Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 1

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APPENDIX A-TOOLS

A.1

Part No. B-45520 Gear Detent Assembly Aid

Part No. B-45676 Sprocket Shaft Seal Installer

Part No. B-45523 Intake and Exhaust Valve Guide Reamer

Part No. B-45847 Cross Plate

Part No. B-45524 Shoulderless Valve Guide Installer

Part No. HD-01289 Rim Protectors

Part No. B-45525 Valve Guide Hone (7 mm)

Part No. HD-21000 Tire Spreader

2006 Sportster: Appendix A

A-1

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Part No. HD-23738-A Mity-Vac Vacuum Pump

Part No. HD-28700 Tire Bead Expander

Part No. HD-25070 Robinair Heat Gun

Part No. HD-33223-1 Cylinder Compression Gauge

(Use with HD-41183)

Part No. HD-26792 Spark Tester

Part No. HD-33413-A Carburetor Idle Adjuster

and Part No. HD-33413-1A Adjuster Tip

HD-28431-6 Fluorescent Additive 6 1-oz. bottles

HD-28431-22 Fluorescent Additive 1 22-oz. container

Part No. HD-28431-B Black Light Fluorescent Additive

Universal Driver Handle

(Use with HD-35457)

4 in. length (Part No. HD-45907), 7 in. length (Part

No. HD-44567), 12 in. length (Part No. HD-33416)

A-2

2006 Sportster: Appendix A

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Part No. HD-33418 Universal Puller Forcing Screw

Part No. HD-34740-A Driver Handle and Remover.

Used with B-45524

Part No. HD-33446-B Cylinder Torque Plates

Part No. HD-34751-A Nylon Valve Guide Cleaning Brush

Part No. HD-34623-C Piston Pin Retaining Ring Installer

Part No. HD-34902-B Mainshaft Primary Bearing Race

Remover And Installer

Part No. HD-34736-B Valve Spring Compressor

Part No. HD-35102 Wrist Pin Bushing Hone (20 mm)

2006 Sportster: Appendix A

A-3

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Part No. HD-35316-C Main Drive Gear Remover/Installer

Part No. HD-35518 Internal/External

and Main Drive Gear Bearing Installer

Retaining Ring Pliers

CYLINDER LEAKDOWN TESTER

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Part No. HD-35381-A Belt Tension Gauge

Part No. HD-35667-A Cylinder Leakdown Tester

Part No. HD-35457 Black Light Leak Detector

Part No. HD-35758-B Neway Valve Seat Cutter Set

(Use with HD-28431-B)

Part No. HD-35500-B Digital Multimeter (Fluke 23)

Part No. HD-35801 Intake Manifold Screw Wrench

(Use with HD-39617)

A-4

2006 Sportster: Appendix A

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Part No. HD-36583 Fork Bushing / Seal Installer

Part No. HD-38361 Cam Gear Gauge Pin Set

(0.108 in. (2.74 mm) Diameter)

Part No. HD-38125-6 Packard Terminal Crimp Tool

Part No. HD-38362 Sprocket Locking Link

(Sealed)

Part No. HD-38125-7 Packard Terminal Crimp Tool

Part No. HD 38515-A Clutch Spring Compressor

(Nonsealed)

Part No. HD-38125-8 Packard Terminal Crimp Tool

Part No. HD-38871 Camshaft Bushing Plate Pilot

and Reamer

2006 Sportster: Appendix A

A-5

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Part No. HD-39301-A Steering Head Bearing

Part No. HD-39621 Electrical Terminal Repair Kit

Race Remover

(Use with HD-33416)

Part No. HD-39302 Steering Head Bearing

Part No. HD-39782-A Cylinder Head Support Stand

Race Installer

Part No. HD-39565 Engine Sound Probe

Part No. HD-39786-A Cylinder Head Holding Fixture

Part No. HD-39617 Inductive Amp Probe.

Part No. HD-39800 Oil Filter Crusher (Small)

(Use with HD-35500-B)

A-6

2006 Sportster: Appendix A

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Part No. HD-39823 Oil Filter Crusher (Large)

Part No. HD-39969 Ultra-Torch UT-100

Part No. HD-39847 Universal Ratcheting

Part No. HD-39978 Multi-Meter (FLUKE 78)

Tap/Reamer Handle

(Use with HD-42682)

Part No. HD-39964 Reamer Lubricant (Cool Tool)

Part No. HD-39994 Paint Repair Kit

Part No. HD-39965 Deutsch Terminal Crimp Tool

Part No. HD-41025-A Tool Organizational System

2006 Sportster: Appendix A

A-7

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Part No. HD-41137 Two-Way Hose Clamp Pliers

Part No. HD-41185 Hose Cutting Tool

Part No. HD-41155 VHS Tape Storage Tower

Part No. HD-41185-1 Hose Cutting Tool Blade

Part No. HD-41177 Fork Tube Holder

Part No. HD-41404 Harness Connector Test Kit

Part No. HD-41183 Robinair Heat Gun Shrink Tool

Part No. HD-41417 Propane Enrichment Kit

Attachment (Use with HD-25070)

A-8

2006 Sportster: Appendix A

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Part No. HD-41475 Deutsch Connector Service Kit

Part No. HD-42135 T-30 I.P. Torx Plus

Includes HD-41475-100

Spoke Nipple Driver

Part No. HD-41475-100 Deutsch Connector Pick Tool

Part No. HD-42310 Engine/Transmission Stand

HD-42310-3 Sportster Cradle

(Use with HD-42310-150)

Part No. HD-41609 Amp Multilock

Part No. HD-42310-45 Engine Cradle

Electrical Terminal Crimp Tool

Part No. HD-41675 Oil Pressure Sending Unit Wrench

Part No. HD-42310-150 Drip Tray

(Use with HD-42310)

2006 Sportster: Appendix A

A-9

HOME

600

200

Made in USA

PP-9606- 0001

Part No. HD-42311 Oil Filter Wrench

Part No. HD-42376 Battery/Charging System

Load Tester

Part No. HD-42320-A Piston Pin Remover/Installer

Part No. HD-42579 Sprocket Bearing/Seal Installer

Part No. HD-42322 Piston Support Plate

Part No. HD-42682 Breakout Box

Part No. HD-42326-A Crankshaft Guide

Part No. HD-42879 Deutsch Solid Barrel Contact

Crimp Tool

A-10

2006 Sportster: Appendix A

HOME

Part No. HD-43646-A Rolling Engine Stand

Part No. HD-44067-A Oil Filter Remover

(Use with HD-43646-10)

Part No. HD-43646-10 Drip pan

Part No. HD-44358 Flywheel Support Fixture

(Use with HD-43646)

Part No. HD-43984 Crankshaft Locking Tool

Part No. HD-44687 Ignition Coil Circuit Adapter

Part No. HD-44060 Wheel Bearing Remover/Installer

Part No. HD-44750-P29 Panasonic Toughbook

(touch screen) and

HD-44750-P50 Panasonic Toughbook (non-touch screen)

2006 Sportster: Appendix A A-11

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Part No. HD-45830 Tech Link

Part No. HD-45967 Shop Dolly

Use with HD-45968

Part No. HD-45835 Road Test Kit

Part No. HD-45968 Fat Jack

Use with HD-45967

Part No. HD-45929 Terminal Crimper (Mini-Packard)

Part No. HD-46281 Swingarm Bearing Remover/Installer

Part No. HD-45928 Electrical Terminal Remover

Part No. HD-46282 Final Drive Sprocket Locking Tool

A-12

2006 Sportster: Appendix A

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Part No. HD-46283 Primary Drive Locking Tool

Part No. HD-46601 Instrument Harness Adapters

Use With HD-42682

Part No. HD-46284 Engine Hook

Part No. HD-46663 Crankcase Bearing Remover Adapter

Part No. HD-46285 Transmission Assembly Fixture

Part No. HD-47114 Fuel Tank Console Alignment Ring

Part No. HD-46287 Lapping Tool Adapter

Part No. HD-47183 Leak Detector Penlight

2006 Sportster: Appendix A A-13

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Part No. HD-47184 Leak Detector Flashlight

Part No. HD-47250 Intake Manifold Wrench

Part No. HD-47187 Technician’s Penlight

Part No. HD-47258 Upper Rocker Box Wrench

Part No. HD-47188 Technician’s Flex Light

Part No. HD-47855 Main Drive Gear

Needle Bearing Installer

Part No. HD-47248 Lower Rocker Box Wrench

Part No. HD-47856 Main Drive Gear Seal Installer

A-14

2006 Sportster: Appendix A

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Part No. HD-59000-B Pro-Level Oil Gauge

Part No. HD-94803-67 Rear Intake Camshaft

Bushing Reamer

Part No. HD-94660-37B Mainshaft Locknut Wrench

Part No. HD-94804-57 Rocker Arm Bushing Reamer

Part No. HD-94681-80 Spoke Nipple Wrench

Part No. HD-94812-1 Pinion Shaft Bushing Reamer.

(Use with HD-94812-87)

Part No. HD-94800-26A Connecting Rod Bushing

Part No. HD-94812-87 Pinion Shaft Reamer Pilot.

Reamers and Pilots

(Use with HD-94812-1)

2006 Sportster: Appendix A A-15

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Part No. HD-94820-75A Rear Shock Spanner Wrench

Part No. HD-95760-69A Bushing/Bearing Puller Tool Set.

Set includes items 1-7. Items 8 (HD-95769-69), 9 (HD-

95770-69) and 10 (HD-95771-69) are optional.

Part No. HD-95017-61 Large External Retaining

Part No. HD-95952-33C Connecting Rod

Ring Pliers

Clamping Tool

Part No. HD-95635-46 All-Purpose Claw Puller

Part No. HD-95970-32D Piston Pin Bushing Tool

(Use with HD-95637-46A)

(Includes HD-95984-99 Receiver Cup

and HD-95986-99 Driver)

Part No. HD-95637-46A Wedge Attachment for

Part No. HD-96215-49 Small Internal Retaining

Claw Puller

Ring Pliers

(Use with HD-95635-46)

A-16

2006 Sportster: Appendix A

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Part No. HD-96333-51D Piston Ring Compressor

Part No. HD-96796-47 Valve Spring Tester

Part No. HD-96650-80 Flywheel Truing Stand

Part No. HD-96921-52B Oil Pressure Gauge

(Use with HD-96925-58)

Part No. HD-96710-40C Crankcase Main Bearing

Part No. HD-96925-58 Oil Pressure Gauge Adapter

Lapping Tool

(Use with HD-96921-52B)

Part No. HD-96718-87 Pinion Bearing Outer Race

Part No. HD-97087-65B Hose Clamp Pliers

Lapping Kit

2006 Sportster: Appendix A A-17

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Part No. HD-99500-80 Wheel Truing Stand

Part No. J-5586-A Transmission Shaft

Retaining Ring Pliers

Part No. HD-48053 Battery and

Electrical System Analyzer

A-18

2006 Sportster: Appendix A

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APPENDIX B-WIRING

AMP MULTILOCK ELECTRICAL CONNECTORS

B.1

3. Bend back the latch slightly and free one side of second-

REMOVING

ary lock, then repeat the step to release the other side.

SOCKET/PIN TERMINALS

Rotate the secondary lock outward on hinge to access

terminals in chambers of connector housing.

See Figure B-1. Remove connector from the retaining

4. Looking in the terminal side of the connector (opposite

device, either attachment or rosebud clip.

the secondary lock), take note of the cavity next to each

Depress the button on the socket terminal side of the

terminal.

connector

(plug) and pull apart the pin and socket

halves.

x0347x7x

Socket terminal

Latch

Secondary lock open

Button

Socket housing

Pin housing

Pin terminal

Figure B-1. 10-Place Amp Multi-Lock Connector

2006 Sportster: Appendix B

B-1

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