🏷️ Basic Information

Make:

Harley-Davidson

Model:

XLH Sportster

Year:

2006

Product Type:

Service Repair Manual

Engine Code:

XLH (General designation for Sportster models)

👋 Introduction

Positioning:

The 2006 Sportster XLH represents a classic American cruiser motorcycle, known for its iconic V-twin engine and customizable nature. This manual serves enthusiasts and owners seeking to maintain and repair their machines.

Competitors:

Direct competitors in the cruiser segment for 2006 included models from Indian, and some Japanese manufacturers' V-twin offerings, but the Sportster holds a distinct place due to its heritage and rider community.

Features:

Iconic Evolution V-Twin engine, classic styling, accessible maintenance, and a strong aftermarket support network.

📋 Manual Details

Primary Coverage:

Harley-Davidson XLH Sportster Motorcycle

Production Years Covered:

2006

Estimated Pages:

Varies by publisher, typically 500+ pages

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Print / Digital (PDF likely available from some sources)

📖 Manual Coverage

Engine:

Detailed diagnostics, disassembly, inspection, assembly, and troubleshooting for the Evolution V-Twin engine (95th Anniversary Edition likely features the 883cc or 1200cc Evolution engine).

Fuel System:

Carburetor (if applicable to specific 2006 XLH variants) or Electronic Fuel Injection (EFI) system diagnostics, maintenance, and repair, including fuel pump, injectors, and sensors.

Ignition System:

Spark plug service, coil testing, timing procedures, and related electronic components.

Transmission:

Clutch operation, gear shifting mechanisms, maintenance, and repair of the 5-speed transmission.

Drivetrain:

Belt drive system inspection, adjustment, and replacement; wheel bearing service.

Brakes:

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

Suspension:

Front fork (telescopic) service, rear shock absorber inspection and replacement, wheel alignment.

Electrical System:

Battery maintenance, charging system (stator, regulator/rectifier), starter system, lighting circuits, instrumentation, and wiring diagrams.

Chassis And Frame:

Frame inspection, swingarm service, steering head bearing maintenance.

Bodywork And Trim:

Fender removal and installation, fuel tank procedures, seat removal, and other cosmetic components.

Maintenance:

Routine maintenance tasks such as oil changes, filter replacements, spark plug servicing, chain/belt adjustments, and lubrication.

Troubleshooting:

Diagnostic flowcharts and step-by-step procedures to identify and resolve common and complex issues.

Repair:

Detailed instructions for component disassembly, inspection, repair, reassembly, and adjustment for all major systems.

Diagnostics:

Procedures for diagnosing electrical issues, engine performance problems, and other system malfunctions.

Special Instructions:

Specific procedures unique to Harley-Davidson motorcycles, including torque specifications, clearances, and alignment guides.

Depth:

Comprehensive, suitable for both experienced DIY mechanics and professional technicians.

📊 Manual Specifications

Format Details:

Typically a PDF for digital versions, offering searchability and printable pages. Printed versions are bound for durability.

Quality:

High-quality paper and clear, legible print for easy reading in a workshop environment.

Binding:

Stapled, perfect bound, or spiral bound for printed versions to allow for lay-flat use.

Paper:

Durable, often glossy or semi-gloss paper to resist grease and shop dirt.

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-Twin

Engine Displacement:

Typically 883cc (53.9 cu in) or 1200cc (73.2 cu in) depending on specific XLH model variant (e.g., XL883, XL1200).

Bore X Stroke:

Varies by displacement. For 1200cc: 3.50 in x 3.81 in (88.9 mm x 96.8 mm).

Compression Ratio:

Varies by displacement and model, typically around 9.0:1 to 9.7:1.

Horsepower:

Approx. 55-70 HP (Varies by displacement and tuning).

Torque:

Approx. 65-75 ft-lbs (Varies by displacement and tuning).

Fuel Delivery:

Electronic Fuel Injection (EFI) for 2006 models, or potentially carburetor on some specific domestic/export variants not explicitly noted in the product name.

Fuel Type:

Unleaded gasoline, 91-92 octane (or higher recommended).

🔧 Transmission

Transmission Type:

5-speed constant mesh, helical gears

Clutch Type:

Wet, multi-plate

Primary Drive:

Spur gear, 26/48 ratio

Final Drive:

Triangular belt, 32/66 ratio (final drive belt) - Harley-Davidson specific belt drive system.

Gear Ratios:

Manual will detail specific gear ratios for each of the 5 speeds.

Transmission Fluid:

Refer to manual for specific Harley-Davidson transmission fluid specifications (e.g., Formula+ or equivalent).

📐 Dimensions

Overall Length:

Varies by model, approx. 88-90 inches (2235-2286 mm).

Wheelbase:

Approx. 60 inches (1524 mm).

Dry Weight:

Approx. 520-540 lbs (236-245 kg).

Fuel Tank Capacity:

Approx. 3.1 US gallons (11.7 Liters).

🛡️ Safety Features

Safety Certifications:

Meets DOT standards for motorcycles.

Braking System:

Dual-action front brake caliper with single disc, dual-action rear brake caliper with single disc. ABS was not typically standard or widely available on Sportster models in 2006.

Lighting:

Halogen headlamp, taillight, brake light, turn signals.

💡 Technology Features

Infotainment System:

Base models typically do not feature advanced infotainment systems. Some aftermarket or higher trim levels might have basic radio or audio components.

Assistance Features:

No specific driver assistance features like ABS (as standard), traction control, or advanced electronic rider aids were common on 2006 Sportsters.

Connectivity Options:

No integrated smartphone connectivity or Bluetooth features. Connectivity is limited to basic vehicle electrical systems.

🔧 Maintenance

Oil Change:

Typically every 2,500-5,000 miles or annually, whichever comes first (refer to manual for exact specification).

Primary Chain Tensioner:

Inspection and adjustment as needed, or per manual recommendations (e.g., at 1,000-mile intervals).

Spark Plugs:

Replace every 10,000-15,000 miles or as per manual. Use correct Harley-Davidson specified plugs (e.g., NGK, Champion).

Drive Belt:

Inspect tension and condition at regular intervals (e.g., every 2,500 miles); adjust as per manual specifications.

Engine Oil:

Harley-Davidson Genuine V-Twin Motor Oil SAE 20W50 or equivalent API SG/SH/SJ rated oil. Capacity approx. 3 US quarts (2.8 Liters) for engine oil change with filter.

Transmission Fluid:

Harley-Davidson Genuine Formula+ Transmission Fluid or SAE 50 motorcycle oil. Capacity approx. 1 US quart (0.95 Liters).

Primary Chain Case Oil:

Harley-Davidson Genuine Formula+ Transmission Fluid or SAE 50 motorcycle oil. Capacity approx. 26 US fluid ounces (769 ml).

Brake Fluid:

DOT 4 or DOT 5.1 (check manual for specific recommendation based on system compatibility; DOT 5 Silicone fluid is often not recommended for systems designed for DOT 4).

Primary Chain Tensioner:

The stock spring-loaded primary chain tensioner can wear prematurely, leading to rattling noise and potential chain damage. Manual provides inspection and replacement procedures.

Carburetor Issues:

If equipped with a Keihin CV carburetor, issues like hard starting, poor idle, or flat spots can occur, often due to vacuum leaks or jetting issues. Manual details troubleshooting.

Electrical Connections:

Corrosion or loose connections in wiring harnesses can lead to intermittent electrical problems. Manual provides wiring diagrams for diagnosis.

📚 Vehicle History

Heritage:

Harley-Davidson, established in 1903, is an iconic American motorcycle manufacturer with a rich history of producing V-twin powered motorcycles. The Sportster line, introduced in 1957, is one of its longest-running and most recognizable models.

Evolution:

The 2006 XLH Sportster represents a mature iteration of the platform, featuring the Evolution engine and transitioning towards more electronic controls and EFI. It retains the classic Sportster silhouette and character.

Production Period:

Sportster models have been in continuous production since 1957, with the XLH designation often used broadly.

🏆 Awards & Recognition

Awards Recognition:

While specific awards for the 2006 model year may not be prominently documented, the Harley-Davidson Sportster line consistently receives recognition within the motorcycle community for its enduring legacy, customization potential, and classic styling.