Target Audience:
Harley-Davidson Sportster XLH 2006 owners, independent repair shops, and DIY enthusiasts seeking detailed repair and maintenance information.
Value Proposition:
Provides essential information for cost-effective maintenance and repairs, empowering owners to perform tasks typically done by dealerships.
Diagrams Illustrations:
Includes detailed exploded views, wiring diagrams, and step-by-step illustrations crucial for complex procedures.
Engine Mechanical:
Full Engine Overhaul, Top End (Cylinder Heads, Valves, Cams), Bottom End (Crankshaft, Connecting Rods, Bearings), Piston & Ring Installation, Cylinder Honing & Reassembly.
Fuel System:
Carburetor Disassembly, Cleaning, Adjustment, and Reassembly (Keihin CV Carburetor), Fuel Tank Removal/Installation, Fuel Lines, Fuel Filter Replacement.
Ignition System:
Ignition Module Testing and Replacement, Spark Plug Specifications and Replacement, Ignition Timing Adjustment (if applicable).
Transmission:
5-Speed Gearbox Disassembly, Inspection, Reassembly, and Adjustment, Clutch Operation and Adjustment, Primary Drive System Maintenance (Chain/Belt).
Electrical System:
Wiring Diagrams, Component Testing (Starter, Alternator, Regulator, Lighting, Horn), Battery Maintenance and Charging System Diagnostics, Fuses and Relays.
Braking System:
Front and Rear Brake System Overhaul, Pad Replacement, Rotor Inspection, Brake Fluid Flush and Bleed Procedure, Master Cylinder and Caliper Service.
Suspension:
Front Fork Disassembly, Seal Replacement, Oil Level and Type Specifications, Rear Shock Absorber Inspection and Replacement, Swingarm and Pivot Bearing Service.
Frame And Bodywork:
Frame Inspection, Body Panel Removal and Installation, Handlebar and Control Lever Service, Seat Removal and Installation.
Routine Maintenance:
Oil and Filter Change Procedures and Specifications, Air Filter Cleaning/Replacement, Spark Plug Replacement, Chain Adjustment (if applicable), Lubrication Points.
Troubleshooting:
Diagnostic Flowcharts for Common Performance Issues, Symptom-Based Troubleshooting Guides, Electrical System Fault Finding.
Repair Procedures:
Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation for all major vehicle systems.
Technical Specifications:
Torque Specifications for all fasteners, Clearances and Tolerances for Engine and Transmission Components, Fluid Capacities and Types, Electrical Component Specifications.
Depth:
Comprehensive: Covers routine maintenance to full engine and transmission rebuilds, including detailed electrical diagnostics.
File Type:
Likely PDF (Portable Document Format)
Searchability:
Typically searchable text for easy information retrieval.
Resolution:
High-resolution digital scans or native digital files ensuring clear diagrams and text.
Binding:
Not applicable for digital format, but intended to be viewed on screen or printed.
Paper Quality:
Not applicable for digital format.
Engine Type:
Evolution (Evo) V-Twin, Air-Cooled
Displacement:
1200cc (73.3 cubic inches) and 883cc (53.7 cubic inches) variants likely covered, with XLH typically referring to the 1200cc models.
Bore X Stroke:
For 1200cc: 3.50 in x 3.81 in (88.9 mm x 96.8 mm)
Compression Ratio:
Typically around 9.0:1 for 1200cc models.
Horsepower:
Approximately 65-70 HP at the crankshaft for 1200cc models.
Torque:
Approximately 70-75 ft-lbs at the crankshaft for 1200cc models.
Carburetor Model:
Keihin CV (Constant Velocity) 40mm
Fuel Type:
Unleaded Gasoline, minimum 87 octane
Oil Type:
Harley-Davidson genuine V-Twin 20W-50 or equivalent API SG rated oil.
Oil Capacity:
Approximately 3.0 US quarts (2.8 liters) with filter change.
Transmission Type:
5-Speed Manual Constant Mesh
Primary Drive:
Multi-plate Wet Clutch, Chain Drive (3/4" x 5/16" primary chain)
Final Drive:
Belt Drive (2006 models primarily used a 132-tooth, 1-inch pitch belt).
Clutch Type:
Hydraulic Clutch Actuation (standard on 2006 models for XLH)
Transmission Oil:
Harley-Davidson Formula+ Transmission and Primary Chaincase Lubricant or equivalent.
Crash Test Information:
Motorcycles are not subject to the same rigorous crash testing as automobiles; emphasis is on rider protection gear and safe operation.
Braking System Description:
Dual-piston calipers front and rear, hydraulic disc brakes.
Tire Specifications:
Front: 100/90-19 57H, Rear: 150/80-16 71H (typical stock fitment, check specific model variant).
Frame Construction:
Steel tube cradle frame.
Initial Service:
First service typically at 1,000 miles (1,600 km) for oil change, filter replacement, and general inspection.
Routine Oil Change:
Every 5,000 miles (8,000 km) or annually, whichever comes first.
Belt Drive Tension:
Check and adjust belt tension every 2,500 miles (4,000 km) or as needed.
Spark Plug Replacement:
Typically every 10,000 miles (16,000 km) or as specified by the manual.
Engine Oil Grade:
20W-50 API SG or higher.
Transmission Oil Type:
Harley-Davidson Formula+ or equivalent.
Brake Fluid Type:
DOT 4 Hydraulic Fluid.
Fork Oil Type:
Check manual for specific weight (often a light fork oil or ATF blend for older models).
Carburetor Tuning:
CV carburetor may require periodic adjustment for optimal performance and idle stability, especially with altitude or air cleaner changes.
Clutch Cable Adjustment:
Clutch lever play can change with temperature; requires occasional adjustment to maintain proper engagement.
Primary Chain Tension:
Primary chain tension can loosen over time and requires periodic checks to prevent premature wear on components.
Exhaust Leaks:
Exhaust header pipe gaskets or clamps can sometimes develop leaks, leading to a loss of power or noise.
Harley Davidson Legacy:
Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer renowned for its V-twin engines and custom styling.
Sportster Lineage:
The Sportster model line dates back to 1957, evolving through various displacements and technological updates while retaining its sporty, compact character.
Manufacturing Location:
Milwaukee, Wisconsin, USA (primary manufacturing, with some components potentially sourced internationally).
Xlh Designation:
XLH historically denoted the higher-performance variant, often with larger displacement engines (like the 1200cc).
Sportster Impact:
The Sportster line is consistently recognized for its accessibility, customization potential, and enduring appeal in the cruiser motorcycle market.
Reliability Perception:
The Evolution engine is generally considered robust and reliable with proper maintenance, a testament to its decades of refinement.
Emissions Compliance:
Compliant with US EPA and California ARB emissions standards for the 2006 model year.
