🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster

Year:

2006

👋 Introduction

Market Segment:

Cruiser motorcycle, popular entry-level and customization platform within the Harley-Davidson lineup.

Key Competitors 2006:

Indian Chief, various Japanese cruiser models (e.g., Yamaha V-Star, Honda Shadow, Kawasaki Vulcan), and other American V-twin motorcycles.

Sportster Identity:

Known for its characterful V-twin engine, accessible price point, and a vast aftermarket for customization. The 2006 model represents a significant evolution leading into fuel injection becoming more standard.

Manual Utility:

Essential resource for owners and technicians to maintain, diagnose, and repair the 2006 Harley-Davidson Sportster, ensuring longevity and optimal performance. The high page count indicates thoroughness.

📋 Manual Details

Coverage:

Workshop Service Repair for Harley-Davidson Sportster 2006

Page Count:

819

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Systems:

Engine overhaul, top-end, bottom-end, lubrication, cooling (air-cooled), fuel system (carbureted and EFI specific for 2006 models), ignition system, exhaust system, performance tuning, troubleshooting.

Transmission Drivetrain:

Clutch operation and service, 5-speed transmission (trapezoidal case design) disassembly and reassembly, primary drive, final drive (belt or chain depending on sub-model), troubleshooting clutch and transmission issues.

Electrical Systems:

Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting (headlight, taillight, turn signals, brake lights), instrumentation, ignition switch, security system (if equipped), troubleshooting electrical faults.

Chassis Suspension Brakes:

Frame and bodywork inspection, front fork service (oil change, seal replacement), rear shock absorber service, wheel bearing maintenance, brake system (calipers, master cylinders, hydraulic lines, pads, rotors), bleeding procedures, troubleshooting brake performance.

Fuel System Carbureted:

Detailed breakdown of Keihin CV 40mm carburetor, including jetting, needle, accelerator pump, idle mixture, and float bowl adjustments, as well as troubleshooting common carburetion issues like bogging, stalling, or poor idle.

Fuel System Efi 2006:

Covers the Electronic Fuel Injection system including the throttle body, fuel pump, injectors, ECM (Engine Control Module), sensors (e.g., MAP, IAT, TPS), and diagnostic routines for EFI models.

Frame And Bodywork:

Instructions for inspecting the frame for damage, removing and reinstalling body panels, fenders, fuel tank, and seat. Includes torque specifications for critical fasteners.

Maintenance Procedures:

Routine scheduled maintenance, oil changes, filter replacements, spark plug service, brake fluid flush, drive belt inspection and tensioning, tire pressure checks, lubrication points, cleaning procedures.

Repair Procedures:

Complete engine rebuilds, transmission overhauls, brake caliper rebuilds, fork seal replacement, electrical component diagnosis and replacement, carburetor tuning and rebuilds (for CV carburetor models), fuel injection system troubleshooting (for EFI models).

Troubleshooting Diagnostics:

Systematic diagnostic trees for common problems, fault code reading (if applicable to EFI models), electrical testing procedures, mechanical component diagnosis.

Diagnostics Electrical Trouble Codes:

For EFI models, the manual will detail diagnostic procedures and potential fault code identification relevant to the year.

Wheel Alignment And Balance:

Procedures for checking and adjusting wheel alignment, and guidance on wheel balancing for optimal ride and tire wear.

Bearing Service:

Guidance on inspection, lubrication, and replacement of wheel bearings, steering head bearings, and swingarm pivot bearings.

Depth Of Coverage:

Comprehensive. Covers everything from basic maintenance and fluid checks to complete engine and transmission teardowns, complex electrical diagnostics, and chassis component overhauls. Suitable for professional mechanics and advanced DIY enthusiasts.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution scans, typically suitable for clear printing.

Binding Type:

Digital (PDF) - No physical binding.

Paper Type:

Digital (PDF) - N/A

Searchable Text:

Typically yes, if the PDF was created from a digitally generated source. Scanned PDFs might have OCR for searchability.

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution (Sportster) V-twin

Engine Displacement:

Typically 883cc (XL883) or 1200cc (XL1200) for the 2006 Sportster range. The manual would cover specific sub-models.

Horsepower Approximate:

883cc: ~53 hp; 1200cc: ~67 hp (at the crankshaft, Varies by model and tuning).

Torque Approximate:

883cc: ~53 lb-ft; 1200cc: ~70 lb-ft (at the crankshaft, Varies by model and tuning).

Fuel Delivery:

Primarily carburetor (Keihin CV 40mm) for most 2006 models, with some potentially offering Electronic Fuel Injection (EFI). Manual covers both.

Bore Stroke 883:

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

Bore Stroke 1200:

3.50 in x 3.81 in (88.9 mm x 96.8 mm)

🔧 Transmission

Transmission Type:

5-speed constant mesh

Optional Transmissions:

N/A for 2006 Sportster, all were 5-speed.

Primary Drive:

Multi-plate wet clutch, enclosed in primary chain case.

Final Drive:

Belt drive (standard on most models), or chain drive on specific sub-models.

Transmission Oil Type:

Harley-Davidson recommended transmission lubricant (e.g., Syn 3 or equivalent API GL-4, SAE 75W-90).

📐 Dimensions

Wheelbase Approx:

Approximately 59.5 inches (1511 mm), varies slightly by model.

Dry Weight Approx:

Around 560-570 lbs (254-259 kg), varies by sub-model (e.g., XL883, XL1200C, XL1200R).

🛡️ Safety Features

Safety Ratings:

Not typically rated by NHTSA/Euro NCAP as motorcycles are excluded from standard automotive crash testing. Manual provides information for safe operation and maintenance.

Braking System:

Hydraulic disc brakes front and rear. ABS was not standard on 2006 Sportsters.

Lighting:

Halogen headlight, taillight, stoplight, front and rear turn signals.

💡 Technology Features

Infotainment System:

Basic instrumentation including speedometer, odometer, tachometer (on some models), and indicator lights. No advanced infotainment systems like touchscreens or Bluetooth were standard.

Driver Assistance Features:

None in the modern automotive sense. Focus is on mechanical and electrical system function.

Connectivity Options:

N/A. Primarily analog systems with basic electrical connections.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 miles or 6 months, whichever comes first. Manual specifies exact intervals and oil types.

Primary Chain Tension:

Check at ~5,000 mile intervals. Manual details procedure.

Engine Oil Type:

Harley-Davidson 20W50 V-Twin Motorcycle Oil (or equivalent API CI-4 or higher).

Primary Chain Case Oil:

Harley-Davidson primary chaincase lubricant or SAE 20W-50 motor oil meeting specific Harley-Davidson standards.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Fork Oil Viscosity:

Typically SAE 10W or SAE 15W fork oil, specified by sub-model. Manual provides exact values.

Common Wear Items:

Clutch wear, primary chain tensioner wear (especially the spring-loaded type), fork seal leaks, voltage regulator failures, wheel bearing wear.

Specific Problems 2006:

Early EFI systems might require diagnostic checks. Carburetor jetting can be model-specific for optimal performance. Belt tension critical.

Oil Filter Part Number:

Examples: Harley-Davidson 63731-35A, aftermarket equivalents such as K&N KN-170C.

Air Filter Part Number:

Varies by sub-model and any aftermarket modifications. Manual will list OE part numbers.

📚 Vehicle History

Harley Davidson Legacy:

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

Sportster Lineage:

The Sportster line dates back to 1957, evolving from the K-model. The 'Evolution' engine (Evo) was introduced in 1986, making the 2006 a mature iteration of this popular platform.

Manufacturing Location:

United States (Milwaukee, Wisconsin; also Kansas City, Missouri).

🏆 Awards & Recognition

Brand Awards:

Harley-Davidson has received numerous accolades for its design, engineering, and brand heritage over its long history. Specific awards for the 2006 Sportster are not commonly highlighted, but its enduring popularity speaks to its success.

Customer Satisfaction:

Sportsters are generally well-regarded for their character and customization potential, often receiving high marks from owners within their segment.