Market Segment:
Cruiser Motorcycle segment, known for its iconic styling and customizable platform.
Competitors 2006:
Competed against models from brands like Indian, Triumph (Bonneville), and other cruiser offerings from Japanese manufacturers like Honda (Shadow series), Yamaha (V-Star series), and Kawasaki (Vulcan series).
Sportster Appeal:
The Sportster line in 2006 offered a blend of classic Harley-Davidson V-twin character, accessible handling, and a wide range of customization options, making it popular for both new and experienced riders.
Value To Owner:
Empowers owners to perform routine maintenance, diagnose issues, and undertake repairs, saving money on dealership service costs and increasing their understanding and connection with their motorcycle.
Models Covered:
All 2006 Harley-Davidson Sportster models including XL883, XL883C (Custom), XL883L (Low), XL883R (Roadster), XL1200C (Custom), XL1200L (Low), XL1200R (Roadster)
Estimated Page Count:
Approximately 600-800 pages (typical for a comprehensive Harley-Davidson service manual of this era)
Manual Type:
Service Repair Manual
Format:
Downloadable Digital File (PDF)
Engine:
All aspects of the Evolution (V-Twin) engine, including disassembly, assembly, inspection, tuning, and repair for both 883cc and 1200cc variants.
Fuel System:
Carburetor (Keihin CV) and Fuel Injection (EFI) systems, including diagnostics, adjustments, component testing, and component replacement.
Ignition System:
Ignition module, coils, spark plugs, and related wiring, including troubleshooting and component replacement.
Transmission:
5-speed gearbox, including clutch operation, gear engagement, lubrication, inspection, and rebuild procedures.
Drivetrain:
Belt drive system, including belt tension adjustment, inspection, and replacement procedures.
Brakes:
Front and rear braking systems, including hydraulic lines, master cylinders, calipers, rotors, and bleeding procedures.
Suspension:
Front forks (including telescopic fork oil changes and seal replacement) and rear shock absorbers, including adjustment and replacement.
Electrical System:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), starter motor, lighting, instrumentation, and switches.
Frame And Bodywork:
Frame inspection, body panel removal and installation, fenders, fuel tank, seat, handlebars, and control levers.
Wheels And Tires:
Wheel bearing maintenance, tire inspection and replacement, and balancing procedures.
Maintenance:
Routine maintenance tasks such as oil changes, filter replacements, spark plug service, chain/belt adjustments, brake checks, and lubrication points.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, including symptom identification, fault finding, and corrective actions.
Repair:
Step-by-step repair instructions for virtually all mechanical and electrical components.
Overhaul:
Complete engine and transmission overhaul procedures, including detailed torque specifications and clearances.
Wiring Diagrams:
Comprehensive and color-coded wiring diagrams for the entire electrical system.
Depth:
Comprehensive, covering everything from basic rider maintenance to in-depth engine rebuilding and advanced electrical diagnostics.
Engine Type:
Air-cooled, Evolution V-Twin
Displacement 883:
883 cc (53.7 cubic inches)
Displacement 1200:
1200 cc (73.2 cubic inches)
Bore Stroke 883:
76.2 mm x 96.8 mm (3.00 in x 3.81 in)
Bore Stroke 1200:
88.9 mm x 96.8 mm (3.50 in x 3.81 in)
Compression Ratio 883:
8.8:1 (Typical)
Compression Ratio 1200:
9.0:1 (Typical)
Valve Train:
Pushrod-actuated, overhead valves, 2 valves per cylinder
Horsepower 883:
Approx. 50-55 HP (at crank)
Horsepower 1200:
Approx. 65-70 HP (at crank)
Torque 883:
Approx. 60-65 ft-lbs (at crank)
Torque 1200:
Approx. 70-75 ft-lbs (at crank)
Fuel Delivery 883:
Keihin CV (Constant Velocity) 40mm Carburetor
Fuel Delivery 1200:
Keihin CV 40mm or Electronic Sequential Port Fuel Injection (ESPFI) depending on specific sub-model
Fuel Type:
Unleaded gasoline, minimum 87 octane
Wheelbase Xl883 Variants:
Approximately 59.6 inches (1514 mm)
Wheelbase Xl1200C:
Approximately 60.3 inches (1532 mm)
Seat Height Unladen Xl883L:
Approximately 26.1 inches (663 mm)
Seat Height Unladen Others:
Approximately 28.0 - 29.5 inches (711 - 750 mm), varies by model
Dry Weight Xl883 Variants:
Approximately 500-520 lbs (227-236 kg)
Dry Weight Xl1200C:
Approximately 537 lbs (244 kg)
Gross Vehicle Weight Rating Gvwr:
Typically around 900-930 lbs (408-422 kg), varies by model
Fuel Capacity:
3.1 gallons (11.7 liters) standard tank
Safety Certification:
N/A (Motorcycles typically not rated by NHTSA or Euro NCAP in the same way as cars)
Braking System:
Hydraulic disc brakes, front and rear.
Lighting:
Halogen headlamp, LED tail lamp, incandescent front and rear turn signals.
Frame Construction:
Steel cradle frame, designed for stability and rider feedback.
Initial Service:
1,000 miles (1,600 km) or 6 months, whichever comes first.
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first.
Engine Oil Type:
Harley-Davidson SYN3 (SAE 20W50) synthetic or equivalent motorcycle oil meeting Harley-Davidson H-D 360 specification.
Engine Oil Capacity:
Approximately 3.0 US quarts (2.8 liters) with filter change.
Primary Chain Case Oil:
Harley-Davidson primary chain lubricant or equivalent motorcycle transmission fluid (e.g., SAE 80W-90 GL-5).
Primary Chain Case Oil Capacity:
Approximately 26 US fluid ounces (770 ml).
Transmission Oil:
Harley-Davidson transmission lubricant or equivalent SAE 85W-140 gear oil.
Transmission Oil Capacity:
Approximately 24 US fluid ounces (710 ml).
Brake Fluid:
DOT 4 hydraulic brake fluid.
Fork Oil:
Refer to manual for specific weight and type (e.g., SAE 10W).
Common Wear Items:
Clutch plates, brake pads, wheel bearings, and fork seals are common wear items that may require periodic inspection and replacement.
Efi Diagnostics:
For EFI models, proper diagnostic tools and knowledge are crucial for resolving idle issues, misfires, or fuel delivery problems.
Carburetor Tuning:
CV carburetor requires periodic adjustment of idle mixture, idle speed, and potentially jetting changes based on modifications or altitude.
Harley Davidson Legacy:
Harley-Davidson has a long history of producing iconic motorcycles, with the Sportster line dating back to 1957, evolving from the 'K' model.
Sportster Line 2006:
The 2006 Sportsters represent a significant iteration of the platform, featuring fuel-injected options for the 1200cc models, improved suspension components, and stylistic updates compared to earlier generations.
Manufacturing Location:
York, Pennsylvania, USA and Milwaukee, Wisconsin, USA (assembly)
Sportster Model Recognition:
The Sportster line consistently receives accolades for its iconic styling, customization potential, and spirited performance in the cruiser segment.
Reliability Perception:
Generally perceived as reliable with proper maintenance. The Evolution engine is known for its durability.
Manual Quality Certification:
N/A (Manuals are factory-produced or professionally replicated based on factory standards)
