🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster XLH

Year:

2006

Model Code:

XLH883 / XL1200 (specific sub-models may vary)

👋 Introduction

Segment:

Cruiser Motorcycle

Target Audience:

Harley-Davidson owners and independent repair shops seeking detailed technical guidance

Competitors:

Other cruiser motorcycles from brands like Indian, Victory, and custom builders.

Vehicle Identity:

Iconic American V-twin cruiser, known for its distinctive styling, rumble, and customization potential.

Manual Value Proposition:

Provides essential, in-depth knowledge for owners to maintain, repair, and optimize their 2006 Sportster XLH, saving time and money compared to dealership service.

📋 Manual Details

Primary Coverage:

Comprehensive repair, maintenance, and troubleshooting for Harley-Davidson Sportster XLH models

Estimated Pages:

400-600+ (typical for comprehensive workshop manuals)

Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Evolution V-Twin (883cc and 1200cc variants), including top-end, bottom-end, lubrication, cooling (air-cooled), and fuel systems

Transmission:

5-speed constant mesh, including clutch, primary drive, final drive, and internal gearbox components

Chassis And Suspension:

Frame, front fork (including hydraulic damping), rear shock absorbers (adjustable preload), steering assembly, wheels, and tires

Brakes:

Front and rear disc brake systems, including calipers, master cylinders, brake lines, pads, and fluid maintenance

Electrical System:

Ignition system (electronic), starting system, charging system (alternator/stator, regulator/rectifier), battery, lighting (headlight, tail light, turn signals), instrumentation, wiring diagrams, and fault diagnosis

Fuel System:

Carbureted fuel delivery (e.g., Keihin CV carburetor), fuel tank, fuel lines, fuel pump (if applicable), and emissions control systems

Exhaust System:

Exhaust pipes, mufflers, heat shields, and related components

Bodywork And Trim:

Fenders, fuel tank, seat, handlebars, controls, and decorative elements

Maintenance:

Routine checks, oil changes, filter replacements, spark plug service, chain adjustment, brake fluid flush, battery maintenance, tire pressure checks

Repair:

Engine overhaul, transmission rebuild, carburetor tuning, fork seal replacement, brake caliper overhaul, electrical component diagnosis and replacement

Troubleshooting:

System-specific diagnostic charts, common problem identification, and corrective actions

Technical Specifications:

Detailed torque specifications, clearances, fluid capacities, and measurement data

Depth:

Expert level, suitable for professional technicians and experienced DIY mechanics; covers complete disassembly, assembly, and calibration

📊 Manual Specifications

File Type:

PDF

Print Readability:

High-resolution, clear text and diagrams suitable for printing

Binding Method:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Family:

Harley-Davidson Evolution V-Twin

Displacement Options:

883cc (53.9 cu in) and 1200cc (73.2 cu in)

Engine Type:

Air-cooled, 45-degree V-twin, pushrod actuated overhead valves

Bore X Stroke 883:

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

Bore X Stroke 1200:

88.8 mm x 96.8 mm (3.496 in x 3.81 in)

Compression Ratio 883:

8.4:1 (typical)

Compression Ratio 1200:

9.0:1 (typical)

Horsepower 883:

Approx. 53 hp @ 6000 rpm

Torque 883:

Approx. 48 lb-ft @ 3500 rpm

Horsepower 1200:

Approx. 65 hp @ 6000 rpm

Torque 1200:

Approx. 70 lb-ft @ 3500 rpm

Carburetor:

Keihin CV (Constant Velocity) 40mm (typical)

Fuel Type:

Unleaded gasoline, minimum 89 octane (87 AKI recommended, but higher octane is preferred)

Fuel Delivery:

Gravity feed from fuel tank to carburetor

Oil Type:

Harley-Davidson recommended V-Twin Motorcycle Oil (e.g., SAE 20W50)

Oil Capacity:

Approx. 3.0 US quarts (2.8 Liters) with filter change

Spark Plugs:

H-D recommended (e.g., Harley-Davidson 6R12, NGK DCPR7E) - gap 0.038-0.043 in (0.97-1.09 mm)

🔧 Transmission

Gearbox:

5-speed Constant Mesh, Manual Synchromesh (except for reverse gear, if equipped)

Primary Drive:

Duplex chain, wet clutch

Final Drive:

Belt drive

Transmission Fluid Type:

Harley-Davidson primary chaincase lubricant or equivalent SAE 50 motorcycle transmission oil

Transmission Fluid Capacity:

Approx. 24 US fluid ounces (0.7 Liters)

📐 Dimensions

Length:

Approx. 88.0 in (2235 mm)

Width:

Approx. 32.3 in (820 mm)

Height:

Approx. 48.3 in (1227 mm)

Wheelbase:

Approx. 60.0 in (1524 mm)

Dry Weight 883:

Approx. 500 lbs (227 kg)

Dry Weight 1200:

Approx. 520 lbs (236 kg)

Gvwr:

Approx. 900 lbs (408 kg)

Fuel Tank Capacity:

3.5 US gallons (13.2 Liters)

Front Tire Size:

MT90B16 (or similar)

Rear Tire Size:

130/90B16 (or similar)

Wheel Type:

Cast Aluminum or Spoked (model dependent)

Wheel Bolt Pattern:

N/A (Hub-mounted)

🛡️ Safety Features

Crash Test Results:

Motorcycles are not subjected to the same crash testing standards as passenger vehicles. Safety is primarily dependent on rider skill and adherence to traffic laws.

Braking:

Front and rear hydraulic disc brakes for reliable stopping power.

Lighting:

Halogen headlight, LED tail light, and front/rear turn signals for visibility.

Frame Construction:

Steel frame providing structural integrity.

Ergonomics:

Classic cruiser riding position, adjustable controls for rider comfort and control.

💡 Technology Features

Audio System:

Base models typically do not feature integrated audio systems; aftermarket solutions are common.

ABS:

Anti-lock Braking System (ABS) was typically an optional feature for this model year and not standard across all trims.

Bluetooth:

Not integrated from the factory; aftermarket communication systems are available.

Dashboard:

Analog speedometer, tachometer (optional), odometer, trip meter, and indicator lights (oil pressure, neutral, turn signals, high beam).

🔧 Maintenance

First Service:

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

Subsequent Service:

Every 5,000 miles (8,000 km) or 12 months (includes oil change, primary chaincase oil, inspection of all systems)

Spark Plug Replacement:

Every 10,000 miles (16,000 km)

Drive Belt Inspection Tension:

Every 2,500 miles (4,000 km)

Engine Oil Viscosity:

SAE 20W50

Primary Chaincase Oil Viscosity:

SAE 50

Brake Fluid Type:

DOT 4 Hydraulic Brake Fluid (check manual for specific manufacturer recommendations)

Carburetor Tuning:

Keihin CV carburetor can require periodic adjustment or cleaning for optimal performance.

Vibration:

Vibration is inherent to V-twin engines; however, excessive vibration can indicate loose mounting points or engine issues.

Electrical Connections:

Corrosion or loose connections in electrical connectors can lead to intermittent faults.

📚 Vehicle History

Brand Legacy:

Harley-Davidson, founded in 1903, is synonymous with American motorcycle culture, freedom, and the iconic V-twin engine.

Sportster Lineage:

The Sportster line, introduced in 1957, is Harley-Davidson's longest-running model, continuously evolving while maintaining its core identity.

2006 Updates:

The 2006 model year saw minor refinements and potential package updates. It represents a mature iteration of the Evolution Sportster platform before significant electronic fuel injection adoption across the range.

Manufacturing Location:

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

🏆 Awards & Recognition

Overall Reputation:

Consistently recognized as a classic and customizable platform within the motorcycle community.