Davidson's longest-running models, known for its compact size and sporty performance.
Evolution Engine:
The Evolution engine (or 'Evo') replaced the Shovelhead and Ironhead engines, offering improved reliability and performance. The 2006 models feature a refined version of this engine.
Manufacturing Location:
Milwaukee, Wisconsin, USA (Assembly)
