🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster

Year:

2006

Model Line:

Sportster Family (XL models)

Oem Manual Code:

99482-06

👋 Introduction

Target Audience:

Harley-Davidson dealerships, independent repair shops, and skilled DIY enthusiasts.

Value Proposition:

Provides the same authoritative technical information used by authorized Harley-Davidson technicians.

Comparison To Aftermarket:

Offers superior detail, accuracy, and completeness compared to generic aftermarket repair manuals.

Detail Level:

Exceptional detail in procedures, specifications, and diagnostic information.

Illustrations Quality:

Clear, precise illustrations that aid in understanding complex procedures.

Authenticity:

Authentic Harley-Davidson factory documentation, ensuring accuracy for all repairs and maintenance.

📋 Manual Details

Primary Coverage:

Complete service and repair for 2006 Harley-Davidson Sportster models

Secondary Coverage:

Maintenance, troubleshooting, diagnostics, specifications

Estimated Pages:

Approximately 600+

Type:

Factory Service Manual / Workshop Manual

Language:

English

Format:

Printed Book

📖 Manual Coverage

Engine Overhaul:

Complete engine disassembly, inspection, repair, and reassembly procedures for Evolution engine variants.

Fuel System:

Carburetor (Keihin CV) and Fuel Injection (EFI) system diagnostics, adjustment, and repair.

Ignition System:

Ignition module, spark plugs, coils, and related components diagnosis and service.

Transmission:

5-speed constant mesh transmission service, clutch operation, and primary drive system.

Drivetrain:

Belt drive system maintenance, adjustment, and inspection.

Frame And Suspension:

Front fork service (including seals and oil), rear shock absorber replacement, frame inspection, and alignment.

Wheels And Tires:

Wheel bearing service, tire replacement, wheel balancing, and spoke tensioning (if applicable).

Brakes:

Front and rear brake system overhaul, including caliper service, master cylinder, hydraulic lines, and pad replacement.

Electrical System:

Wiring diagrams, battery, charging system (stator, regulator/rectifier), starting system, lighting, and instrumentation.

Body And Fenders:

Body panel removal and installation, fender adjustments, and seat mounting.

Controls:

Handlebar controls, throttle, clutch and brake levers, and foot controls.

Exhaust System:

Exhaust component inspection and replacement.

Scheduled Maintenance:

Detailed service intervals for oil changes, filter replacements, spark plug service, and more.

Troubleshooting Guides:

Systematic troubleshooting procedures for common and uncommon problems with diagnostic flowcharts.

Component Diagnostics:

Step-by-step diagnostic routines for all major electrical and mechanical components.

Disassembly Assembly:

Comprehensive instructions for removing, overhauling, and reinstalling all major assemblies and components.

Adjustments:

Detailed procedures for adjusting carburetors, clutches, drive belts, and other critical components.

Specifications Data:

Torque values, clearances, fluid capacities, and other critical technical specifications.

Wiring Diagrams:

Detailed, color-coded wiring diagrams for all electrical systems.

Depth:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds.

Illustrations:

Numerous detailed exploded views, diagrams, and photographic illustrations.

Diagnostic Tools:

Information relevant to using Harley-Davidson's Digital Technician II for EFI models.

📊 Manual Specifications

Format Details:

Physical printed book with durable cover and binding.

Print Quality:

High-quality paper stock for durability and clear reproduction of illustrations.

Binding:

Staple-bound or perfect-bound, designed for shop use.

Paper Type:

Durable, often coated paper to resist grease and shop contaminants.

⚙️ Engine Specifications

Engine Family:

Harley-Davidson Evolution (Evo) V-Twin

Engine Displacement Xl883:

883 cc (53.9 cubic inches)

Engine Displacement Xl1200:

1200 cc (73.2 cubic inches)

Bore Stroke Xl883:

76.2 mm x 96.8 mm (3.00 in x 3.81 in)

Bore Stroke Xl1200:

88.8 mm x 96.8 mm (3.496 in x 3.811 in)

Compression Ratio Xl883:

8.8:1 (typical, can vary slightly)

Compression Ratio Xl1200:

9.0:1 (typical, can vary slightly)

Engine Type:

Air-cooled, 45-degree V-twin, pushrod actuated overhead valves

Horsepower Xl883:

Approx. 50-55 HP (at crankshaft, estimated)

Torque Xl883:

Approx. 55-60 lb-ft (at crankshaft, estimated)

Horsepower Xl1200:

Approx. 65-70 HP (at crankshaft, estimated)

Torque Xl1200:

Approx. 70-75 lb-ft (at crankshaft, estimated)

Fuel Delivery Carb:

Keihin CV 40mm (Carbureted models)

Fuel Delivery Efi:

Electronic Fuel Injection (EFI) with 38mm throttle body (EFI models)

Fuel Type:

Unleaded gasoline, minimum 91 octane recommended

🔧 Transmission

Type:

5-speed, constant mesh, sequential manual transmission

Optional Transmissions:

N/A for 2006 Sportster models

Clutch Type:

Wet, multi-plate, diaphragm spring

Primary Drive:

3-inch belt drive

Final Drive:

Enclosed, right-side, carbon fiber reinforced belt

Transmission Fluid Spec:

Harley-Davidson Transmission and Primary Chaincase Lubricant (or equivalent SAE 80W-90 hypoid gear oil)

Transmission Fluid Capacity:

Approx. 20-24 fl oz (600-700 ml)

📐 Dimensions

Wheelbase:

Approx. 56.5 inches (1435 mm)

Length:

Approx. 84.2 inches (2139 mm)

Seat Height Laden:

Approx. 26.1 inches (663 mm)

Ground Clearance:

Approx. 4.0 inches (102 mm)

Dry Weight Xl883:

Approx. 500 lbs (227 kg)

Dry Weight Xl1200:

Approx. 505 lbs (229 kg)

Gross Vehicle Weight Rating:

Approx. 937 lbs (425 kg)

Fuel Capacity:

3.0 gallons (11.4 L)

Oil Capacity:

Approx. 3.0 quarts (2.8 L)

🛡️ Safety Features

Safety Ratings:

Motorcycles are not subject to the same safety rating standards as automobiles (e.g., NHTSA crash tests).

Active Safety:

Disc brakes (front and rear), good chassis dynamics and rider control.

Passive Safety:

Sturdy frame construction.

💡 Technology Features

Infotainment System:

Minimal by modern standards. Features a speedometer, tachometer (optional on some models), odometer, trip meter, and indicator lights.

Driver Assistance:

N/A (motorcycle)

Connectivity:

N/A (motorcycle, unless aftermarket additions are made)

Diagnostic Interface:

OBD-II port for EFI models, allowing connection to diagnostic tools like Harley-Davidson's Digital Technician II for reading fault codes and live data.

🔧 Maintenance

Initial Service:

First service recommended at 1,000 miles (1600 km).

Regular Oil Change:

Every 5,000 miles (8,000 km) or annually, whichever comes first.

Spark Plug Replacement:

Recommended every 10,000 miles (16,000 km).

Drive Belt Inspection:

Inspect and adjust tension at 2,500 mile intervals and every 6 months.

Engine Oil:

Harley-Davidson SYN3 (20W-50 Full Synthetic) or similar motorcycle-specific 20W-50 oil.

Primary Chaincase Fluid:

Harley-Davidson Primary Chaincase Lubricant (or equivalent SAE 80W-90 hypoid gear oil)

Brake Fluid:

DOT 4 brake fluid (for hydraulic clutch and brake systems).

Fork Oil:

Harley-Davidson Spectro HD 10W fork oil or equivalent (refer to manual for specific fork types).

Common Wear Items:

Clutch plates, brake pads, drive belt, fork seals, wheel bearings.

Electrical Concerns:

Voltage regulator failure (less common on later Evos but possible), starter solenoid issues, wiring harness wear.

Engine Wear:

While generally robust, premature valve guide wear or oil consumption can occur with high mileage or aggressive use.

Transmission Noise:

Some inherent transmission noise (clatter) is characteristic of the Sportster 5-speed, but excessive grinding or popping requires immediate attention.

📚 Vehicle History

Heritage Overview:

Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and distinctive styling.

Sportster Lineage:

The Sportster line, introduced in 1957, is Harley-Davidson's longest-running model. It has evolved significantly over the decades, maintaining its reputation as a lighter, sportier alternative to larger Harley models.

2006 Updates:

The 2006 model year saw continued refinement of the Evolution engine, including upgrades to the fuel system (EFI becoming more prevalent on 1200 models) and chassis components.

Production Location:

United States (Kansas City, Missouri)

🏆 Awards & Recognition

Awards:

The Harley-Davidson Sportster has consistently been a popular and well-regarded motorcycle in its class, contributing significantly to the brand's sales and cultural impact. Specific awards for the 2006 model year are not widely publicized as the focus is on its enduring legacy and functionality.