🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster XLH

Model Variant:

XLH Series (including XLH883, XLH1200)

Year:

2006

Engine Family Code:

Evolution (Evo)

Chassis Code:

XL

👋 Introduction

Target Audience:

Harley-Davidson owners, independent repair shops, enthusiasts performing their own maintenance and repairs

Value Proposition:

Provides dealer-level expertise, saving significant costs on professional servicing and repairs

Comparison To Oem:

Offers equivalent technical depth and accuracy to official Harley-Davidson factory service manuals

Diagnostic Tools:

Includes information on diagnostic fault codes and troubleshooting methods, although direct mention of specific electronic diagnostic tools is limited in manuals of this era (primarily mechanical diagnostics)

Step By Step Guides:

Emphasizes clear, sequential instructions for complex procedures

Diagram Rich:

Extensive use of visual aids to clarify mechanical relationships and assembly sequences

📋 Manual Details

Manual Type:

Workshop Service & Repair Manual

Language:

English

Format:

Digital Download (PDF)

Estimated Page Count:

400-600 (typical for comprehensive Harley-Davidson workshop manuals)

Content Type:

Comprehensive, dealer-level technical information

📖 Manual Coverage

Engine:

883cc and 1200cc Evolution V-Twin engine disassembly, assembly, tuning, diagnostics

Fuel System:

Carburetor (Keihin CV) tuning, overhaul, and troubleshooting; fuel tank, fuel lines, and fuel pump inspection

Ignition System:

Electronic ignition system diagnostics, component testing, timing adjustments

Transmission:

5-speed constant mesh transmission disassembly, assembly, gear inspection, clutch operation

Drivetrain:

Primary drive system (clutch, compensator), final drive belt inspection and adjustment

Brakes:

Front and rear hydraulic disc brake system service, caliper overhaul, pad replacement, fluid flush

Suspension:

Front fork (conventional telescopic) disassembly, seal replacement, oil level/viscosity specifications; rear shock absorber inspection and replacement

Electrical System:

Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting, switches, and accessories

Frame And Bodywork:

Frame inspection, component removal/installation (fenders, tank, seat), handlebars, controls

Wheels And Tires:

Wheel bearing service, tire pressure recommendations, wheel removal/installation

Maintenance:

Scheduled maintenance, oil changes, filter replacements, brake fluid flushes, belt inspections

Troubleshooting:

Diagnostic charts and procedures for common running issues, electrical faults, and component failures

Repair:

Step-by-step instructions for component disassembly, overhaul, assembly, and adjustment

Diagnostics:

Component testing procedures, specifications, and expected results

Performance Tuning:

Carburetor jetting, ignition timing adjustments for optimal performance

Depth Level:

Complete rebuild and overhaul of all major mechanical and electrical systems

Diagrams:

Detailed exploded views and step-by-step diagrams for all procedures

Specifications:

Torque specifications, clearances, fluid capacities, electrical resistance values, timing settings

📊 Manual Specifications

File Type:

PDF

Searchability:

Text-searchable, allowing quick access to specific topics

Printability:

Printable pages for use in a workshop environment

Image Resolution:

High-resolution images and diagrams ensuring clarity

Binding Type Digital:

N/A (Digital Download)

Paper Type Digital:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Harley-Davidson Evolution (Evo) V-Twin

Displacement Variants:

883cc (XLH883) and 1200cc (XLH1200)

Bore X Stroke 883Cc:

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

Bore X Stroke 1200Cc:

3.44 in. x 4.00 in. (87.4 mm x 101.6 mm)

Compression Ratio Typical:

9.0:1 (approx. for 883cc), 9.0:1 to 9.5:1 (approx. for 1200cc, varies by sub-model)

Cooling System:

Air-cooled

Valve Train:

OHV (Overhead Valve), 2 valves per cylinder, pushrod actuated

Horsepower 883Cc Approx:

50-55 HP (at crankshaft)

Horsepower 1200Cc Approx:

65-70 HP (at crankshaft)

Torque 883Cc Approx:

50-55 lb-ft (at crankshaft)

Torque 1200Cc Approx:

70-75 lb-ft (at crankshaft)

Carburetor Type:

Keihin 36mm Constant Velocity (CV) carburetor

Fuel Type:

Unleaded gasoline, 91 octane (95 RON) or higher recommended

Fuel Delivery:

Gravity feed from fuel tank to carburetor

🔧 Transmission

Transmission Type:

5-speed Constant Mesh

Primary Drive:

Duplex chain with compensator

Clutch Type:

Wet, multi-plate, diaphragm spring

Final Drive:

Belt drive (70 tooth rear pulley, 32 tooth front pulley typical)

Gear Ratios Typical:

1st: 10.34, 2nd: 7.01, 3rd: 4.91, 4th: 3.74, 5th: 3.15

Transmission Fluid Type:

Harley-Davidson Formula+ or equivalent SAE 50 transmission oil

Transmission Fluid Capacity:

24 US fl oz (710 ml) recommended

📐 Dimensions

Wheelbase Approx:

59.8 inches (1519 mm)

Length Approx:

88.1 inches (2238 mm)

Seat Height Unladen Approx:

26.1 inches (663 mm)

Dry Weight Approx:

463 lbs (210 kg)

Gross Vehicle Weight Rating Gvwr Approx:

880 lbs (399 kg)

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycles typically do not undergo formal crash testing like automobiles)

Brakes:

Dual-action, front and rear hydraulic disc brakes

Lighting:

Halogen headlamp, taillight, brake light, turn signals

Frame Construction:

Steel tube frame

Operator Controls:

Handlebar controls for throttle, clutch, brakes, ignition

💡 Technology Features

Infotainment System:

None (This era of Sportster models typically did not feature integrated infotainment systems. Audio systems were aftermarket additions.)

Driver Assistance Features:

None (Motorcycle-specific driver assistance features were not prevalent in 2006.)

Connectivity Features:

None (No built-in Bluetooth or smartphone integration.)

Instrument Panel:

Analog speedometer, tachometer (on some models), odometer, trip meter, fuel gauge (if equipped), indicator lights (oil pressure, neutral, turn signals, high beam)

🔧 Maintenance

Oil Change Interval:

Every 5,000 miles (8,000 km) or 12 months, whichever comes first

Primary Chain Tensioner Inspection:

Every 10,000 miles (16,000 km)

Belt Tension Check:

Every 5,000 miles (8,000 km)

Spark Plug Replacement:

Every 10,000 miles (16,000 km)

Brake Fluid Flush:

Every 24 months

Engine Oil Type:

Harley-Davidson 20W-50 SYN3 Synthetic Motorcycle Oil or equivalent

Engine Oil Capacity:

Approximately 3.0 US quarts (2.8 liters) with filter change

Primary Chain Case Oil Type:

Harley-Davidson Formula+ or equivalent SAE 50 transmission oil

Primary Chain Case Oil Capacity:

24 US fl oz (710 ml)

Brake Fluid Type:

DOT 4 hydraulic brake fluid

Fork Oil Type And Level:

Specific Harley-Davidson fork oil or equivalent (e.g., Bel-Ray 10W), level typically 5.0 inches (127 mm) from top of fork tube when compressed

Primary Chain Tensioner Wear:

The hydraulic tensioner shoe can wear out, leading to a rattling noise from the primary drive. Recommended replacement with an upgraded aftermarket tensioner or the revised stock tensioner design.

Carburetor Idle Issues:

The Keihin CV carburetor can sometimes develop issues with idle stability or poor throttle response, often requiring cleaning, jetting adjustment, or diaphragm replacement.

Rear Brake Caliper Sticking:

Occasional issues with rear brake calipers sticking due to dirt or corrosion, requiring cleaning and lubrication of the caliper slide pins.

📚 Vehicle History

Harley Davidson Legacy:

Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer with a rich history of V-twin engines and custom styling.

Sportster Lineage:

The Sportster line, introduced in 1957, is Harley-Davidson's longest-running model line. The Evolution engine was introduced in 1986, replacing the Ironhead engine, offering improved performance and reliability.

2006 Sportster Updates:

The 2006 Sportster models received updates including a new rubber isolation engine mount system, improved clutch lever effort, and enhanced electrical connectors. The 1200 Custom variant also saw a revised fuel tank and fender design.

Manufacturing Location:

United States (York, Pennsylvania and Milwaukee, Wisconsin for final assembly and engine production typical)

🏆 Awards & Recognition

Sportster Market Impact:

The Sportster line is consistently recognized for its iconic styling, customization potential, and approachable performance, making it a staple in the cruiser motorcycle segment.

Reliability Perception:

Generally considered reliable with proper maintenance. The Evolution engine is known for its robustness.