🏷️ Basic Information

Make:

Harley-Davidson

Model:

XLH Sportster

Year:

2006

Engine Family Code:

XLH

👋 Introduction

Market Position:

The Harley-Davidson XLH Sportster is a cornerstone of the cruiser/custom motorcycle segment, known for its iconic V-twin engine and classic styling. This manual targets owners and independent repair shops looking for in-depth maintenance and repair information.

Key Features:

Provides detailed procedural guidance, diagnostic flowcharts, wiring diagrams, and critical specifications essential for maintaining and repairing the 2006 XLH Sportster models. Emphasis on the Evolution engine and associated drivetrain.

📋 Manual Details

Manual Type:

Service Workshop Repair Manual

Language:

English

Format:

Book (likely printed, based on typical product offerings)

Applicable Models:

All Harley-Davidson XLH Sportster models for the 2006 model year, including variants such as XL883, XL883R, XL883C (Custom), XL1200C (Custom), XL1200R (Roadster), XL1200L (Low), XL1200S (Sport).

📖 Manual Coverage

Engine:

Complete engine overhaul, tuning, carburetor operation (likely Keihin CV), ignition system, lubrication system, cooling system (air-cooled), fuel system.

Transmission:

5-speed gearbox, clutch assembly, primary drive, final drive belt maintenance, troubleshooting.

Chassis:

Frame inspection and repair, front suspension (forks, steering head bearings), rear suspension (shocks, swingarm), wheels, tires, spokes, braking system (front and rear calipers, master cylinders, lines, pads), control cables (throttle, clutch, brake).

Electrical:

Wiring diagrams, battery system, starting system (starter motor, solenoid), charging system (alternator, regulator/rectifier), lighting system (headlight, taillight, turn signals), ignition system components (ignition module, coil, spark plugs), instrumentation, horn, accessory circuits.

Bodywork:

Fenders, fuel tank mounting and removal, seat assembly, handlebars, mirrors, side covers, basic body panel alignment.

Fuel System Efi:

If EFI models are covered, detailed information on the EFI system, sensors (e.g., MAP, TPS, IAT, O2), ECU operation, and diagnostic port access.

Maintenance:

Scheduled maintenance intervals, oil changes (engine, transmission, primary), filter replacement, spark plug replacement, drive belt tensioning and inspection, brake fluid flush, tire pressure checks, chain lubrication (if applicable to specific XLH sub-models), battery maintenance.

Troubleshooting:

Diagnostic procedures for common running issues, electrical faults, braking problems, and drive train malfunctions. Symptom-based troubleshooting guides.

Repair:

Step-by-step instructions for component disassembly, reassembly, and repair. Engine rebuild procedures, transmission overhaul, suspension fork seal replacement, brake caliper rebuild, electrical component replacement.

Engine Tuning Carburetor:

Detailed procedures for carburetor adjustment, idle speed setting, jetting recommendations based on altitude and modifications, and troubleshooting lean/rich conditions.

Ignition Timing:

Procedures for checking and adjusting ignition timing (if applicable to the specific ignition system) and component replacement.

Suspension Fork Rebuild:

Step-by-step instructions for disassembling front forks, replacing seals and bushings, and refilling with the correct fork oil type and quantity.

Brake System Service:

Instructions for bleeding brake systems, replacing brake pads and rotors, rebuilding calipers and master cylinders, and checking brake line condition.

Electrical Diagnostics:

Comprehensive wiring diagrams for all electrical circuits. Troubleshooting guides for common electrical issues like no-start, charging problems, and lighting malfunctions.

Wheel Bearing Service:

Procedures for checking, repacking, or replacing wheel bearings.

Drive Belt Replacement:

Detailed steps for removing and installing the final drive belt, including required tension adjustments.

Depth:

Comprehensive, covering routine maintenance to complete engine and transmission rebuilds. Includes detailed torque specifications, diagnostic procedures, and component clearances.

Torque Specifications:

Extensive list of torque specifications for all critical fasteners and components, essential for proper assembly and safety.

Diagnostic Charts:

Includes flowcharts and symptom-to-cause tables for efficient troubleshooting.

📊 Manual Specifications

File Format:

Print (Physical Book)

Searchable Text:

Likely yes, if it's a professionally produced digital version of a print manual, but for a physical book, this is not applicable. For a physical book, it implies clear indexing and chapter organization.

Print Quality:

Professional, clear diagrams and text. Likely standard professional printing.

Diagram Clarity:

High clarity, detailed line drawings and schematics for all components and systems.

Binding Type:

Perfect Bound or Spiral Bound (common for service manuals for durability and lay-flat use)

Paper Type:

Durable, glossy paper suitable for workshop environments. May include thicker cover stock.

⚙️ Engine Specifications

Engine Type:

Air-cooled, 45-degree V-twin, Evolution engine

Displacement Options:

Typically 883cc (53.9 cu in) and 1200cc (73.2 cu in) for 2006 XLH models. Specific model variants (e.g., XL883, XL1200 Custom, XL1200 Roadster) will dictate exact displacement.

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:

Approximately 8.8:1

Compression Ratio 1200:

Approximately 9.7:1

Horsepower Range:

Approx. 50-67 hp (depending on engine displacement and tuning).

Torque Range:

Approx. 50-70 ft-lbs (depending on engine displacement).

Fuel Delivery:

Carbureted (typically Keihin CV 40mm for 1200cc, Keihin CV 34mm for 883cc) or Electronic Fuel Injection (EFI) depending on specific sub-model.

Ignition System:

Electronic ignition, distributorless for 2006.

Oil Type:

Harley-Davidson recommends specific V-Twin motorcycle oil, typically 20W-50 or 25W-60 depending on ambient temperature. Specific part numbers for oils and filters will be detailed in the manual.

Oil Change Interval:

Typically every 2,500-5,000 miles or annually, whichever comes first. Manual will provide exact intervals.

🔧 Transmission

Transmission Type:

5-speed constant mesh

Transmission Options:

N/A (5-speed was standard)

Primary Drive:

Wet, multi-plate clutch; chain drive to transmission.

Final Drive:

Belt drive

Transmission Oil Type:

Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant (or equivalent V-twin specific gear oil) is typically recommended. Manual will specify.

📐 Dimensions

Wheelbase Range:

Approx. 56.5 - 60.0 inches (depending on model variant).

Dry Weight Range:

Approx. 480 - 520 lbs (depending on model and specific components).

🛡️ Safety Features

Safety Ratings:

Motorcycles are not typically assigned NHTSA or IIHS crash test ratings in the same manner as cars. Focus is on rider safety features and handling dynamics.

Active Safety Features:

Effective hydraulic braking system (front and rear disc brakes), responsive steering, stable chassis design.

Passive Safety Features:

Handlebar grips designed for control, sturdy frame, rider footpegs and seat.

💡 Technology Features

Infotainment Features:

Basic instrumentation including speedometer, tachometer (optional on some models), odometer, trip meter, and indicator lights. No advanced infotainment systems typical of modern vehicles.

Driver Assistance Features:

N/A (Motorcycle)

Connectivity Features:

N/A (Motorcycle)

🔧 Maintenance

Initial Service Mileage:

Typically around 1,000 miles. Manual will detail specific checks and adjustments.

Major Service Intervals:

Recommended at higher mileage intervals (e.g., 10,000, 20,000 miles) for more in-depth inspections and component replacements. Manual will provide a detailed schedule.

Engine Oil Capacity:

Approx. 2.5-3.0 quarts (depending on engine displacement and oil filter size). Manual to confirm.

Transmission Oil Capacity:

Approx. 1.0-1.2 quarts. Manual to confirm.

Primary Chaincase Oil Capacity:

Approx. 2.5-3.0 quarts (shares oil with transmission in some configurations, but often separate lubricant). Manual to confirm.

Brake Fluid Type:

DOT 4

Common Issues 2006 Sportster:

Potential for carburetor tuning issues (if equipped), starter solenoid problems, regulator/rectifier failures, front fork leaks, and drive belt wear. The manual will offer diagnostic and repair procedures for these.

📚 Vehicle History

Brand Heritage:

Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and distinct styling. The Sportster line, introduced in 1957, is one of the longest-running motorcycle model families in continuous production.

Model Evolution 2006:

The 2006 model year Sportster continued the evolution of the Evolution engine, with 2006 being a transition year for some models towards electronic fuel injection. It represents a blend of classic Sportster lines with modern mechanical improvements over earlier generations.

Production Location:

United States (primarily Milwaukee, Wisconsin and Kansas City, Missouri for Harley-Davidson).