Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 4
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Acronyms and Abbreviations
ACRONYM OR ABBREVIATION
DESCRIPTION
IGN
Ignition Light/Key Switch
IM
Instrument Module
In.
Inch
INJ PW
Injector Pulse Width
in-lbs
Inch-Pounds
Kg
Kilogram
Km
Kilometer
kPa
Kilopascal
km/hr
Kilometers Per Hour
L
Liter
LCD
Liquid Crystal Display
LED
Light Emitting Diode
mA
Milliampere
MAP
Manifold Absolute Pressure
ml
mililiter
mm
millimeter
MPH
Miles Per Hour
ms
millisecond
Nm
Newton-Meter
N/A
Not Applicable
no.
number
O2
oxygen
OD
Outside Diameter
OEM
Original Equipment Manufacturer
oz
Ounce
P&A
Parts and Accessories
PN
Part Number
PSI
Pounds Per Square Inch
RES
Reserve
RPM
Revolutions Per Minute
SCFH
Cubic Feet per Hour at Standard Conditions
TDC
Top Dead Center
TP
Throttle Position
TSM
Turn Signal Module
TSSM
Turn Signal/Security Module
V
Volt
VAC
Volts of Alternating Current
VDC
Volts of Direct Current
VIN
Vehicle Identification Number
VSS
Vehicle Speed Sensor
E-2
Glossary
HOME
GENERAL
1.1
SERVICING A NEW
Removing Parts
MOTORCYCLE
Always consider the weight of a part when lifting. Use a hoist
whenever necessary. Do not lift heavy parts by hand. A hoist
and adjustable lifting beam or sling are needed to remove
some parts. The lengths of chains or cables from the hoist to
1WARNING
the part should be equal and parallel and should be posi-
Perform the service and maintenance operations as indi-
tioned directly over the center of the part. Be sure that no
cated in the regular service interval table. Lack of regular
obstructions will interfere with the lifting operation. Never
maintenance at the recommended intervals can affect
leave a part suspended in mid-air.
the safe operation of your motorcycle, which could result
in death or serious injury. (00010a)
1WARNING
Service operations to be performed before customer delivery
are specified in the applicable model year PREDELIVERY
Always check the capacity rating and condition of hoists,
AND SETUP MANUAL.
slings, chains or cables before use. Failure to do so
could lead to an accident which could result in death or
The performance of new motorcycle initial service is required
serious injury.
to keep warranty in force and to ensure proper emissions sys-
tems operation.
Always use blocking or proper stands to support the part that
has been hoisted. If a part cannot be removed, verify that all
After a new motorcycle has been driven its first 1000 miles
bolts and attaching hardware have been removed. Check to
(1600 km), and at every 5000 mile (8000 km) interval thereaf-
see if any parts are in the way of the part being removed.
ter, have a Harley-Davidson dealer perform the service oper-
ations listed under 1.3 MAINTENANCE SCHEDULE.
When removing hoses, wiring or tubes, always tag each part
to ensure proper installation.
SHOP PRACTICES
Cleaning
If you intend to reuse parts, follow good shop practice and
Repair Notes
thoroughly clean the parts before assembly. Keep all dirt out
of parts; the unit will perform better and last longer. Seals, fil-
NOTES
ters and covers are used in this vehicle to keep out environ-
● General maintenance practices are given in this section.
mental dirt and dust. These items must be kept in good
● Repair = Disassembly/Assembly.
condition to ensure satisfactory operation.
● Replace = Removal/Installation.
Clean and inspect all parts as they are removed. Be sure all
holes and passages are clean and open. After cleaning,
All special tools and torque values are noted at the point of use.
cover all parts with clean lint-free cloth, paper or other mate-
All required parts or materials can be found in the appropriate
rial. Be sure the part is clean when it is installed.
PARTS CATALOG.
Always clean around lines or covers before they are removed.
Plug, tape or cap holes and openings to keep out dirt, dust
Safety
and debris.
Safety is always the most important consideration when per-
Always verify cleanliness of blind holes before assembly.
forming any job. Be sure you have a complete understanding
Tightening a screw with dirt, water or oil in the hole can cause
of the task to be performed. Use common sense. Use the
castings to crack or break.
proper tools. Protect yourself and bystanders with approved
eye protection. Don’t just do the job - do the job safely.
2006 Sportster: Maintenance
1-1
HOME
Disassembly and Assembly
Bearings
Always assemble or disassemble one part at a time. Do not
Anti-friction bearings must be handled in a special way. To
work on two assemblies simultaneously. Be sure to make all
keep out dirt and abrasives, cover the bearings as soon as
necessary adjustments. Recheck your work when finished.
they are removed from the package.
Be sure that everything is done.
Wash bearings in a non-flammable cleaning solution. Knock
Operate the vehicle to perform any final check or adjust-
out packed lubricant inside by tapping the bearing against a
ments. If all is correct, the vehicle is ready to go back to the
wooden block. Wash bearings again. Cover bearings with
customer.
clean material after setting them down to dry. Never use com-
pressed air to dry bearings.
Magnetic Parts Trays
Coat bearings with clean oil. Wrap bearings in clean paper.
Magnetic parts trays are becoming common in the service
When bearings are installed against shoulders, be sure that
facility because they are convenient and can keep parts from
the chamfered side of the bearing always faces the shoulder.
becoming lost during a repair procedure.
Lubricate bearings and all metal contact surfaces before
However, hardened steel parts can become magnetized
pressing into place. Only apply pressure on the part of the
when held in magnetic parts trays. Metal fragments that
bearing that makes direct contact with the mating part.
would ordinarily be washed away in the oil and trapped in the
Always use the proper tools and fixtures for removing and
oil filter or magnetic drain plug during vehicle operation could
installing bearings.
be captured by magnetized parts in the engine, potentially
causing accelerated engine wear and damage.
Bearings do not usually need to be removed. Only remove
bearings if necessary.
Parts that will be returned to service inside the vehicle’s pow-
ertrain such as gears, thrust washers and especially bearings
Bushings
should never be kept in magnetic parts trays.
Do not remove a bushing unless damaged, excessively worn
or loose in its bore. Press out bushings that must be replaced.
REPAIR AND REPLACEMENT
When pressing or driving bushings, be sure to apply pressure
PROCEDURES
in line with the bushing bore. Use a bearing/bushing driver or
a bar with a smooth, flat end. Never use a hammer to drive
bushings.
Hardware and Threaded Parts
Inspect the bushing and the mated part for oil holes. Be sure
Install helical thread inserts when inside threads in castings
all oil holes are properly aligned.
are stripped, damaged or not capable of withstanding speci-
fied torque.
Gaskets
Replace bolts, nuts, studs, washers, spacers and small com-
Always discard gaskets after removal. Replace with new gas-
mon hardware if missing or in any way damaged. Clean up or
kets. Never use the same gasket twice. Be sure that gasket
repair minor thread damage with a suitable tap or die.
holes match up with holes in the mating part.
Replace all damaged or missing lubrication fittings.
Lip Type Seals
Use Teflon pipe sealant on pipe fitting threads.
Lip seals are used to seal oil or grease and are usually
Wiring, Hoses and Lines
installed with the sealing lip facing the contained lubricant.
Seal orientation, however, may vary under different applica-
Replace hoses, clamps, electrical wiring, electrical switches
tions.
or fuel lines if they do not meet specifications.
Seals should not be removed unless necessary. Only remove
Instruments and Gauges
seals if required to gain access to other parts or if seal dam-
age or wear dictates replacement.
Replace broken or defective instruments and gauges.
Replace dials and glass that are so scratched or discolored
Leaking oil or grease usually means that a seal is damaged.
that reading is difficult.
Replace leaking seals to prevent overheated bearings.
Always discard seals after removal. Do not use the same seal
twice.
1-2
2006 Sportster: Maintenance
HOME
O-Rings (Preformed Packings)
Rust or Corrosion Removal
Always discard O-rings after removal. Replace with new O-
Remove rust and corrosion with a wire brush, abrasive cloth,
rings. To prevent leaks, lubricate the O-rings before installa-
sand blasting, vapor blasting or rust remover. Use buffing cro-
tion. Apply the same type of lubricant as that being sealed.
cus cloth on highly polished parts that are rusted.
Be sure that all gasket, O-ring and seal mating surfaces are
thoroughly clean before installation.
Bearings
Clean open bearings by soaking them in a petroleum clean-
Gears
ing solution. Never use a solution that contains chlorine.
Always check gears for damaged or worn teeth.
Let bearings stand and dry. Do not dry with compressed air.
Lubricate mating surfaces before pressing gears on shafts.
Do not spin bearings while they are drying.
Shafts
TOOL SAFETY
If a shaft does not come out easily, check that all nuts, bolts
or retaining rings have been removed. Check to see if other
parts are in the way before using force.
Air Tools
Shafts fitted to tapered splines should be very tight. If shafts
● Always use approved eye protection equipment when
are not tight, disassemble and inspect tapered splines. Dis-
performing any task using air-operated tools.
card parts that are worn. Be sure tapered splines are clean,
● On all power tools, use only recommended accessories
dry and free of burrs before putting them in place. Press mat-
with proper capacity ratings.
ing parts together tightly.
● Do not exceed air pressure ratings of any power tools.
Clean all rust from the machined surfaces of new parts.
● Bits should be placed against work surface before air
Part Replacement
hammers are operated.
Always replace worn or damaged parts with new parts.
● Disconnect the air supply line to an air hammer before
attaching a bit.
● Never point an air tool at yourself or another person.
CLEANING
● Protect bystanders with approved eye protection.
Part Protection
Wrenches
Before cleaning, protect rubber parts (such as hoses, boots
● Never use an extension on a wrench handle.
and electrical insulation) from cleaning solutions. Use a
● If possible, always pull on a wrench handle and adjust
grease-proof barrier material. Remove the rubber part if it
your stance to prevent a fall if something lets go.
cannot be properly protected.
● Never cock a wrench.
Cleaning Process
● Never use a hammer on any wrench other than a STRIK-
ING FACE wrench.
Any cleaning method may be used as long as it does not
result in parts damage. Thorough cleaning is necessary for
● Discard any wrench with broken or battered points.
proper parts inspection. Strip rusted paint areas to bare metal
● Never use a pipe wrench to bend, raise or lift a pipe.
before repainting.
2006 Sportster: Maintenance
1-3
HOME
Pliers/Cutters/Prybars
Ratchets and Handles
● Plastic- or vinyl-covered pliers handles are not intended
● Periodically clean and lubricate ratchet mechanisms with
to act as insulation; don’t use on live electrical circuits.
a light grade oil. Do not replace parts individually; ratch-
ets should be rebuilt with the entire contents of service
● Don’t use pliers or cutters for cutting hardened wire
kit.
unless they were designed for that purpose.
● Never hammer or put a pipe extension on a ratchet or
● Always cut at right angles.
handle for added leverage.
● Don’t use any prybar as a chisel, punch or hammer.
● Always support the ratchet head when using socket
extensions, but do not put your hand on the head or you
Hammers
may interfere with the action of its reversing mechanism.
● Never strike a hammer against a hardened object, such
● When breaking loose a fastener, apply a small amount of
as another hammer.
pressure as a test to be sure the ratchet’s gear wheel is
● Always grasp a hammer handle firmly, close to the end.
engaged with the pawl.
● Strike the object with the full face of the hammer.
Sockets
● Never work with a hammer which has a loose head.
● Never use hand sockets on power or impact wrenches.
● Discard hammer if face is chipped or mushroomed.
● Select the right size socket for the job.
● Wear approved eye protection when using striking tools.
● Never cock any wrench or socket.
● Protect bystanders with approved eye protection.
● Select only impact sockets for use with air or electric
Punches/Chisels
impact wrenches.
● Never use a punch or chisel with a chipped or mush-
● Replace sockets showing cracks or wear.
roomed end; dress mushroomed chisels and punches
● Keep sockets clean.
with a file.
● Always use approved eye protection when using power
● Hold a chisel or a punch with a tool holder if possible.
or impact sockets.
● When using a chisel on a small piece, clamp the piece
firmly in a vise and chip toward the stationary jaw.
Storage Units
● Wear approved eye protection when using these tools.
● Don’t open more than one loaded drawer at a time.
Close each drawer before opening up another.
● Protect bystanders with approved eye protection.
● Close lids and lock drawers and doors before moving
Screwdrivers
storage units.
● Don’t use a screwdriver for prying, punching, chiseling,
● Don’t pull on a tool cabinet; push it in front of you.
scoring or scraping.
● Set the brakes on the locking casters after the cabinet
● Use the right type of screwdriver for the job; match the tip
has been rolled to your work.
to the fastener.
● Don’t interchange POZIDRIV®, PHILLIPS® or REED
AND PRINCE screwdrivers.
● Screwdriver handles are not intended to act as insula-
tion; don’t use on live electrical circuits.
● Don’t use a screwdriver with rounded edges because it
will slip - redress with a file.
1-4
2006 Sportster: Maintenance
HOME
FUEL AND OIL
1.2
FUEL
ENGINE OIL
Harley-Davidson motorcycles were designed to obtain the
Use the proper grade of oil for the lowest temperature
best performance and efficiency using unleaded gasoline (91
expected before the next oil change.
pump octane or higher for the XL 1200 Custom and XL 1200
If it is necessary to add oil and Harley-Davidson oil is not
Roadster, 87 or higher for all other models). Pump octane is
available, use an oil certified for diesel engines. Acceptable
the octane number usually shown on the gas pump. Some
diesel engine oil designations include CF, CF-4, CG-4 and
fuel suppliers sell gasoline/alcohol blends as a fuel. The type
CH-4. The preferred viscosities for the diesel engine oils, in
and amount of alcohol added to the fuel is important.
descending order, are 20W-50, 15W-40 and 10W-40. At the
first opportunity, see a Harley-Davidson dealer to change
1WARNING
back to 100 percent Harley-Davidson oil.
See 1.5 ENGINE OIL AND FILTER for all service information.
Avoid spills. Slowly remove filler cap. Do not fill above bot-
tom of filler neck insert, leaving air space for fuel expan-
sion. Secure filler cap after refueling. Gasoline is
WINTER LUBRICATION
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)
Normal fuel combustion in a gasoline engine produces water
vapor and carbon dioxide along with other gases and particu-
lates. During starting and warm-up in cold weather, especially
GASOLINE BLENDS
in freezing temperatures, the vapor condenses to water
before the crankcase is hot enough to exhaust it through the
breather system. If the engine is driven long enough to thor-
CAUTION
oughly warm the crankcase, most of this liquid water is again
Do not use gasoline that contains methanol. Doing so
vaporized and exhausted through the crankcase breather
can result in fuel system component failure, engine dam-
system.
age and/or equipment malfunction. (00148a)
A moderately driven vehicle making short runs may not be
Harley-Davidson motorcycles are designed to give the best
able to vacate water vapors allowing liquid water to accumu-
performance using unleaded gasoline. Some fuel suppliers
lates in the oil tank. This is especially true if the vehicle is
sell gasoline/alcohol blends as a fuel. The type and amount of
operated in cold weather. In freezing weather, an accumula-
alcohol added to the fuel is important.
tion of water in the engine oil may become slush or ice, which
can block oil lines and lead to severe engine damage. Water
● DO NOT USE GASOLINES CONTAINING METHANOL.
remaining in the engine oil for long periods of time can form
Using gasoline/methanol blends will result in starting and
an acidic sludge that is corrosive to metal engine parts and
driveability deterioration and damage to critical fuel sys-
causes accelerated wear of moving components.
tem components.
Always change the engine oil more often in winter. The colder
● ETHANOL is a mixture of 10% ethanol (Grain alcohol)
the weather, the shorter the recommended oil change inter-
and 90% unleaded gasoline. It is identified as “gasohol,”
val. If the engine is used for short runs, change the oil even
“ethanol enhanced,” or “contains ethanol.” Gasoline/etha-
more frequently.
nol blends can be used in your motorcycle if the ethanol
content does not exceed 10%.
● REFORMULATED OR OXYGENATED GASOLINES
(RFG):
“Reformulated gasoline” is a term used to
describe gasoline blends that are specifically designed to
burn cleaner than other types of gasoline. Your motorcy-
cle will run normally using this type of gasoline.
Because of their generally higher volatility, these blends may
adversely affect the starting, driveability and fuel efficiency of
your motorcycle. If you experience these problems, Harley-
Davidson recommends you operate your motorcycle on
straight, unleaded gasoline.
2006 Sportster: Maintenance
1-5
HOME
MAINTENANCE SCHEDULE
1.3
If more detailed information is needed, turn to the sections
GENERAL
which follow for step-by-step instructions.
The table below lists the periodic maintenance requirements
Also, throughout this manual, you will be instructed to use
for Sportster model motorcycles. If you are familiar with the
various lubricants, greases and sealants. Refer to Table 1-3.
procedures, just refer to the table for the recommended ser-
for the correct part numbers of these items.
vice interval. If necessary, see the quick reference table
(Table 1-2.) on page 1-8 for the required specifications.
Table 1-1. Regular Service Intervals For Sportster Models
1000
5000
10,000
15,000
20,000
25,000
MI
MI
MI
MI
MI
MI
ITEM SERVICED
PROCEDURE
NOTES
1600
8000
16,000
24,000
32,000
40,000
KM
KM
KM
KM
KM
KM
Engine oil and filter
Replace
X
X
X
X
X
X
Oil lines and brake system
Inspect for leaks
X
X
X
X
X
X
1
Air cleaner
Inspect, service as required
X
X
X
X
X
X
Tires
Check pressure, inspect tread
X
X
X
X
X
X
Wheel spokes
Check tightness
X
X
X
X
X
X
1, 4
Transmission lubricant
Replace
X
X
X
Clutch
Check adjustment
X
X
X
X
X
X
1
Primary chain
Check adjustment
X
X
X
X
X
X
Rear belt and sprockets
Inspect, adjust belt
X
X
X
X
X
X
1
Throttle, brake, enrichener and
Check, adjust and lubricate
X
X
X
X
X
X
1
clutch controls
Jiffy stand
Inspect and lubricate
X
X
X
1
Fuel valve, lines and fittings
Inspect for leaks
X
X
X
X
X
X
1
Fuel tank filter screen
Clean
X
1
Brake fluid
Check levels and condition
X
X
X
X
X
X
Brake pads and discs
Inspect for wear
X
X
X
X
X
X
Front brake lever pin
Inspect
X
X
X
X
1, 2
Lubricate
X
1, 2
Brake caliper pins
Inspect
X
X
X
X
1, 2
Lubricate
X
1, 2
Brake caliper boots and bush-
Inspect
X
X
X
X
1, 2
ings
Replace
X
1, 2
Rear master cylinder outer
Inspect
X
X
X
X
X
1, 2
boot
Brake components
Replace brake rubber components
in
X
1, 2
master cylinders and calipers
Lubricate master cylinder pistons
X
1, 2
Spark plugs
Inspect
X
X
X
X
Replace
X
X
Electrical
equipment and
Check operation
X
X
X
X
X
X
switches
Engine idle speed
Check adjustment
X
X
X
X
X
X
1
Front fork oil
Replace
X
1
Steering head bearings
Adjust
X
X
1
Lubricate
X
1
1-6
2006 Sportster: Maintenance
HOME
Table 1-1. Regular Service Intervals For Sportster Models
1000
5000
10,000
15,000
20,000
25,000
MI
MI
MI
MI
MI
MI
ITEM SERVICED
PROCEDURE
NOTES
1600
8000
16,000
24,000
32,000
40,000
KM
KM
KM
KM
KM
KM
Rear fork bearings
Replace every 30,000 mi (48,000 km)
1
Shock absorbers
Inspect
X
X
X
X
X
X
1
Critical fasteners
Check tightness
X
X
X
1
Engine mounts and stabilizer
Inspect
X
X
1
links
Battery
Check battery and clean connections
3
Road test
Verify component and system functions
X
X
X
X
X
X
NOTES
1.
Should be performed by an authorized Harley-Davidson dealer, unless you have the
proper tools, service data and are mechanically qualified.
2.
Replace every four (4) years.
3.
Perform annually.
4.
Not all vehicles are equipped with spoke wheels. Consult appropriate topic in service
manual.
2006 Sportster: Maintenance
1-7
HOME
Table 1-2. Quick Reference Maintenance Chart
ITEM SERVICED
SPECIFICATION
DATA
Engine oil and filter
Oil capacity
3.6 qt. (3.4 L)
Filter
Hand tighten 1/2-3/4 turn after gasket contact
Chrome filter (XL 1200C)
Part no. 63796-77A
Black filter (all except XL 1200C)
Part no. 63805-80A
Primary chain tension
Deflection with hot engine
1/4-3/8 in. (6.3-9.5 mm)
Deflection with cold engine
3/8-1/2 in. (9.5-12.7 mm)
Chain tensioner nut torque
20-25 ft-lbs (27.1-33.9 Nm)
Primary chain inspection cover torque
40-60 in-lbs (4.5-6.8 Nm)
Primary chain/
Lubricant capacity
32 oz. (946 mL)
transmission lubricant
Primary chaincase drain plug torque
14-30 ft-lbs (19.0-40.7 Nm)
Lubricant
Genuine Harley-Davidson Formula+ Transmission and
Primary Chaincase Lubricant
Clutch adjustment
Free play at adjuster screw
1/4 turn
Free play at hand lever
1/16-1/8 (1.6-3.2 mm)
Clutch inspection cover torque
84-108 in-lbs (9.5-12.2 Nm)
Tire condition and
Pressure for solo rider
Front: 30 psi (207 kPa), Rear: 36 psi (248 kPa)
pressure
Pressure for rider and passenger
Front: 30 psi (207 kPa), Rear: 40 psi (276 kPa)
Wear
Replace tire if 1/32 in. (0.8 mm) or less of tread pattern
remains
Wheel spokes
Spoke nipple torque
40-50 in-lbs (4.5-5.7 Nm)
Steering head bearings
Lubricant for neck fitting
SPECIAL PURPOSE GREASE
Brake fluid reservoir level
Brake fluid type
D.O.T. 5 brake fluid
Proper fluid level (front brake)
1/4 in. (6 mm) from the top of the reservoir
Proper fluid level (rear brake)
Upper fluid level in reservoir
Front master cylinder reservoir cover
9-17 in-lbs (1.0-2.0 Nm)
screws
Brake pad linings and
Minimum brake pad thickness
0.04 in. (1.02 mm)
discs
Minimum brake disc thickness
See stamp on side of disc
Drive belt
Upward measurement force applied at
10 lb. (4.5 kg)
midpoint of bottom belt strand
Belt deflection with motorcycle on jiffy
XL 883L/XL 883C/XL 1200C: 1/4-5/16 in. (6.4-7.9 mm)
stand, belt and sprockets at ambient
XL 883/XL 883R/XL 1200R: 3/8-7/16 in. (9.5-11.1 mm)
temperature (cold engine), without
rider or luggage
Air cleaner
Air filter element screw torque
40-60 in-lbs (4.5-6.8 Nm)
Air cleaner cover screw torque
30-60 in-lbs (4.1-6.8 Nm)
Enrichener control
Hex nut torque
20-35 in-lbs (2.3-4.0 Nm)
Engine idle speed
Idle speed
950-1050 RPM
1-8
2006 Sportster: Maintenance
HOME
Table 1-2. Quick Reference Maintenance Chart
ITEM SERVICED
SPECIFICATION
DATA
Fuel tank filter
Sealant for fuel valve and fuel tank
LOCTITE PIPE SEALANT WITH TEFLON 565
adapter
Part no. 99818-97 (6 ml)
Hex jam nut torque
15-20 ft-lbs (20.3-27.1 Nm)
Clutch and throttle
Lubricant
SUPER OIL
cables
Handlebar clamp screw torque
108-132 in-lbs (12.2-14.9 Nm)
Handlebar switch housing screw
35-45 in-lbs (3.9-5.0 Nm)
torque
Spark plugs
Type
HD-6R12
Gap
0.038-0.043 in. (0.96-1.09 mm)
Torque
12-18 ft-lbs (16.3-24.4 Nm)
Front fork oil
Type
HYDRAULIC FORK OIL (TYPE E)
Amount
See 1.20 FRONT FORK OIL
Battery
Lubricant
ELECTRICAL CONTACT LUBRICANT
Terminal screw torque
40-50 in-lbs (4.5-5.7 Nm)
Critical fasteners
See 1.4 CRITICAL FASTENERS
Engine mounts/isolators
See 2.22 FRONT ENGINE MOUNT/ISOLATOR, 2.23 REAR ENGINE MOUNT/ISOLATOR,
and Stabilizers
2.21 STABILIZER LINKS
Table 1-3. Lubricants, Greases, Sealants
ITEM
PART NUMBER
PACKAGE
Anti-Seize Lubricant
98960-97
1 oz squeeze tube
D.O.T. 5 Brake Fluid
99902-77
12 oz. bottle
99901-77
1 gal
Electrical Contact Lubricant
99861-02
1 oz squeeze tube
Genuine Harley-Davidson Formula+ Transmission
99851-05
1 qt bottle
and Primary Chaincase Lubricant
G40M Brake Grease
42820-04
squeeze packet
Gray High Performance Sealant
99650-02
1.9 oz squeeze tube
HYLOMAR® Gasket and Thread Sealant
99653-85
3.5 oz tube
Loctite® Pipe Sealant With Teflon 565
99818-97
6 ml squeeze tube
Loctite® Prism Primer (770)
Loctite® Prism Superbonder (411)
Loctite® Superbonder 420 Adhesive
Loctite® Threadlocker 243 (blue)
99642-97
6 ml squeeze tube
Loctite® Threadlocker 262 (red)
94759-99
6 ml squeeze tube
Loctite® Threadlocker 272
98618-03
10 ml bottle
Special Purpose Grease
99857-97
14 oz. cartridge
Super Oil
94968-85TV
1/4 fl. oz
Type “E” Hydraulic Fork Oil
99884-80
16 oz bottle
2006 Sportster: Maintenance
1-9
HOME
CRITICAL FASTENERS
1.4
Refer to Table 1-4. Tighten all critical fasteners, except head
INSPECTION
bolts, to service manual specifications. Replace any dam-
aged or missing hardware.
Inspect critical fasteners, except head bolts.
Table 1-4. Critical Fasteners
SYSTEM
FASTENER
TORQUE
Upper and lower switch housing screws
35-45 in-lbs
3.9-5.0 Nm
Hand controls
Clutch lever handlebar clamp screws
108-132 in-lbs
12.2-14.9 Nm
Master cylinder handlebar clamp screws
108-132 in-lbs
12.2-14.9 Nm
Stabilizer link screws
25-35 ft-lbs
33.9-47.5 Nm
Upper front stabilizer link-to-frame mounting
25-35 ft-lbs
33.9-47.5 Nm
bracket screws
Upper front stabilizer link-to-engine mounting
55-65 ft-lbs
74.6-88.2 Nm
bracket screws
Lower front stabilizer link-to-frame mounting
Engine
25-35 ft-lbs
33.9-47.5 Nm
bracket screws
Front isolator mounting bolt
60-70 ft-lbs
81.4-95.0 Nm
Rear isolator/rear fork pivot shaft bolts
60-70 ft-lbs
81.4-95.0 Nm
Front isolator mounting bracket screws (left side)
25-35 ft-lbs
33.9-47.5 Nm
Rear isolator mounting bracket screws (left side)
25-35 ft-lbs
33.9-47.5 Nm
Brake line banjo bolts
20-25 ft-lbs
27.1-33.9 Nm
Brake disc mounting screws, front
16-24 ft-lbs
21.7-32.5 Nm
Brake disc mounting screws, rear
30-45 ft-lbs
40.7-61.0 Nm
Front master cylinder reservoir cover screws
9-17 in-lbs
1.0-2.0 Nm
Brakes
Rear master cylinder mounting screws
15-20 ft-lbs
20.3-27.1 Nm
Rear master cylinder bracket-to-frame
17-22 ft-lbs
23.1-29.9 Nm
mounting screws
Front brake caliper mounting screws
28-38 ft-lbs
38.0-51.6 Nm
Front axle
50-55 ft-lbs
67.8-74.6 Nm
Axle nuts
Rear axle
72-78 ft-lbs
98-106 Nm
Lower bracket pinch screws
30-35 ft-lbs
40.7-47.5 Nm
Upper bracket pinch screws
30-35 ft-lbs
40.7-47.5 Nm
Steering stem bolt
15 ft-lbs, loosen, 7 ft-lbs
20.4 Nm, loosen, 9.5 Nm
Front fork/
Steering stem pinch screw
30-35 ft-lbs
40.7-47.5 Nm
handlebars
Front axle pinch screw
21-27 ft-lbs
28.5-36.6 Nm
Handlebar clamp mounting screw
12-18 ft-lbs
16.3-24.4 Nm
Riser mounting bolts
30-40 ft-lbs
40.7-54.3 Nm
Final drive
Rear sprocket mounting bolts
55-65 ft-lbs
74.6-88.2 Nm
1-10
2006 Sportster: Maintenance
HOME
ENGINE OIL AND FILTER
1.5
CHECKING AND ADDING OIL
11310
Check engine oil level in oil tank and add oil if necessary. Oil
tank capacity is 3.6 quarts (U.S.) (3.4 liters). Refer to Table 1-
5. on the next page for recommended engine oil viscosity.
Removing and Replacing Oil Filler Cap
1.
See Figure 1-1. Remove filler cap from oil tank on right
side of vehicle.
a. Press straight down on filler cap and release. Cap
will pop up.
b. Pull up on filler cap while turning counterclockwise
one-quarter turn as if unscrewing filler cap.
2.
Wipe attached dipstick clean.
NOTE
Figure 1-1. Filler Cap/Dipstick Location
See Figure 1-2. Note that dipstick has a wide slot (1) and a
narrow slot (2) and can only be inserted in oil tank one way.
3.
Insert dipstick into tank. Turn filler cap clockwise one-
x0575x1x
quarter turn as if screwing filler cap into tank. When filler
cap stops turning, it is fully seated. Press down on filler
1
cap until it snaps in place, flush with top of oil tank cover.
Checking Oil With Cold Engine
1.
Position motorcycle so that it is leaning on jiffy stand.
2.
Remove filler cap. See Removing and Replacing Oil
Filler Cap above. Wipe attached dipstick clean. Reinstall
oil filler cap in tank.
2
3.
Remove oil filler cap again and check oil level on dipstick.
See Figure 1-3. Dipstick has two marks. If oil level is at or
below lower mark (2), add only enough oil to bring the
level to a point between the two arrows on the dipstick.
1.
Wide slot
Replace filler cap.
2.
Narrow slot
Checking Oil With Warm Engine
Figure 1-2. Filler Cap/Dipstick
1.
Run engine until engine oil is at normal operating tem-
perature. Turn engine off.
2.
Position motorcycle so that it is leaning on jiffy stand.
x0576x1x
1
3.
Remove filler cap. See Removing and Replacing Oil
Filler Cap above. Wipe attached dipstick clean. Reinstall
oil filler cap in tank.
4.
Remove filler cap again and check warm oil level on dip-
stick. See Figure 1-3. Dipstick has two marks. If oil level
in tank is at or below lower mark, add one quart (0.946
liter) of Harley-Davidson oil to tank. Replace filler cap.
5.
If you added oil in step 4, remove filler cap and verify cor-
2
rect engine oil level in oil tank. Do not fill oil tank to a level
1.
Upper mark (full)
above upper mark on dipstick. Replace filler cap.
2.
Lower mark
Figure 1-3. Checking Oil Level
2006 Sportster: Maintenance
1-11
HOME
Table 1-5. Recommended Engine Oil Viscosity
COLD WEATHER
HARLEY-DAVIDSON
HARLEY-DAVIDSON
LOWEST AMBIENT
VISCOSITY
STARTS BELOW 50˚F
TYPE
RATING
TEMPERATURE
(10˚C)
HD Multigrade
SAE 10W40
HD 360
Below 40˚ F (4˚ C)
Excellent
HD Multigrade
SAE 20W50
HD 360
Above 40˚ F (4˚ C)
Good
HD Regular Heavy
SAE 50
HD 360
Above 60˚ F (16˚ C)
Poor
HD Extra Heavy
SAE 60
HD 360
Above 80˚ F (27˚ C)
Poor
3. Loosen worm drive clamp (2) and pull drain plug (3) from
CHANGING OIL AND FILTER
end of drain hose. Completely drain engine oil from oil
tank. It is not necessary to drain engine crankcase.
General
4. Replace drain plug into end of drain hose and tighten
worm drive clamp securely.
PART NO.
SPECIALTY TOOL
11763
HD-42311 or
Oil filter wrench
HD-44067-A
Completely drain oil tank of used oil at scheduled service
intervals as specified in 1.3 MAINTENANCE SCHEDULE.
Refer to Table 1-1. Refill with fresh oil.
NOTES
1
● If vehicle is driven extremely hard, used in competition,
or driven on dusty roads, change engine oil at shorter
intervals.
● Always change oil filter when changing engine oil.
Draining Oil Tank
2
1.
Run engine until engine oil has reached normal operat-
ing temperature.
NOTE
Oil will drain more quickly if filler cap/dipstick is removed from
3
oil tank as described on previous page.
2.
See Figure 1-4. Place a suitable container directly under
the drain hose (1) at the bottom rear of the engine crank-
case. The container must be able to hold approximately
four quarts (U.S.) (3.8 liters).
1.
Oil tank drain hose
2.
Worm drive clamp
3.
Drain plug
Figure 1-4. Oil Tank Drain Hose
1-12
2006 Sportster: Maintenance
HOME
Removing Oil Filter
Installing New Oil Filter
1.
Place a drain pan beneath front of engine crankcase.
NOTE
2.
See Figure 1-5. See Figure 1-6. Remove oil filter using
Partially fill oil filter before installation to minimize the time
HARLEY-DAVIDSON OIL FILTER WRENCH. Turn oil fil-
required for buildup of oil pressure when engine is first
ter counterclockwise to remove from filter mount.
started.
3.
Drain oil filter into drain pan. Discard oil filter.
1. Pour about 4 fluid ounces (U.S.) (120 ml) of fresh, clean
4.
Clean any oil spills off crankcase and frame.
engine oil into new oil filter. Allow time for oil to soak into
filter element.
2. Wipe filter gasket contact surface of oil filter mount with a
11352
clean cloth.
3. See Figure 1-7. Coat oil filter gasket with clean Harley-
Davidson 20W-50 engine oil.
NOTE
Do not use oil filter wrench to install new oil filter.
4. Install new oil filter. Turn filter clockwise to install. Hand
tighten filter
1/2 to 3/4-turn after gasket contacts filter
mount surface.
1
d0384x1x
2
1.
Oil filter mount
2.
Oil filter
Figure 1-5. Oil Filter
h42311
hd44067
Figure 1-7. Lubricating New Oil Filter Gasket
Refilling Oil Tank
1. Refer to Table 1-5. Always use the proper grade of oil for
the lowest expected air temperature before the next reg-
ularly scheduled oil change. Pour
3.6 quarts
(U.S.)
(3.4 liters) of oil into engine oil tank minus the 4 fl. oz.
(120 ml) added in step 1.
Figure 1-6. Oil Filter Wrench
2. Install filler cap onto oil tank as described on previous
Part No. HD-42311 (left), HD-44067-A (right)
page. Make sure cap is fully seated.
3. Start engine. See Figure 1-8. Verify that oil pressure sig-
nal lamp turns off when engine speed is 1000 RPM or
above. Turn engine off.
4. Check for oil leaks at oil filter and oil tank drain hose.
Check engine oil level. See CHECKING AND ADDING
OIL earlier in this section.
x0666x1x
Figure 1-8. Oil Pressure Indicator Lamp
2006 Sportster: Maintenance
1-13
HOME
LEFT SIDE COVER
1.6
GENERAL
11461
See Figure 1-9. The left side cover (5) provides access to the
battery (1), fuses (3, 4) and diagnostic electrical connector
(6). No tools are required to open or close the cover.
See Figure 1-10. The left side cover is secured to the motor-
1
cycle by two upper slots (3) that fit into clips (1), and a bottom
slot (4) that fits onto a mounting tab (2) on the battery tray.
NOTE
The left side cover does not need to be completely removed
from the vehicle to access the battery or fuses.
11458
2
1
x0628a1x
3
2
4
3
6
4
5
1.
Mounting clips (on frame)
1.
Battery
2.
Mounting tab (on battery tray)
2.
Positive (+) battery terminal (under protective
3.
Side cover mounting slots (top)
rubber boot)
4.
Side cover mounting slot (bottom)
3.
Maxi-Fuse (main fuse) and holder
4.
System fuses and starter relay
Figure 1-10. Left Side Cover
5.
Left side cover
6.
Diagnostic connector
x0656x1x
x0657x1x
Figure 1-9. Maxi-Fuse and Battery Location
1
1
2
3
2
1.
Battery tray assembly
4
2.
Mounting tab
3.
Side cover (closed)
4.
Side cover (open)
Figure 1-11. Left Side Cover
1-14
2006 Sportster: Maintenance
HOME
OPENING LEFT SIDE COVER
REMOVING LEFT SIDE COVER
1.
Place a shop cloth or other clean, dry cloth over rear
It is rarely necessary to remove the left side cover completely.
brake master cylinder reservoir and left passenger foot
However, if left side cover removal is necessary, proceed as
peg (if equipped). This will protect left side cover from
follows:
damage.
1. See Figure 1-10. Grasp side cover at upper corners and
2.
See Figure 1-10. Grasp left side cover at upper corners
gently pull away from plastic mounting clips (1) on frame.
and gently pull away from plastic mounting clips (1) on
2. See Figure 1-13. Lift side cover up and tilt cover to the
frame.
rear of the motorcycle. With a slight back and forth rock-
ing motion, pull up gently until cover disengages from
3.
While rotating top of cover out away from motorcycle,
mounting tab on battery tray.
slide cover down slightly so mounting slot (4) slides down
mounting tab (2) on battery tray. See Figure 1-11. See
Figure 1-12. Side cover (3) will now rest on top of rear
11460
brake master cylinder reservoir and left passenger foot-
peg (if equipped) with slot (2) hanging off bottom of
mounting tab (1).
CAUTION
Do NOT lean on left side cover or place tools or parts on
side cover while it is in “open” position shown in Figure
1-12. Doing so could damage side cover and/or break
mounting tab on battery tray.
11459
1
Figure 1-13. Removing Left Side Cover
2
INSTALLING LEFT SIDE COVER
3
It is rarely necessary to remove the left side cover completely.
However, if left side cover has been removed, reinstall cover
1.
Side cover mounting tab (on battery tray)
as follows:
2.
Mounting slot (bottom of left side cover)
1. See Figure 1-10. Position side cover over battery tray
3.
Left side cover
assembly with slot (4) in bottom of cover resting on
mounting tab (2) on battery tray.
Figure 1-12. Left Side Cover in Open Position
2. Gently press downward on side cover until slot snaps
down over mounting tab.
CLOSING LEFT SIDE COVER
3. Line up top slots (3) of side cover with mounting clips (1)
on motorcycle frame, aligning front clip first. Press top of
1.
See Figure 1-12. Grasp top corners of side cover (3).
side cover into clips until snug.
While rotating top of cover up toward motorcycle, gently
pull cover up so that mounting slot (2) slides up mounting
tab (1).
2.
See Figure 1-10. Line up top slots (3) of side cover with
mounting clips (1) on motorcycle frame, aligning with
front clip first. Press top of side cover into clips until snug.
CAUTION
Side cover should snap into clips with minimal pressure.
Using excessive force or striking side cover to close it
can damage clips.
2006 Sportster: Maintenance
1-15
HOME
BATTERY MAINTENANCE
1.7
GENERAL
11519
3
1
1WARNING
Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BATTERIES AWAY FROM CHIL-
DREN. (00063a)
2
1WARNING
Never remove warning label attached to top of battery.
Failure to read and understand all precautions contained
in warning, could result in death or serious injury.
4
(00064a)
1.
Warning label
1WARNING
2.
Positive (+) terminal
3.
Negative (-) terminal
Batteries, battery posts, terminals and related accesso-
4.
Warranty/date code label
ries contain lead and lead compounds, and other chemi-
cals known to the State of California to cause cancer and
Figure 1-14. Battery
birth defects or other reproductive harm. Wash hands
after handling. (00019d)
All AGM batteries are permanently sealed, maintenance-free,
valve-regulated, lead/calcium and sulfuric acid batteries. The
batteries are shipped pre-charged and ready to be put into
service. Do not attempt to open these batteries for any
reason.
f2396x8x
1
2
3
4
5
6
1.
Contents are corrosive
4.
Keep flames away
2.
Wear safety glasses
5.
Read instructions
3.
Contents are explosive
6.
Keep away from children
Figure 1-15. Battery Warning Label
1-16
2006 Sportster: Maintenance
HOME
4. See Figure 1-17. Remove nut (2) that secures negative
Table 1-6. Battery Electrolyte Antidotes
(-) battery cable (1) connector to ground stud (5) on
crankcase boss behind starter motor assembly
(3).
CONTACT
SOLUTION
Remove cable connector from stud.
External
Flush with water.
5. Pull end of negative (-) cable forward gently to free it
from cable clip (4).
Internal
Drink large quantities of milk or
water, followed by milk of magne-
sia, vegetable oil or beaten eggs.
x0609x1x
Call doctor immediately.
Eyes
Flush with water, get immediate
medical attention.
1
BATTERY DISCONNECTION AND
4
REMOVAL
3
1.
Open left side cover. See 1.6 LEFT SIDE COVER.
2.
See Figure 1-16. Remove Maxi-Fuse and holder (1) from
5
battery strap (3) by grasping holder and sliding it toward
the rear of the motorcycle. Then remove Maxi-Fuse
holder from its mounting pin on battery strap.
3.
Remove battery strap screw and flat washer (4). Unhook
battery strap from battery tray mount on top of battery
and remove strap.
1WARNING
Prevent accidental vehicle start-up, which could cause
death or serious injury. First disconnect negative (-) bat-
tery cable at engine and then positive (+) cable from bat-
tery. (00280b)
2
1.
Negative (-) battery cable
2.
Nut
11458
3.
Starter motor assembly
4.
Cable clip
5.
Ground stud
Figure 1-17. Negative (-) Battery Connection
1WARNING
3
2
Make sure negative (-) battery cable does not touch any
grounded point on the motorcycle while disconnecting
the cables from the battery positive (+) terminal in the
1
4
next step. If the positive
(+) cables should contact
ground with the negative (-) cable grounded, the result-
ing sparks may cause a battery explosion which could
result in death or serious injury.
6. See Figure 1-16. Lift up protective rubber boot covering
1.
Maxi-Fuse (main fuse) and holder
battery positive (+) terminal (2). Unthread screw from
2.
Positive (+) battery terminal (under protective
battery positive (+) terminal and remove positive (+) bat-
rubber boot)
tery cables.
3.
Battery strap
4.
Screw and flat washer
Figure 1-16. Maxi-Fuse and Battery Location
2006 Sportster: Maintenance
1-17
HOME
7.
See Figure 1-18. Disengage positive (+) battery cable (2)
BATTERY STORAGE
from cable holders (1).
8.
Remove battery from battery tray. Note routing of nega-
tive (-) battery cable around frame downtube (see Figure
1CAUTION
1-17.).
Store the battery out of the reach of children. Inadequate
9.
If battery is to be left out of vehicle (i.e., winter storage),
safety precautions may result in minor or moderate
close left side cover.
injury.
11466
CAUTION
Do not allow battery to completely discharge. The elec-
trolyte in a discharged battery will freeze. The more dis-
charged a battery is, the more easily it can freeze and
crack the battery case. (00218a)
If the motorcycle will not be operated for several months,
such as during the winter season, remove the battery from
the motorcycle and fully charge.
1
See Figure 1-19. Self-discharge is a normal condition and
occurs continuously at a rate that depends on the ambient
temperature and the battery’s state of charge. Batteries dis-
2
charge at a faster rate at higher ambient temperatures. To
reduce the self-discharge rate, store battery in a cool (not
1. Cable holders
freezing), dry place.
2. Positive battery cable
Figure 1-18. Positive (+) Battery Cable Holders
x0300x7x
Effect of temperature on
BATTERY INSPECTION
battery self-discharge rate
1.
Battery top must be clean and dry. Dirt and electrolyte on
C
top of the battery can cause battery to self-discharge.
a
p
Clean battery top with a solution of baking soda (sodium
a
bicarbonate) and water (5 teaspoons baking soda per
c
quart or liter of water). When the solution stops bubbling,
i
rinse off the battery with clean water.
t
2.
Clean cable connectors and battery terminals using a
y
wire brush or sandpaper. Remove any oxidation.
Months of stand
3.
Inspect the battery screws, clamps and cables for break-
age, loose connections and corrosion. Clean clamps.
4.
Check the battery posts for melting or damage caused
Figure 1-19. Battery Self-Discharge Rate
by overtightening.
Charge the battery every month if stored at temperatures
5.
Inspect the battery for discoloration, raised top or a
below 60˚ F (16˚ C). Charge the battery more frequently if
warped or distorted case, which might indicate that the
stored in a warm area above 60˚ F (16˚ C).
battery has been frozen, overheated or overcharged.
6.
Inspect the battery case for cracks or leaks.
NOTE
The GLOBAL BATTERY CHARGER (Part No. 99863-01) may
be used to maintain battery charge for extended periods of
time without risk of overcharging or boiling.
1-18
2006 Sportster: Maintenance
HOME
9. Hook Maxi-Fuse holder (1) to pin on battery strap and
BATTERY INSTALLATION AND
slide forward until it snaps into place.
CONNECTION
10. See Figure 1-17. Press negative (-) battery cable (1) into
cable clip (4).
1.
If negative (-) battery cable was removed from battery,
11. Place negative (-) battery cable connector onto ground
insert screw through negative (-) battery cable and into
stud (5) on crankcase boss behind starter motor assem-
negative (-) battery terminal. Thread screw into terminal.
bly (3). Thread nut (2) onto stud.
Position negative
(-) battery cable so that it hangs
straight down from negative (-) battery terminal. Tighten
12. See Figure 1-20. Press negative (-) battery cable con-
screw to 40-50 in-lbs (4.5-5.7 Nm).
nector
(1) against cable stop
(2) on crankcase and
tighten nut (3) to 55-75 in-lbs (6.2-8.5 Nm).
2.
Apply a light coat of petroleum jelly or corrosion retardant
material to the negative (-) battery terminal.
13. Close left side cover.
3.
Open left side cover. See 1.6 LEFT SIDE COVER.
4.
Slide fully charged battery into battery tray, routing nega-
11302
tive (-) battery cable around frame downtube.
3
1WARNING
2
Connect positive (+) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explo-
sion, which could result in death or serious injury.
(00068a)
5.
See Figure 1-16. With negative (-) battery cable discon-
nected from grounding point on crankcase, insert screw
through positive (+) battery cables: through maxi-fuse
cable first, then through main positive (+) battery cable,
and into positive (+) battery terminal (2). Thread screw
1
into terminal. Tighten to 40-50 in-lbs (4.5-5.7 Nm).
6.
Apply a light coat of petroleum jelly or corrosion retardant
material to the positive (+) battery terminal. Place protec-
tive rubber boot over terminal.
1. Negative battery cable connector
2. Cable stop
7.
Hook top of battery strap (3) to battery tray mount on top
3. Nut
of battery. Install flat washer and strap screw (4). Tighten
to 36-60 in-lbs (4.1-6.8 Nm).
Figure 1-20. Attaching Negative (-) Battery Cable
8.
Route main positive (+) battery cable through holders on
to Ground Stud Crankcase
electrical bracket.
2006 Sportster: Maintenance
1-19
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