Market Segment:
Cruiser Motorcycle Segment, Entry-level to Mid-range Harley-Davidson
Competitors 2006:
Indian Chief, Triumph Bonneville, Yamaha V-Star, Honda Shadow, Kawasaki Vulcan
Vehicle Appeal:
Iconic styling, V-twin rumble, Customizable platform, Accessible Harley-Davidson ownership experience
Target Audience:
Professional Technicians, Experienced DIY Mechanics, Harley-Davidson Enthusiasts
Benefit To Owner:
Enables proper maintenance, efficient troubleshooting, and reliable repairs, saving time and money.
Primary Coverage:
Repair, Service, Troubleshooting, Maintenance
Secondary Coverage:
Diagnostics, Component Replacement, Specifications
Estimated Page Count:
500-700
Type:
Factory Service Manual (FSM) / Repair Manual
Engine:
Engine Mechanical (Disassembly, Assembly, Reassembly), Fuel System (Carburetor tuning, Fuel pump, Lines), Ignition System, Lubrication System, Cooling System (Air-Cooled)
Transmission:
5-Speed Constant Mesh Gearbox (Disassembly, Assembly, Adjustment), Clutch System, Primary Drive System
Electrical:
Wiring Diagrams, Lighting System, Ignition System, Charging System (Stator, Regulator/Rectifier), Starting System (Starter Motor, Solenoid), Instrument Cluster, Switches, Fuses, Relays
Chassis And Suspension:
Frame, Front Fork (Internal components, Oil levels, Seals), Rear Shocks (Adjustment, Replacement), Swingarm, Bearings (Steering Head, Swingarm)
Brakes:
Front and Rear Brake Systems (Hydraulic), Calipers, Rotors, Master Cylinders, Brake Lines, Bleeding Procedures
Bodywork And Trim:
Fuel Tank, Fenders, Seat, Handlebars, Controls, Mirrors, Paint and Finish Recommendations
Maintenance:
Oil Changes, Filter Replacements, Spark Plug Replacement, Air Filter Cleaning/Replacement, Chain Adjustment/Lubrication, Brake Pad Inspection/Replacement, Tire Pressure Checks, Battery Maintenance
Repair:
Engine Rebuilds (Top-end and Bottom-end), Transmission Overhaul, Clutch Replacement, Fork Seal Replacement, Brake System Overhaul, Electrical Component Diagnosis and Replacement, Carburetor Rebuild and Tuning
Troubleshooting:
Diagnostic Flowcharts, Symptom-Based Troubleshooting for Engine, Electrical, and Drivetrain Issues
Specifications And Data:
Torque Specifications, Clearances, Fluid Types and Capacities, Electrical Resistance Values, Timing Data
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics)
Engine Type:
Air-Cooled, 45-degree V-Twin, Evolution Engine
Displacement:
1200 cc (73.7 cubic inches)
Bore X Stroke:
3.496 in. x 3.800 in. (88.8 mm x 96.5 mm)
Valve Train:
Pushrod-activated, Overhead Valves (OHV), 2 valves per cylinder
Horsepower Est:
67 HP @ 5000 RPM (approximate, varies by tuning)
Torque Est:
70 lb-ft @ 3500 RPM (approximate, varies by tuning)
Carburetor:
Keihin CV 40mm (Constant Velocity)
Fuel Capacity:
3.1 US gallons (11.7 Liters)
Fuel Type:
Unleaded Gasoline, 91 Octane (95 RON) or higher recommended
Oil Type Engine:
Harley-Davidson 20W-50 or equivalent motorcycle-specific synthetic
Oil Capacity Engine W Filter:
3.0 US quarts (2.8 Liters)
Ignition System:
Electronic Ignition with Single Fire Coil
Transmission Type:
5-Speed Manual, Constant Mesh
Optional Transmission:
N/A (Standard 5-speed)
Clutch Type:
Wet, Multi-plate, Diaphragm Spring
Primary Drive:
Duplex Chain, 34/48 Tooth Sprockets (1.41:1 Ratio)
Final Drive:
Belt Drive, 29/65 Tooth Pulleys (2.24:1 Ratio)
Transmission Oil Type:
Harley-Davidson Primary Chaincase Lubricant or equivalent heavy-duty primary fluid
Transmission Oil Capacity:
26 US fluid ounces (770 ml)
Crash Test Ratings:
N/A (Motorcycles are not subject to standardized automotive crash testing like cars)
Braking System:
Dual-piston front caliper, Single-piston rear caliper, Disc brakes front and rear
Lighting:
Halogen Headlight, LED Taillight, Incandescent Turn Signals
Frame Construction:
Mild steel, two-piece welded backbone and downtube with forged and cast steel components
Instrumentation:
Analog Speedometer, Tachometer, Fuel Gauge, Oil Pressure Light, Neutral Indicator, Turn Signal Indicators, High Beam Indicator
ABS:
N/A (Anti-lock Braking System not standard or optional on most 2006 Sportster models)
Connectivity Features:
N/A (No Bluetooth or smartphone integration)
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months
Engine Oil Change:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first
Transmission Oil Change:
Every 10,000 miles (16,000 km) or 24 months
Fork Oil Type:
Harley-Davidson Type E Fork Oil or equivalent (e.g., Bel-Ray 10W)
Fork Oil Level:
Refer to manual for specific level (typically measured from top of fork tube with spring removed)
Brake Fluid Type:
DOT 5.1 Silicone-based (avoid DOT 3/4 if possible to prevent seal swelling, though some may have been spec'd with DOT 4)
Carburetor Issues:
CV carb can require tuning for optimal performance, especially with exhaust/intake modifications. Jetting can be sensitive.
Electrical Issues:
Wiring harness integrity can degrade over time, leading to intermittent electrical faults. Regulator/rectifier failure is not uncommon.
Transmission Issues:
Clutch adjustment may be needed periodically. Shifting can be stiff if oil is old or incorrect type.
Front Fork Leaks:
Fork seals can degrade, leading to leaks. Regular inspection and replacement are advised.
Harley Davidson Founding:
Founded in 1903 by William S. Harley, Arthur Davidson, Walter Davidson, and William A. Davidson
Sportster Introduction:
The Sportster line was introduced in 1957 as a successor to the K-Model, featuring the Ironhead engine initially, and later the Evolution engine.
Xlh Evolution Engine:
The Evolution engine was introduced in 1984, offering improved reliability, performance, and reduced vibration compared to the Ironhead.
2006 Updates:
The 2006 models largely carried over the Evolution engine platform, with minor refinements in styling and componentry. Key focus was on reliability and emissions compliance for the era.
Manufacturing Location:
United States (Milwaukee, Wisconsin and Kansas City, Missouri)
