🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster XLH

Year:

2006

👋 Introduction

Market Position:

The Harley-Davidson Sportster line represents an iconic and enduring segment of the cruiser motorcycle market, appealing to riders seeking a classic V-twin experience with a blend of performance and style. The XLH models, particularly for 2006, are renowned for their accessibility and customization potential.

Competitive Landscape:

Competes with similar displacement models from Japanese manufacturers (e.g., Honda Shadow, Yamaha V-Star, Suzuki Boulevard) and other American V-twin brands, offering a distinct Harley-Davidson character and community.

Key Features Of The Vehicle:

Characterized by its Evolution V-twin engine, robust chassis, and classic styling. The 2006 models often featured a carbureted engine, offering a more visceral riding experience for traditionalists. Known for its accessible seat height and manageable weight within the Harley-Davidson lineup.

📋 Manual Details

Manual Type:

Factory Service Repair Workshop Manual

Language:

English

Format:

Downloadable PDF

Page Count:

Detailed (Exact count not specified, but comprehensive factory manuals typically exceed 500 pages)

📖 Manual Coverage

Engine Systems:

Engine disassembly, assembly, inspection, lubrication, cooling system, fuel system (carburetion/injection), ignition system, exhaust system, starting system, charging system

Drivetrain Systems:

Transmission (gearbox), clutch, primary drive, final drive (belt/chain), drive shafts, bearings

Chassis Systems:

Frame, suspension (front forks, rear shocks), steering, wheels, tires, brakes (front and rear systems, hydraulic components), swingarm

Electrical Systems:

Wiring diagrams, lighting, instruments, ignition switches, batteries, fuses, relays, sensors, ECUs (Electronic Control Units), diagnostics

Bodywork And Accessories:

Body panels, fuel tank, seat, fenders, handlebars, controls, accessories installation, cosmetic repairs

Maintenance Procedures:

Routine service, oil changes, filter replacements, spark plug service, chain/belt adjustments, brake fluid service, battery maintenance, tire pressure checks

Repair Procedures:

Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper service, electrical component diagnosis and replacement, fuel system repair

Troubleshooting:

Diagnostic charts, fault finding for electrical and mechanical issues, common problems and solutions

Technical Specifications And Data:

Torque specifications, clearances, fluid capacities, electrical resistance values, timing specifications, component tolerances

Depth Of Coverage:

Comprehensive: Covers everything from basic scheduled maintenance and minor repairs to complete engine and transmission overhauls, electrical system diagnostics, and frame-off restorations.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Print Quality:

High-resolution, designed for clear printing of text and diagrams. Searchable text is typically included in professionally produced PDF manuals.

Binding Type:

Not Applicable (Downloadable PDF format)

Paper Type:

Not Applicable (Digital format)

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-twin

Displacement:

Typically 88 cubic inches (1449cc) for the XLH models, though variations might exist. The manual will detail specific displacements.

Horsepower:

Approximately 65-70 HP (Varies by specific model variant and tuning)

Torque:

Approximately 70-75 lb-ft @ 3200 RPM (Varies by specific model variant)

Fuel Delivery:

Carbureted (e.g., Keihin CV Carburetor - specific model to be confirmed in manual) for most 2006 XLH models, though some might have early EFI. Manual will cover specific configuration.

Fuel Type:

Unleaded gasoline, minimum 91 octane (RON+MON)/91 AKI recommended

Ignition Type:

Electronic, breakerless

Oil Type:

Harley-Davidson SYN3 (or equivalent SAE 20W-50 motorcycle oil meeting Harley-Davidson specifications)

Oil Capacity:

Approximately 3 quarts (2.8 liters) with filter change (Specific capacity to be verified in the manual)

🔧 Transmission

Transmission Type:

5-speed constant mesh, manual transmission

Optional Transmission:

None specified for 2006 XLH models.

Clutch Type:

Wet, multi-plate

Primary Drive:

Hyphoid gears, chain drive

Final Drive:

Belt drive

Transmission Oil Type:

Harley-Davidson Formula Plus (or equivalent SAE 80W-90 GL-5 gear oil)

Transmission Oil Capacity:

Approximately 20 oz (0.6 liters) (Specific capacity to be verified in the manual)

📐 Dimensions

Length:

Varies by specific Sportster model (e.g., 88.5 inches / 2248 mm for XLH883)

Width:

Varies by specific Sportster model (e.g., 33.5 inches / 851 mm)

Height:

Varies by specific Sportster model (e.g., 49.4 inches / 1255 mm)

Wheelbase:

Varies by specific Sportster model (e.g., 60.0 inches / 1524 mm)

Dry Weight:

Approximately 500-550 lbs (227-250 kg) depending on the specific model (e.g., XLH883, XLH1200)

Gvwr:

Not explicitly stated for all models, but typically around 900-1000 lbs (408-454 kg)

Fuel Tank Capacity:

Typically 3.0 gallons (11.4 liters) for standard tanks, or 4.7 gallons (17.8 liters) for larger custom tanks (check manual for specific model)

🛡️ Safety Features

Safety Ratings:

Motorcycles are not typically assigned the same safety ratings (e.g., NCAP) as automobiles. Safety is assessed by rider skill and adherence to traffic laws.

Active Safety Features:

Disc brakes (front and rear), well-balanced chassis for stability. ABS was not standard or widely available on Sportster models in 2006.

Passive Safety Features:

Robust frame construction, rider ergonomics for control.

💡 Technology Features

Infotainment Systems:

Basic instrumentation: speedometer, odometer, tachometer (on some models), engine warning lights. No integrated infotainment systems like modern motorcycles.

Driver Assistance Features:

None. Safety relies on rider input and basic mechanical systems.

Connectivity Features:

None. Standalone motorcycle with no external connectivity.

Diagnostic Capabilities:

The manual provides detailed procedures for using diagnostic tools (like Harley-Davidson's Digital Technician if applicable to the era, or manual troubleshooting guides) to identify issues with the EFI system (if equipped) and other electronic components.

🔧 Maintenance

First Service:

1,000 miles (1,600 km) or 6 months, whichever comes first (includes oil change, primary chain adjustment, inspection)

Subsequent Service Intervals:

Every 5,000 miles (8,000 km) or 12 months for most service items, with more detailed inspections recommended at higher mileages (e.g., 10,000 miles, 15,000 miles). Detailed schedule in the manual.

Brake Fluid:

DOT 4 (or specified Harley-Davidson equivalent)

Fork Oil:

Harley-Davidson Type E or H-D 10WT (or equivalent SAE 10W fork oil). Capacity per fork leg will be specified in the manual.

Common Wear Items:

Clutch wear, belt drive tension and wear, front fork seals, brake pad wear, battery life.

Potential Electrical Issues:

Aging wiring harnesses, regulator/stator issues (though improved on Evolution engines), battery charging problems can occur over time.

Engine Specifics:

While generally robust, consistent oil changes and proper maintenance are crucial. Carburetor tuning may be required periodically.

📚 Vehicle History

Brand Heritage:

Harley-Davidson, founded in 1903, is one of the most iconic motorcycle manufacturers globally, synonymous with the American V-twin cruiser. The Sportster line, introduced in 1957, is the longest-running motorcycle model in continuous production.

Sportster Evolution Overview:

The Sportster has evolved significantly from its early Ironhead engine to the Evolution engine, which was introduced in 1986. The 2006 models represent a mature stage of the Evolution engine's development, offering a balance of classic character and modern reliability. Key updates in this era included revised ergonomics, improved braking, and chassis refinements.

Manufacturing Location:

United States (primarily Milwaukee, Wisconsin, and York, Pennsylvania)

🏆 Awards & Recognition

Model Recognitions:

The Sportster line itself has received numerous accolades over its decades of production for its enduring design and contribution to motorcycling culture. Specific awards for the 2006 model year are not typically highlighted in general reviews, but its longevity speaks to its success.

Consumer Ratings:

Sportster models are generally well-regarded by owners for their authentic V-twin character, customization potential, and community support. Reviews often praise the accessible nature and classic riding experience.