Market Position:
Harley-Davidson Touring motorcycles represent the pinnacle of American cruising motorcycles, designed for long-distance comfort and performance. This manual caters to owners and technicians looking for authoritative guidance on these premium machines.
Competitive Analysis:
The 2006 touring models with the Twin Cam 96 engine were in direct competition with other large-displacement cruiser motorcycles from brands like Honda (Gold Wing), Indian, and Victory, offering a distinct V-twin experience and customization potential.
Key Features:
These models are characterized by their large fairings (on FLHT/FLTR), saddlebags, comfortable seating, and powerful V-twin engines, making them ideal for touring and comfortable daily riding.
Engine Systems:
Engine overhaul, cylinder heads, pistons, crankshaft, camshaft, lubrication system, cooling system (if applicable to specific models within the touring range), fuel injection, ignition system, exhaust system.
Transmission Systems:
Primary drive, clutch, transmission assembly (5-speed), shifter mechanism, final drive.
Chassis Systems:
Frame, suspension (front forks, rear shock absorbers), steering, wheels, tires, braking system (front and rear discs).
Electrical Systems:
Battery, charging system (alternator, regulator), starting system (starter motor), lighting system (headlight, taillight, turn signals), instrumentation, ignition switch, wiring diagrams, accessory circuits, fuel level sender, diagnostics.
Bodywork And Trim:
Fairings, saddlebags, tour-pak mounting, fenders, seat, handlebars, controls, fairing lowers, chrome components.
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacement, brake fluid replacement, clutch fluid replacement, spark plug replacement, air filter cleaning/replacement, lubrication points.
Repair Procedures:
Engine rebuilds, transmission overhaul, brake caliper service, fork seal replacement, electrical component diagnosis and replacement, fuel system servicing, clutch replacement.
Troubleshooting Guides:
Diagnostic flowcharts, common problem identification, symptom-based troubleshooting for engine, electrical, and mechanical issues.
Rebuilding And Restoration:
Detailed instructions for component disassembly, inspection, repair, and reassembly for major vehicle systems.
Technical Depth:
Comprehensive, covering everything from basic routine maintenance to complete engine and transmission overhauls, electrical system diagnostics, and chassis component repair. Detailed torque specifications, clearances, and assembly instructions are provided.
Engine Type:
Air-cooled, Twin Cam 96, V-twin
Displacement:
96 cubic inches (1584 cc)
Bore X Stroke:
3.75 in. x 4.38 in. (95.25 mm x 111.25 mm)
Compression Ratio:
8.2:1 (typical for Twin Cam 96)
Valve Train:
Overhead valves (OHV), 2 valves per cylinder, pushrod actuated.
Horsepower:
Approximately 65-70 HP (estimated, specific figures vary by model and tuning)
Torque:
Approximately 85-90 ft-lbs @ 3500 RPM (estimated, specific figures vary by model and tuning)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI) - Harley-Davidson's system.
Fuel Type:
Unleaded Gasoline, 91 octane (RVP 70) or higher recommended.
Oil Type:
Harley-Davidson recommends SYN3 (5W-30 Synthetic) or H-D 20W-50 Motorcycle Oil. Conventional 20W-50 is also acceptable.
Length:
Varies by model (approx. 96-100 inches)
Wheelbase:
63.5 inches (1612.9 mm) typical
Seat Height:
26.1 inches (662.9 mm) typical (unladen)
Dry Weight:
Approximately 700-750 lbs (317-340 kg) depending on model
Gross Vehicle Weight Rating:
Typically around 1200 lbs (544 kg)
Safety Ratings:
Motorcycles are not subjected to formal crash test ratings like automobiles. Safety depends on rider skill, adherence to maintenance, and responsible operation.
Active Safety Features:
Disc brakes (front and rear), responsive suspension, stable chassis design. Advanced rider aids like ABS were not standard or widely available on all 2006 touring models.
Passive Safety Features:
Sturdy frame construction, integrated saddlebags and fairings offer some protection. Rider protective gear is essential.
Infotainment System:
Many touring models in 2006 featured premium sound systems with AM/FM radio, CD player (often single disc, dash-mounted or in tour-pak), and handlebar-mounted controls. Some models might have had CB radio and intercom options.
Driver Assistance:
Limited. Primarily focused on ergonomics and handling. Cruise control was often an option or standard on higher trims like the FLHTCI.
Connectivity:
Basic connectivity primarily through the audio system. No integrated smartphone connectivity or Bluetooth in this era.
Initial Service:
Typically 1,000 miles (1,600 km) for the first service, including oil change, primary chain tension check, and general inspection.
Routine Maintenance:
Oil changes every 5,000 miles (8,000 km) or annually, whichever comes first. Other checks and services at 5,000, 10,000, 20,000-mile intervals (e.g., brake fluid, spark plugs, drive belt inspection, fork oil).
Engine Oil Capacity:
Approximately 3.5 US quarts (3.3 liters) with filter change.
Primary Chain Case Oil Capacity:
Approximately 1.2 US quarts (1.1 liters).
Transmission Oil Capacity:
Approximately 0.9 US quarts (0.85 liters).
Brake Fluid Type:
DOT 4 (for clutch and brake systems where applicable). Always consult the specific manual for the exact specification.
Common Issues Twin Cam 96:
While the Twin Cam 96 is generally robust, common areas for attention include cam chain tensioners (earlier versions), potential oil leaks from seals, and wear on the primary drive components. Clutch adjustments and primary fluid level are critical. Overheating can be a concern on very hot days or in stop-and-go traffic without proper airflow.
Electrical Common Issues:
Aging wiring harnesses, charging system issues (stator, regulator), and junction box corrosion can occur. Ensure all connections are clean and secure.
Brand Heritage:
Harley-Davidson, founded in 1903, has a long and storied history in motorcycle manufacturing, particularly known for its V-twin engines and iconic cruiser styling. The Touring line has evolved from early dressers to the sophisticated machines of the 2000s.
Model Evolution Touring:
The FL models represent Harley-Davidson's long-standing commitment to touring motorcycles. The introduction of the Twin Cam engine family and subsequent refinements in chassis and features defined this era, with the Twin Cam 96 being a significant upgrade in displacement and torque over earlier models.
Production Years Twin Cam 96:
The Twin Cam 96 engine was introduced in 2007 model year as the standard for most Harley-Davidson motorcycles, including the touring line. However, some sources indicate its introduction for certain models earlier, or that 2006 was a transition year, with some models potentially having the Twin Cam 88 and others the 96. This manual explicitly states '06, suggesting coverage for the earliest Twin Cam 96 deployments or overlap. For clarity, the Twin Cam 96 was officially rolled out for the 2007 model year, making the '06 specification potentially for specific early builds or a slightly earlier introduction of the engine architecture in some contexts, which this manual addresses.
