Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 6

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See Figure 1-52. Check belt deflection at position “A,”

x0630x1x

midway between transmission sprocket and rear wheel

sprocket. Apply 10 lbs (4.5 Kg) of upward force on lower

Belt

span of rear belt using HARLEY-DAVIDSON BELT TEN-

SION GAUGE.

Measure belt deflection “B” several times, each time with

belt moved (by rotating rear wheel) to a different position

on sprockets. With sprockets rotated to the tightest belt

position, belt deflection should be as listed in Table 1-10.

NOTES

● Do not rely on “feel” for the proper deflection as this typi-

Incorrect

cally results in belts which are under tensioned. Always

Correct

use HARLEY-DAVIDSON BELT TENSION GAUGE to

determine the 10 lb. (4.5 Kg) deflection force. Loose

Front-to-back

belts will fail due to “ratcheting” (jumping a tooth) with

resultant tensile cord crimping and breakage.

● See Figure 1-53. Tool must be at a 90 degree angle to

belt both front-to-back and side-to-side in order to obtain

an accurate reading.

Belt

x0254a6x

Correct

Incorrect

Side-to-side

Figure 1-53. Using Belt Tension Gauge

Figure 1-52. Secondary Drive Belt Deflection

Table 1-10. Belt Deflection

MODEL

DEFLECTION

XL 883C/XL 1200C/

1/4-5/16 in. (6.4-7.9 mm) with 10

XL 883L

lbs (4.5 Kg) of force.

XL 883/XL 883R/

3/8-7/16 in. (9.5-11.1 mm) with

XL 1200R

10 lbs (4.5 Kg) of force.

1-40

2006 Sportster: Maintenance

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BELT DEFLECTION ADJUSTMENT

10343

See Figure 1-52. Determine belt deflection in manner speci-

fied in INSPECTION. If belt deflection “B” is not correct,

adjust per the following procedure.

NOTE

Rear brake line is clamped tightly to rear fork to avoid chafing

of brake line in clamp. See Figure 1-54. A small amount of

slack must be maintained in rear brake line (2) between

clamp (3) and rear caliper (5) when rear wheel is adjusted.

10400

See Figure 1-54. Remove screw (4) from clamp (3) on

rear brake line (2).

See Figure 1-55. Remove e-clip (1) and loosen rear axle

nut (4). Turn axle adjuster nuts (2) on each side of rear

fork clockwise to decrease belt deflection (increase ten-

sion), or counterclockwise to increase belt deflection

(decrease tension). Turn both adjuster nuts the same

number of turns in order to maintain approximate align-

ment of rear wheel.

Now check rear wheel alignment. Wheel must be cen-

tered between swing arm. See WHEEL ALIGNMENT on

Rear fork

the next page.

Rear brake line

Clamp

1WARNING

Screw

Rear brake caliper

Do not exceed 78 ft-lbs (106 Nm) when tightening the

axle nut. Exceeding 78 ft-lbs (106 Nm) may cause the

Figure 1-54. Rear Brake Line

wheel bearings to seize during operation, which could

result in death or serious injury.

After belt deflection and wheel alignment are properly

10625

adjusted,

a. Tighten axle nut (4) to 72-78 ft-lbs (98-106 Nm).

Install e-clip (1).

b. See Figure 1-54. Reposition clamp (3) on rear brake

line (2) and secure clamp to rear fork (1) with screw

(4). Tighten to 30-40 in-lbs (3.4-4.5 Nm).

1. E-clip

2. Axle adjuster nut (2)

3. Axle adjuster (2)

4. Axle nut

5. Washer

Figure 1-55. Secondary Drive Belt Adjustment

2006 Sportster: Maintenance

1-41

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WHEEL ALIGNMENT

Adjusting Wheel Alignment

1. See Figure 1-57. Remove and discard e-clip (1).

Checking Wheel Alignment

2. Loosen rear axle nut (4).

3. On side of rear fork that has longer distance from swing

1WARNING

arm pivot bolt to axle center, turn nut (2) on axle adjuster

stud (3) counterclockwise to shorten distance. Adjust

Check vehicle alignment according to following proce-

axle until left and right side alignment measurements are

dures. Incorrect alignment can adversely affect stability

equal.

and handling, which could result in death or serious

injury. (00287a)

NOTES

● Keep axle adjuster mechanisms firmly seated (under

See Figure 1-56. Fabricate an alignment tool (1) using a

tension) on each side of rear fork during wheel alignment

piece of 1/8-in. (3.175 mm) diameter aluminum welding

procedures above. Do so by applying moderate upward

rod 21.5 in. (546 mm) long. Grind one end down to a

force on lower span of rear belt. This tensions rear belt,

blunt point. Use pliers to bend rod at a 90 degree angle,

which holds rear axle forward against both adjuster

2.25 in. (57 mm) from the blunt point, as shown. Place a

mechanisms.

snug-fitting rubber grommet (4) on rod to act as a slide

measurement indicator.

● Do not tighten rear axle nut or install new e-clip until after

Insert pointed end of alignment tool in swing arm pivot

checking rear drive belt tension.

bolt dimple (2) on right side of swing arm (3). Slide rub-

ber grommet along tool shaft until it aligns with center of

4. Verify rear drive belt deflection after aligning rear wheel;

rear axle. Measure distance from pointed end of align-

adjust if required. See BELT DEFLECTION ADJUST-

ment tool to grommet. Repeat measurement for left side

MENT on the previous page.

of swing arm.

NOTE

If left and right side measurements are not equal, adjust

Rear brake line is clamped tightly to rear fork to avoid chafing

rear wheel alignment according to the following proce-

of brake line in clamp. If rear axle has been moved forward or

dure - Adjusting Wheel Alignment.

back, make sure there is a small amount of slack in rear

brake line between clamp and rear caliper. If necessary,

loosen clamp screw, reposition brake line, then tighten screw.

10627

See BELT DEFLECTION ADJUSTMENT on the previous

page.

1WARNING

Do not exceed 78 ft-lbs (106 Nm) when tightening the

axle nut. Exceeding 78 ft-lbs (106 Nm) may cause the

x0232x2x

wheel bearings to seize during operation, which could

result in death or serious injury.

2.25 in.

(57 mm)

5. If not yet done, tighten axle nut to 72-78 ft-lbs (98-106

Nm) and install new e-clip.

10625

19-1/4 in. (489 mm)

Wheel alignment tool

Swing arm pivot bolt dimple

Swing arm

Rubber grommet

Blunt point

Figure 1-56. Checking Wheel Alignment

Using Wheel Alignment Tool

1. E-clip

2. Axle adjuster nut (2)

3. Axle adjuster (2)

4. Axle nut

5. Washer

Figure 1-57. Rear Axle and Adjusters

1-42

2006 Sportster: Maintenance

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REAR BELT AND SPROCKETS

1.16

GENERAL

x0492a1x

1. Tooth

2. Groove

Clean and inspect the drive belt and rear sprocket as

described below.

NOTE

When a drive belt is replaced for any reason other than stone

damage, it is recommended that the transmission and rear

sprockets also be replaced to increase the longevity of the

new drive belt. In the case of stone damage, inspect sprock-

ets for damage and replace as required.

CLEANING

Keep dirt, grease, oil, and debris off the belt and sprockets.

Clean the belt with a rag slightly dampened with light cleaning

Figure 1-58. Rear Sprocket

agent.

NOTES

●

When a

drive belt is replaced for any reason other

than

INSPECTION

stone damage, it is recommended that the transmission

and

rear sprockets also be replaced to increase the lon-

gevity of the new drive belt. In the case of stone damage,

Sprockets

inspect sprockets for damage and replace as required.

See Figure 1-58. Inspect each tooth of rear sprocket for:

●

See Figure 1-59. Condition #1 may develop into #2 or #3

● major tooth damage

over time. Condition #1 is not grounds for replacing the

● large chrome chips with sharp edges

belt,

but it should be watched closely before condition #2

● gouges caused by hard objects

develops which will require belt replacement.

● excessive loss of chrome plating (see Step 3).

See Figure 1-59. Inspect drive belt:

If chrome chips or gouges are large enough to be harm-

ful, they will leave a pattern on the belt face.

● for cuts or unusual wear patterns.

To check if chrome plating has worn off, drag a scribe or

● for outside edge bevelling (#8). Some bevelling is com-

sharp knife point across the bottom of a groove (between

mon, but it indicates that sprockets are misaligned.

two teeth) with medium pressure.

● outside ribbed surface for signs of stone puncture (#7). If

● If scribe or knife point slides across groove without

cracks/damage exists near edge of belt, replace belt

digging in or leaving a visible mark, chrome plating

immediately. Damage to center of belt will require belt

is still good.

replacement eventually, but when cracks extend to edge

● If scribe or knife point digs in and leaves a visible

of belt, belt failure is imminent.

mark, it is cutting the bare aluminum. A knife point

will not penetrate the chrome plating.

● inside (toothed portion) of belt for exposed tensile cords

Replace rear sprocket if major tooth damage or loss of

(normally covered by nylon layer and polyethylene layer).

chrome exists.

This condition will result in belt failure and indicates worn

transmission sprocket teeth. Replace belt and transmis-

Rear Belt

sion sprocket.

The rear belt should be checked for unusual wear, cracking,

● for signs of puncture or cracking at the base of the belt

or loss of teeth. Check the belt sprocket for unusual wear,

teeth. Replace belt if either condition exists.

broken teeth, or damaged flange.

Replace belt if conditions #2, #3, #6, or #7 (on edge of belt)

Inspect the drive belt at the 1000 mile (1600 km) service

exist.

interval, and at every 5000 mile (8000 km) service interval

thereafter.

2006 Sportster: Maintenance

1-43

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d0598x1x

Stone

Cross-section shown

Sprocket

side of belt

Figure 1-59. Drive Belt Wear Patterns

Table 1-11. Drive Belt Wear Analysis

PATTERN

CONDITION

REQUIRED ACTION

Internal tooth cracks (hairline)

OK to run, but monitor condition

External tooth cracks

Replace belt

Missing teeth

Replace belt

Chipping (not serious)

OK to run, but monitor condition

Fuzzy edge cord

OK to run, but monitor condition

Hook wear

Replace belt

Stone damage

Replace belt if damage is on the edge

Bevel wear (outboard edge only)

OK to run, but monitor condition

1-44

2006 Sportster: Maintenance

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SHOCK ABSORBER ADJUSTMENT

1.17

GENERAL

10628

PART NO.

SPECIALTY TOOL

HD-94820-75A

Shock absorber spanner wrench

Shock absorber spring preload can be adjusted for the weight

the motorcycle is to carry. To ensure that the suspension has

the proper amount of travel, increase the preload to accom-

modate any additional weight of rider, passenger or luggage.

Likewise, carrying less weight requires a reduction in preload.

● XL 883, XL 883R and XL 1200R have three preload posi-

tions.

● XL 883L, XL 883C and XL 1200C have five preload posi-

Shock absorber spring adjuster

tions.

Spanner wrench

Figure 1-60. Rear Shock Absorber Spring Adjustment

PROCEDURE

x0493a1x

1WARNING

Be sure both shock absorbers are adjusted to same pre-

load position. Improper adjustment can adversely affect

stability and handling, which could result in death or

serious injury. (00036a)

See Figure 1-60. To adjust the preload on the rear shock

absorber spring, turn spring adjuster

(1) using HARLEY-

DAVIDSON SHOCK ABSORBER SPANNER WRENCH (2).

Adjust spring adjusters on both shock absorbers to the same

position.

When returning to a lower preload position, spring adjusters

should be backed off in the opposite direction.

Figure 1-61. Shock Absorber Spanner Wrench

(Part No. HD-94820-75A)

NOTE

Evaluating and changing the preload adjustment is a very

subjective process and should be approached carefully.

2006 Sportster: Maintenance

1-45

HOME

STEERING HEAD BEARINGS

1.18

GENERAL

x0497a1x

Check steering head bearing adjustment.

ADJUSTMENT

Place suitable blocking under frame to raise front wheel

several inches off floor.

Remove all items that could interfere with front end swing

momentum. If clutch control cable inhibits front end

swing, disconnect it.

Place a strip of masking tape over tip of front fender.

Install a pointer mounted to a floor stand. The pointer is

positioned at the center of the fender with the front wheel

pointed straight ahead.

Repeatedly nudge the fender a short distance on one

side until the front end begins to “fall-away” (i.e., pivot

about its steering head center) by itself. Mark the point

on the tape where the front end begins to “fall-away.”

Repeat this procedure in the opposite direction.

Measure the distance between the two “fall-away” marks.

The distance must be 1-2 in. (25-50 mm) for proper bear-

ing adjustment.

See Figure 1-62. If the distance is not correct, perform

the following procedure:

a. Loosen the two lower bracket pinch screws (6) and

the fork stem clamp screw (4).

b. Remove fork stem bolt cap (1) (XL 1200R only).

c. Loosen or tighten the fork stem bolt (2) until the “fall-

away” distance is 1-2 in. (25-50 mm).

NOTE

Loosen fork stem bolt if “fall-away” point is more than 2 in. (50

mm). If “fall-away” point is less than 1 in. (25 mm), tighten fork

stem bolt.

d. Tighten fork stem clamp screw to

30-35 ft-lbs

(40.7-47.5 Nm).

Fork stem bolt cap (XL 1200R only)

e. Tighten lower bracket pinch screws to 30-35 ft-lbs

Bolt

(40.7-47.5 Nm).

Washer

Reinstall fork stem bolt cap (XL 1200R only).

Screw

g. Recheck “fall-away.”

Upper bracket

6. Screw (4)

7. Seal (2)

LUBRICATION

8. Tapered roller bearing (2)

9. Bearing cup (2)

See Figure 1-62. Disassemble the steering head assembly

10. Lower bracket

and lubricate the tapered roller bearings (8) with HARLEY-

11. Retaining ring

DAVIDSON SPECIAL PURPOSE GREASE. See 2.18 FORK

STEM AND BRACKET ASSEMBLY for disassembly and

Figure 1-62. Steering Head Assembly

reassembly procedures.

1-46

2006 Sportster: Maintenance

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REAR FORK BEARINGS

1.19

GENERAL

PROCEDURE

The rear fork bearings are sealed units and need no lubrica-

See 2.19 REAR FORK for rear fork bearing replacement pro-

tion.

cedure.

2006 Sportster: Maintenance

1-47

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NOTES

1-48

2006 Sportster: Maintenance

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FRONT FORK OIL

1.20

GENERAL

x0499x1x

PART NO.

SPECIALTY TOOL

HD-59000-A

Pro-level oil gauge

Replace front fork oil:

● At scheduled service intervals as specified in 1.3 MAIN-

TENANCE SCHEDULE. Refer to Table 1-1.

● Prior to storage.

CHANGING FORK OIL

Have an assistant hold vehicle upright (not resting on jiffy

stand), with front fork pointed straight ahead.

Place a drain pan under bottom of right fork slider. See

Figure 1-63. Remove drain screw and washer (5) from

bottom of one slider (4).

Drain fork oil by repeatedly compressing front suspen-

sion slowly.

NOTE

If fork oil is emulsified, aerated or light brown in color, it has

been contaminated by water. Replace fork oil seals (see 2.17

FRONT FORK).

Replace drain screw and washer. Tighten to 13-17 in-lbs

(1.5-2.0 Nm).

Repeat Steps 2 through 4 above for left side fork.

NOTE

Refer to Table 1-12. Fork oil amounts can be measured two

Fork slider tube cap

ways.

O-ring

Slider tube

● Use oz/ml measurement if fork is left in frame.

Fork slider

● Use in/mm measurement if fork is disassembled.

Fork oil drain screw w/washer

Figure 1-63. Draining Front Fork Oil

Table 1-12. Type E Fork Oil Amounts

MODEL

XL 883L

12.3

364

4.80

122

All others

11.6

342

5.75

146

2006 Sportster: Maintenance

1-49

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Filling Fork Oil: Forks Assembled, in

x0631x1x

Frame

Block motorcycle under frame so that the front wheel is

raised off the ground slightly; this enables front fork to

extend fully and allows most of spring preload (compres-

sion force) to be relieved.

1WARNING

Wear safety glasses or goggles when servicing fork

assembly. Do not remove slider tube caps without reliev-

ing spring preload or caps and springs can fly out, which

could result in death or serious injury. (00297a)

Unscrew fork slider tube cap (1) with O-ring (2) from

each slider tube (3). Replace the O-ring if damaged or

worn.

x0632x1x

Fill each slider tube/slider assembly with 11.6 fl oz. (342

ml) TYPE “E” HYDRAULIC FORK OIL.

Install each slider tube cap with O-ring. Tighten to 22-58

ft-lbs (29.9-78.7 Nm).

Lower motorcycle to the ground.

Filling Fork Oil: Forks Disassembled, out

of Frame

Position fork tube assembly upright. Remove spring and

compress assembly fully.

Pour approximately

12 fl oz.

(355 ml) TYPE

“E”

HYDRAULIC FORK OIL into fork.

See Figure

1-64. Using HARLEY-DAVIDSON PRO-

LEVEL OIL GAUGE, adjust oil level:

4.80 in. (122 mm) for XL 883L.

5.75 in. (146 mm) for all models except XL 883L.

Fork slider tube

Pro Level Oil Gauge (Part No. HD-59000-A)

Install spring and slider tube cap with O-ring. Tighten to

Fork oil

22-58 ft-lbs (29.9-78.7 Nm).

Correct fork oil level is 4.80 in (122 mm) (XL 883L)

Assemble fork and install in frame.

or 5.75 in (146 mm) (all except XL 883L) below top

Repeat this procedure for other fork tube assembly.

of fork tube.

Figure 1-64. Refilling Front Fork Oil

1-50

2006 Sportster: Maintenance

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SPARK PLUGS

1.21

GENERAL

4636

Harley-Davidson 6R12 spark plugs have a resistor element to

reduce the radio interference which originates in the motorcy-

cle ignition system. Use only the resistor-type spark plugs

specified.

ADJUSTMENT

Spark plug gap is 0.038-0.043 in. (0.96-1.09 mm). Use only

a wire-type feeler gauge. Bend the outside electrode so a

slight drag on the gauge is felt when passing it between elec-

trodes. Never make adjustments by bending the center elec-

trode.

CLEANING AND INSPECTION

Inspection

Examine spark plugs as soon as they have been removed.

The deposits on the spark plug base are an indication of the

spark plug efficiency and are a guide to the general condition

of pistons, piston rings, valves, valve guides, valve seals, car-

Figure 1-65. Typical Spark Plug Deposits

buretor and ignition system.

Cleaning

Spark Plug Condition

If spark plugs require cleaning between tune-ups, proceed as

See Figure 1-65. Compare your observations of the spark

follows:

plug deposits with the descriptions provided below.

1. Degrease firing end of spark plug using ELECTRICAL

A wet, black and shiny deposit on spark plug base,

CONTACT CLEANER. Dry spark plug with compressed

electrodes and ceramic insulator tip indicates an oil

air.

fouled spark plug. The condition may be caused by

one or more of the following: worn pistons, worn pis-

2. Use a thin file to flatten spark plug electrodes. A spark

ton rings, worn valves, worn valve guides, worn

plug with sharp edges on its electrodes requires 25%-

valve seals, a weak battery or a faulty ignition sys-

40% less firing voltage than one with rounded edges.

tem.

3. Adjust spark plug gap. See ADJUSTMENT under 1.21

A dry, fluffy or sooty black deposit indicates a carbu-

SPARK PLUGS.

retor air-fuel mixture that is too rich, engine idling for

excessive periods of time and/or enrichener usage

for excessive periods of time.

INSTALLATION

A light brown, glassy deposit indicates an over-

heated spark plug. This condition may be accompa-

1. Before installing spark plugs, check condition of threads

nied by cracks in the insulator or by erosion of the

in cylinder head and on spark plug. If necessary, soften

electrodes and is caused by an air-fuel mixture that

deposits with penetrating oil and clean out with a thread

is too lean, a hot-running engine, valves not seating

chaser.

or improper ignition timing. The glassy deposit on

2. Apply a very light coating of ANTI-SEIZE LUBRICANT to

the spark plug is a conductor when hot and may

spark plug threads. Install spark plug. Tighten spark plug

cause high-speed misfiring. A spark plug with

to 12-18 ft-lbs (16.3-24.4 Nm).

eroded electrodes, heavy deposits or a cracked

insulator must be replaced.

If a torque wrench is not available, finger-tighten spark

plug and then using a spark plug wrench, tighten spark

A spark plug with a white, yellow, tan or rusty brown

plug an additional 1/4-turn.

powdery deposit indicates balanced combustion.

Clean off spark plug deposits at regular intervals.

3. Check engine idle speed. With engine at operating

See Cleaning.

temperature and enrichener OFF

(enrichener knob

pushed all the way in), adjust idle speed as necessary.

See 1.25 IDLE SPEED AND IGNITION TIMING.

2006 Sportster: Maintenance

1-51

HOME

CABLE AND CHASSIS LUBRICATION

1.22

GENERAL

FOOT SHIFT LEVER AND REAR

BRAKE PEDAL

Inspect and lubricate the front brake hand lever, throttle con-

trol cables, clutch hand lever, clutch cable and throttle control

Clean and lubricate the foot shift lever (XL 883C/XL 1200C)

grip sleeve at scheduled service intervals as specified in 1.3

and rear brake pedal pivot with ANTI-SEIZE LUBRICANT at

MAINTENANCE SCHEDULE. Refer to Table 1-1.

scheduled service intervals as specified in

1.3 MAINTE-

If service is on muddy or dusty roads, clean and lubricate

NANCE SCHEDULE. Refer to Table 1-1.

components at shorter intervals.

If service is on muddy or dusty roads, clean and lubricate

components at shorter intervals.

CABLES AND HAND LEVERS

JIFFY STAND

CAUTION

Clean and lubricate the jiffy stand at scheduled service inter-

Do not lubricate the enrichener cable or inside of

vals as specified in 1.3 MAINTENANCE SCHEDULE. Refer

enrichener cable conduit. The cable must have sliding

to Table 1-1. See 2.31 JIFFY STAND for procedure.

resistance to work properly.

If service is on muddy or dusty roads, clean and lubricate

See 1.24 THROTTLE CABLES AND ENRICHENER for throt-

components at shorter intervals.

tle cable lubricating procedure.

Use SUPER OIL for hand levers.

STEERING HEAD BEARINGS

Lubricate the steering head bearings with HARLEY-DAVID-

SON SPECIAL PURPOSE GREASE at scheduled service

intervals as specified in 1.3 MAINTENANCE SCHEDULE.

Refer to Table 1-1.

1-52

2006 Sportster: Maintenance

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AIR FILTER ELEMENT

1.23

GENERAL

REMOVAL

The air cleaner prevents foreign material from entering the

1. See Figure 1-66. Remove two screws (1) and trim insert

carburetor and engine, trapping airborne dust and dirt in the

(2) from air cleaner cover (3).

filter element.

2. Remove air cleaner cover from air cleaner backplate (9).

Service the air cleaner:

Remove air cleaner seal (4) from cover.

3. Remove three screws (5). Remove air filter element (6)

● At scheduled service intervals as specified in 1.3 MAIN-

and gasket (7) from air cleaner backplate. Discard gas-

TENANCE SCHEDULE. Refer to Table 1-1.

ket.

● More often if the motorcycle is operated in a dusty envi-

ronment.

CAUTION

Install air filter before running engine. Failure to do so

can draw debris into the engine and could result in

engine damage. (00207a)

Screw (2)

x0502a1x

Trim insert

Air cleaner cover

Air cleaner seal

Screw (3)

Air filter element (includes item 7)

Gasket

O-ring (2)

Air cleaner backplate

Figure 1-66. Air Cleaner Assembly

2006 Sportster: Maintenance

1-53

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CLEANING, INSPECTION AND

INSTALLATION

REPAIR

See Figure 1-66. Apply a thin coat of engine oil or light

grease to O-rings (8). This will help prevent them from

See Figure 1-66. Thoroughly clean air cleaner backplate

being damaged when air filter element is installed.

(9) and inside of air cleaner cover (3).

Position new gasket (7) on air cleaner backplate (9).

If air filter element (6) is damaged or if filter media cannot

Make sure gasket holes are lined up with backplate

be adequately cleaned, replace element and proceed to

holes.

step 6.

Install air filter element (6) onto backplate. The words

“This Side Out” should be readable on the upper edge of

1WARNING

the air filter element when installed. Secure with three

screws (5). Tighten to 40-60 in-lbs (4.5-6.8 Nm).

Do not use gasoline or solvents to clean filter element.

Flammable cleaning agents can cause an intake system

Fit air cleaner seal

(4) onto air cleaner cover (3). To

fire, which could result in death or serious injury.

ensure proper sealing, make sure air cleaner seal covers

(00101a)

entire edge of air cleaner cover.

Wash air filter element thoroughly in warm, soapy water.

Install air cleaner cover onto backplate. Make sure air

To remove soot and carbon, soak air filter element for 30

cleaner seal fits inside backplate and is not pinched or

minutes in warm water with mild detergent.

distorted.

Install trim insert (2) and secure cover assembly with two

screws (1). Tighten to 36-60 in-lbs (4.1-6.8 Nm).

1WARNING

Compressed air can pierce the skin and flying debris

from compressed air could cause serious eye injury.

Wear safety glasses when working with compressed air.

Never use your hand to check for air leaks or to deter-

mine air flow rates. (00061a)

Dry air filter element using low-pressure (32 psi/221 kPa

maximum) compressed air. Rotate air filter element while

moving air nozzle up and down filter element interior. Do

not tap air filter element on hard surface.

Hold air filter element up to strong light source. Element

can be considered sufficiently clean if light is uniformly

visible through filter material.

NOTE

Do not use air cleaner filter oil on Harley-Davidson paper air

filter elements.

Examine O-rings (8). If damaged, replace with new O-

ring(s).

Examine air cleaner seal (4). If cracked, torn or other-

wise damaged, replace with new seal.

1-54

2006 Sportster: Maintenance

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THROTTLE CABLES AND ENRICHENER

1.24

CABLE INSPECTION,

10089

LUBRICATION AND ADJUSTMENT

Inspect, lubricate and adjust throttle control cables as

described below.

Inspection and Lubrication

See Figure 1-67. Remove two screws (1) to separate the

upper handlebar housing from the lower housing.

Unhook each ferrule and cable from the throttle grip and

remove the throttle sleeve.

Inspect each cable. Replace cable assembly if cable is

frayed or kinked.

Inspect entire cable outer sheath from throttle grip to car-

buretor for damage. Replace if necessary.

Apply a light coat of graphite to the handlebar and

replace throttle grip.

Pour one or two drops of SUPER OIL into the housing of

each cable.

x0505a1x

Assemble handlebar housing. Tighten both screws (1) to

35-45 in-lbs (4.0-5.1 Nm).

Adjustment

1WARNING

Check to ensure proper throttle control functions. The

throttle control MUST operate freely without binding.

Irregular or sticking throttle response could result in loss

of control of the vehicle and death or serious injury.

See Figure 1-67. With throttle friction screw (3) backed off,

carburetor throttle must return to closed (idle) position. Check

control cable adjustment. With engine idling, turn handlebars

through full range of travel. If engine speed changes during

this maneuver, adjust control cables according to the follow-

Screw (2)

ing procedure.

Throttle control grip

Loosen throttle friction screw (3).

Throttle friction screw

Throttle control (pull open) cable

Slide rubber boot off each control cable adjuster (6).

Idle control (pull close) cable

Loosen jam nut (7) on each cable adjuster.

Control cable adjuster (2)

Turn cable adjusters in direction which will shorten cable

Jam nut (2)

housings to minimum length.

Throttle cam

Point front wheel straight ahead. With engine OFF, turn

Spring

throttle control grip (2) to fully open position and hold.

10.

Throttle cam stop

11.

Cable guide

Gently turn adjuster (6) on throttle control cable (4) until

throttle cam (8) touches throttle cam stop (10). Release

Figure 1-67. Throttle Cable Adjustment

throttle control grip and turn adjuster counterclockwise

an additional 0-1 turn. Tighten jam nut on throttle control

cable adjuster.

Turn handlebars fully to right. Turn adjuster (6) on idle

control cable (5), lengthening sleeve until end of cable

housing just touches spring (9) within cable guide (11).

2006 Sportster: Maintenance

1-55

HOME

Check adjustment. With throttle friction screw loosened,

1. Loosen hex nut (5) at backside of enrichener bracket (6).

twist and release throttle control grip two or three times.

2. Move cable assembly free of slot in mounting bracket.

Carburetor throttle must return to idle position each time

3. Hold cable assembly at flat

(3) with an adjustable

throttle grip is released. If throttle does not return to idle,

wrench. Turn plastic nut by hand counterclockwise

turn idle adjuster, shortening sleeve until correct adjust-

(reducing sliding resistance) until knob slides inward

ment is reached. Tighten jam nut.

unaided.

Slide rubber boot over each cable adjuster. Check

4. Turn plastic nut clockwise (increasing sliding resistance)

engine slow idle speed. Adjust if required.

until knob remains fully open without holding, and closes

with relative ease.

ENRICHENER ADJUSTMENT

5. Position cable assembly in slot in bracket with hex nut

and star washer behind bracket. Tighten hex nut (5) to

20-35 in-lbs (2.3-4.0 Nm).

CAUTION

NOTE

Pay close attention to the vehicle's warm-up time. Either

Star lock washer (4) is positioned between bracket and hex

excessive or insufficient use of the enrichener may

nut.

cause poor performance, erratic idle, poor fuel economy,

spark plug fouling and equipment damage. (00164a)

x0605x3x

Inspect enrichener operation at every scheduled service

interval.

CAUTION

Do not lubricate the enrichener cable or inside of

enrichener cable conduit. The cable must have sliding

resistance to work properly.

See Figure 1-68. Check fuel enrichener operation. The fuel

enrichener knob (1) should open, remain open and then

close without binding. The knurled plastic nut (2) next to the

enrichener knob controls the sliding resistance of the

Fuel enrichener knob

enrichener control cable within the cable conduit.

Knurled plastic nut

Flat

Star lock washer

Hex nut

Enrichener bracket

Figure 1-68. Enrichener Control

1-56

2006 Sportster: Maintenance

HOME

IDLE SPEED AND IGNITION TIMING

1.25

IDLE SPEED ADJUSTMENT

x0506a1x

PART NO.

SPECIALTY TOOL

HD-33413-A

Carburetor idle adjuster

HD-33413-1A

Adjuster tip

Check and adjust engine idle speed as described below.

NOTES

●

The CV carburetor enrichener circuit will cause engine to

idle above the normal idle range (950-1050 RPM) with

engine running at normal operating temperature and

enrichener knob pulled out fully. With enrichener knob

pulled out partially, and engine running at normal operat-

ing temperature, engine idle speed will also increase

above normal idle range.

●

The increase in idle speed is intended to alert rider that

engine is warmed up to normal operating temperature

and enrichener knob should be pushed in all the way.

Figure 1-69. Idle Speed Adjustment Screw

●

Continued use of enrichener after engine is at normal

operating temperature WILL cause fouled spark plugs.

Start motorcycle and let vehicle reach normal operating

Sensor

temperature. Push enrichener knob fully in (enrichener

data

MAP

closed).

sensor

Ignition

See Figure 1-69. Adjust idle speed adjusting screw so

Control

engine idles at 950-1050 RPM.

Module

Sensor

(ICM)

a. Turn screw clockwise to increase idle speed.

data

CKP

sensor

b. Turn screw counterclockwise to decrease idle

speed.

NOTES

●

Use CARBURETOR IDLE ADJUSTER and ADJUSTER

TIP to turn idle adjusting screw if necessary.

Ignition coil

control signals

●

To adjust the idle speed on models without a tachometer,

use a digital engine tachometer, such as the Snap-On

SE-1100, held near a spark plug cable while the motor-

cycle is idling.

Ignition

Coil

IGNITION TIMING

See Figure 1-70. Ignition timing is controlled by the Ignition

Control Module (ICM) based on input from:

● Manifold Absolute Pressure (MAP) sensor.

● Crank Position (CKP) sensor.

No ignition timing adjustment is required, or possible. Should

a sensor fail, the resulting diagnostic trouble code (DTC) will

identify the problem. See the SPORTSTER MODELS ELEC-

x0552a1x

TRICAL DIAGNOSTIC MANUAL for more information.

Figure 1-70. Ignition Control

2006 Sportster: Maintenance

1-57

HOME

FUEL SUPPLY VALVE FILTER

1.26

INSPECTION

WARNING

Stop the engine when refueling or servicing the fuel sys-

PART NO.

SPECIALTY TOOL

tem. Do not smoke or allow open flame or sparks near

gasoline. Gasoline is extremely flammable and highly

HD-23738-A

Plastic Mity-Vac hand pump

explosive, which could result in death or serious injury.

HD-41137

Hose clamp pliers

(00002a)

2. See Figure 1-71. Remove clamp (8) and fuel hose (9)

See Figure 1-71. Check fuel valve filter strainer (1) as follows:

from outlet nipple (7). Remove vacuum hose (10) from

Turn ignition OFF. See Figure 1-72. Turn fuel supply

vacuum nipple (5).

valve handle to OFF (horizontal) position.

CAUTION

x0509a1x

Do not allow dirt or fluids to get into the vacuum hose

assembly that connects the fuel valve to the carburetor.

Contaminants could block the vacuum signal or inhibit

free motion of moving parts which could cause the fuel

valve to remain open.

3. Attach a piece of fuel hose to fuel outlet nipple and route

hose into a proper, clean gasoline container.

4. See Figure 1-72. Turn valve handle to RESERVE (handle

up).

x0510a1x

Fuel strainer

Gasket

Hex fitting

Fuel supply valve assembly

Vacuum nipple

Fuel supply valve handle

OFF

Outlet nipple (underneath)

Clamp

Reserve

Fuel hose

Figure 1-72. Fuel Valve Operating Positions

10. Vacuum hose

Figure 1-71. Fuel Supply Valve

1-58

2006 Sportster: Maintenance

HOME

See Figure 1-73. Using the appropriate hose adapter,

11. Attach fuel supply valve assembly to tank.

connect the PLASTIC MITY-VAC® HAND PUMP to vac-

a. Thread hex fitting (3) on right hand threads of fuel

uum nipple on fuel valve.

tank two turns. Collar on hex fitting faces fuel tank.

b. Hold hex fitting and thread body of fuel supply valve

CAUTION

assembly into left hand threads of hex fitting two

turns.

Do not apply a vacuum greater than 25 in. of Hg to the

valve at the vacuum nipple to avoid damaging the valve

c. Hold fuel supply valve assembly so that handle

diaphragm.

points to the left, straight away from motorcycle.

Tighten hex fitting (clockwise) to 15-20 ft-lbs (20.3-

Gently apply a vacuum of 1-10 in. of Mercury (Hg) or just

27.1 Nm).

enough vacuum to get a good flow of gasoline through

12. See Figure 1-74. Connect the fuel hose to the outlet nip-

the valve.

ple on the fuel supply valve assembly using new clamp

See Figure 1-71. After draining tank, turn the hex fitting

and HOSE CLAMP PLIERS.

(3) that attaches the fuel valve assembly (4) to the fuel

13. See Figure 1-71. Connect vacuum hose (10) to vacuum

tank counterclockwise and remove the valve assembly,

nipple (5) and fill tank with gasoline. Check for leaks at

gasket (2), and fuel strainer (1). Discard gasket.

fitting.

14. See Figure 1-72. Turn fuel supply valve handle ON and

HD-23738A

start engine. No special procedures are required to start

fuel flow. Carefully inspect for leaks. Turn fuel supply

valve OFF and shut off engine after inspection is com-

plete.

FUEL SYSTEM LINES AND

FITTINGS

Inspect the fuel system lines:

● At every scheduled service interval.

● After the fuel tank filter has been serviced.

Check fuel system lines and fittings for leaks.

Figure 1-73. Mity-Vac Hand Pump

(Part No. HD-23738-A)

HD-41137

Clean or replace fuel strainer.

Coat fuel valve threads with LOCTITE PIPE SEALANT

WITH TEFLON.

10. Install new gasket and fuel strainer on fuel valve assem-

bly.

1WARNING

Do not thread fitting onto valve more than two turns to

avoid “bottoming” fitting on valve. This could cause a

gasoline leak and a fire hazard which could result in

death or serious injury.

Figure 1-74. Hose Clamp Pliers

(Part No. HD-41137)

2006 Sportster: Maintenance

1-59

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Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 6

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