Positioning:
The Harley-Davidson Sportster XLH series represented a more accessible entry point into Harley ownership, known for its classic styling and V-twin character. This manual serves owners and independent shops seeking to maintain and repair these iconic motorcycles.
Competitors:
Competes with other V-twin cruisers from brands like Indian, Yamaha (V-Star), Honda (Shadow), Kawasaki (Vulcan), and Suzuki (Intruder) in its segment.
Features Of Bike:
Air-cooled Evolution V-twin engine, belt drive, classic styling, customizable platform, responsive handling for its class.
Value:
Empowers owners with the knowledge to perform their own maintenance and repairs, saving on dealership costs and fostering a deeper connection with their machine.
Markets Covered:
North America, Europe, Asia-Pacific (based on typical Harley-Davidson distribution for this era)
Estimated Page Count:
700-900 pages (typical for a comprehensive workshop manual of this era)
Type:
Workshop Service Repair Manual
Format:
Instant Download (likely PDF)
Engine:
Engine disassembly, assembly, inspection, overhaul, troubleshooting, specific component repairs (carburetor, ignition, lubrication, cooling)
Transmission:
Gearbox operation, disassembly, assembly, troubleshooting, clutch operation and adjustment, final drive maintenance
Chassis:
Frame inspection, fork and suspension service, wheel and tire maintenance, brake system service (hydraulic and mechanical components), steering system service
Electrical:
Wiring diagrams, lighting system, ignition system, charging system (alternator, regulator), starting system, battery service, instrumentation, accessory installation
Fuel System:
Carburetor adjustment and overhaul (e.g., Keihin CV), fuel tank service, fuel lines, fuel filter replacement
Bodywork And Trim:
Fender removal and installation, fuel tank removal and installation, seat service, handlebar and control adjustments, minor body panel repairs and painting guidelines
Preventative Maintenance:
Routine checks, lubrication points, fluid changes, filter replacements, bolt torque specifications
Troubleshooting:
Diagnostic procedures for common issues, symptom-based troubleshooting guides, electrical system diagnostics
Repair Procedures:
Step-by-step instructions for component disassembly, overhaul, and reassembly for all major systems
Special Tools:
Identification and usage of specialized tools required for specific repair procedures
Depth:
Comprehensive (covers everything from basic maintenance to complete engine and transmission rebuilds)
Format Details:
Digital download, typically PDF for ease of searching and printing
Quality:
High-resolution scans or digital originals, ensuring clarity of diagrams and text
Binding:
Not Applicable (Instant Download)
Paper Type:
Not Applicable (Instant Download)
Engine Type:
Air-cooled, Evolution V-twin
Displacement 883:
883 cc (53.9 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:
8.4:1 (typical)
Compression Ratio 1200:
9.0:1 (typical)
Horsepower Approx 883:
50-55 HP (at crankshaft, approximate)
Horsepower Approx 1200:
65-70 HP (at crankshaft, approximate)
Torque Approx 883:
50-55 ft-lbs (at crankshaft, approximate)
Torque Approx 1200:
65-70 ft-lbs (at crankshaft, approximate)
Fuel Delivery:
Carburetor (typically Keihin CV 40mm for 1200cc, Keihin CV 34mm for 883cc)
Fuel Type:
Unleaded Gasoline, minimum 91 octane (R+M)/2 (95 RON)
Oil Capacity:
Approx. 3 quarts (2.8 liters) with filter change
Oil Type:
Harley-Davidson SYN3 Synthetic Motorcycle Oil (20W-50) or equivalent API SG, Jaso MA rated oil
Type:
5-speed constant mesh, helical gear
Clutch Type:
Wet, multi-plate
Primary Drive:
Chain drive, 34/46 ratio
Final Drive:
Belt drive, 32/65 ratio
Transmission Fluid Type:
Harley-Davidson Primary Chain Case Oil or SAE 50 motorcycle oil
Transmission Fluid Capacity:
Approx. 1 quart (0.95 liters)
Crash Test Ratings:
Not Applicable (Motorcycle) - focus is on mechanical and operational safety systems.
Braking System:
Single disc front and rear with hydraulic actuation. Front caliper typically 2-piston, rear caliper typically 1-piston. ABS was not standard or commonly available on this model year.
Lighting:
Halogen headlamp, LED taillight, incandescent turn signals.
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Services:
Every 5,000 miles (8,000 km) or 12 months
Engine Oil Viscosity:
20W-50
Brake Fluid Type:
DOT 4 (for hydraulic systems)
Fork Oil Type:
Harley-Davidson Type 'E' or equivalent SAE 10W fork oil (check specific model for exact type)
Common Wear Items:
Clutch plates, drive belt, wheel bearings, fork seals, carburetor adjustments (idle stability), ignition coil issues (less common).
Electrical Considerations:
Corrosion on connectors, aging wiring harness insulation, starter solenoid reliability.
Spark Plugs:
Harley-Davidson OE (e.g., NGK Iridium CR10EIX or equivalent)
Oil Filter Part Number:
Harley-Davidson OE 63796-77B or equivalent aftermarket (e.g., K&N KN-170, Mann-Filter ML092)
Air Filter Part Number:
Harley-Davidson OE 29442-99 or equivalent aftermarket
Heritage:
Harley-Davidson, founded in 1903, is an American motorcycle manufacturer with a long history of producing iconic V-twin engines and cruiser-style motorcycles.
Sportster Lineage:
The Sportster line originated in 1957 and has evolved significantly, with the Evolution engine being introduced in 1986. The 2006 models represent a mature iteration of the Evolution-powered Sportster.
Manufacturing Location:
United States (Milwaukee, Wisconsin)
