Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 7
HOME
ENGINE MOUNTS AND STABILIZER LINKS
1.27
3. Check that all engine mount bolts and stabilizer link
INSPECTION
screws are tight. See 2.21 STABILIZER LINKS, 2.22
FRONT ENGINE MOUNT/ISOLATOR, or 2.23 REAR
Check engine mounts and stabilizer links as follows:
ENGINE MOUNT/ISOLATOR for torque specifications.
1.
See Figure 1-75. Check for cracks or tears in engine
4. Check that the mounts are supporting the weight of the
mount isolator rubber (17, 18).
motor.
2.
Check stabilizer links (8) for wear.
x0591b1x
10
20
18
4
1
14
15
8
4
16
3
5
4
13
2
7
18
20
9
5
15
8
12
4
8
6
19
4
11
17
3
1.
Screw @ 80-120 in-lbs (9.05-13.6 Nm) (3)
11. Nut @ 60-70 ft-lbs (81.4-95.0 Nm)
2.
Screw @ 55-65 ft-lbs (74.6-88.2 Nm) (2)
12. Bolt
3.
Screw @ 25-35 ft-lbs (33.9-47.5 Nm) (3)
13. Swing arm pivot shaft
4.
Screw @ 25-35 ft-lbs (33.9-47.5 Nm) (11)
14. Rear pivot lockplate
5.
Washer (4)
15. Stabilizer link bracket (2)
6.
Spacer
16. Engine bracket
7.
Lock washer (2)
17. Front mount isolator (2)
8.
Stabilizer link (3)
18. Rear mount isolator (2)
9.
Front isolator mount
19. Grounding strap
10. Rear isolator mount
20. Swing arm pivot bolt @ 60-70 ft-lbs
(81.4-95.0 Nm) (2)
Figure 1-75. Engine Mounting Assemblies
1-60
2006 Sportster: Maintenance
HOME
HEADLAMP ALIGNMENT
1.28
8. Check headlamp beam for proper height alignment:
INSPECTION
a.
Main beam of light
(broad, flat pattern of light)
should be centered equally above and below hori-
1WARNING
zontal line on screen or wall.
b.
Main beam of light should be directed straight
The automatic-on headlamp feature provides increased
ahead. Properly adjusted headlamps project an
visibility of the rider to other motorists. Be sure head-
equal area of light to right and left of center.
lamp is on at all times. Poor visibility of rider to other
c.
Adjust headlamp alignment if necessary.
See
motorists can result in death or serious injury. (00030b)
ADJUSTMENT which follows.
Check headlamp beam for proper height and lateral align-
ment:
● When the new owner takes delivery of the motorcycle.
x0302x7x
● When there is a change in load (adding luggage, etc.).
1.
Verify correct front and rear tire inflation pressure. See
1.11 TIRES AND WHEELS.
A
2.
Place motorcycle on level floor (or pavement) in an area
with minimum light.
25 ft. (7.62 m)
3.
See Figure 1-76. Position motorcycle 25 ft (7.62 m) away
A= 35 in. (889 mm)
from a screen or wall. Measure distance from directly
below front axle to base of screen/wall.
Figure 1-76. Headlamp Alignment
4.
Draw a horizontal line, on screen or wall, 35 in. (889 mm)
above floor.
5.
Stand motorcycle upright with both tires resting on floor
and with front wheel held in straight alignment (directly
forward).
6.
Load motorcycle with rider, passenger
(if normally
present) and any cargo normally carried. Weight will
compress vehicle suspension slightly.
7.
Turn ignition/light switch to IGNITION position. Set han-
dlebar headlamp switch to HIGH beam position.
2006 Sportster: Maintenance
1-61
HOME
ADJUSTMENT
XL 883C, XL 1200C
1. See Figure 1-78. To adjust headlamp horizontally,
a. Loosen horizontal adjustment screw (3). Turn head-
XL 883, XL 883L, XL 883R, XL 1200R
lamp right or left as necessary to direct headlamp
1.
See Figure 1-77. Remove snap plug (1) from top of
beam straight ahead.
headlamp bracket (2). Loosen headlamp clamp nut (3).
b. Tighten horizontal adjustment screw to 30-35 ft-lbs
2.
Tilt headlamp up or down to properly aim it in relation to
(40.7-47.5 Nm).
the horizontal line and, at the same time, turn it right or
2. To adjust headlamp vertically,
left to direct headlamp beam straight ahead.
a. Loosen vertical adjustment bolt (1) and nut (2). Tilt
3.
Tighten headlamp clamp nut to 120-240 in-lbs (13.6-
headlamp up or down to properly aim it in relation to
27.1 Nm) after headlamp is properly positioned. Install
the horizontal line.
snap plug in headlamp bracket.
b. Tighten vertical adjustment bolt and nut to 30-35 ft-
lbs (40.7-47.5 Nm).
4908
10708
2
1
4909
1
2
3
3
1. Vertical adjustment bolt
2. Nut
3. Horizontal adjustment screw
1.
Snap plug
Figure 1-78. Headlamp Adjustment
2.
Headlamp bracket
(Custom Models)
3.
Headlamp clamp nut
Figure 1-77. Headlamp Adjustment
(Non-Custom Models)
1-62
2006 Sportster: Maintenance
HOME
FLUID/LUBRICANT REQUIREMENTS
1.29
BRAKE FLUID
ENGINE OIL
Engine oil is a major factor in the performance and service life
1WARNING
of the engine. Refer to Table 1-13. Always use the proper
grade of oil for the lowest temperature expected before the
Direct contact of D.O.T. 5 brake fluid with eyes can cause
next scheduled oil change.
eye irritation, swelling, and redness. Avoid eye contact.
In case of eye contact flush with large amounts of water
If it is necessary to add oil and Harley-Davidson oil is not
and get medical attention. Swallowing large amounts of
available, use an oil certified for diesel engines. Acceptable
D.O.T. 5 brake fluid can cause digestive discomfort. If
diesel engine oil designations include CF, CF-4, CG-4 and
swallowed, obtain medical attention. Use in well venti-
CH-4. The preferred viscosities for the diesel engine oils, in
lated area. KEEP OUT OF REACH OF CHILDREN.
descending order, are 20W-50, 15W-40 and 10W-40. At the
(00144a)
first opportunity, see a Harley-Davidson dealer to change
Use only Harley-Davidson brand D.O.T. 5 BRAKE FLUID.
back to 100 percent Harley-Davidson oil.
BRAKE COMPONENT GREASE
PRIMARY DRIVE/TRANSMISSION
Use only G40M BRAKE GREASE to lubricate brake system
LUBRICANT
components.
Use only GENUINE HARLEY-DAVIDSON FORMULA+
FRONT FORK OIL
TRANSMISSION
AND PRIMARY CHAINCASE
LUBRICANT.
Use only HARLEY-DAVIDSON TYPE “E” HYDRAULIC FORK
OIL.
Table 1-13. 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
2006 Sportster: Maintenance
1-63
HOME
STORAGE
1.30
GENERAL
10551
If the motorcycle will not be operated for several months,
such as during the winter season, there are several things
which should be done to protect parts against corrosion, to
preserve the battery and to prevent the buildup of gum and
varnish in the carburetor.
This work should be performed by your local Harley-Davidson
dealer or other qualified technician following Service Manual
procedures.
1WARNING
Do not store motorcycle with gasoline in tank within the
home or garage where open flames, pilot lights, sparks
or electric motors are present. Gasoline is extremely
flammable and highly explosive, which could result in
death or serious injury. (00003a)
1.
Prepare fuel system by one of the two methods outlined
below:
a. Fill fuel tank and add a gasoline stabilizer. Use one
1
of the commercially available gasoline stabilizers fol-
2
lowing the manufacturer’s instructions. Turn fuel sup-
1.
Carburetor drain screw
ply valve off. See Figure 1-79. Place end of fuel
2.
Fuel overflow/drain hose
overflow/drain hose (2) into an approved fuel con-
tainer. Drain all gasoline from carburetor by loosen-
Figure 1-79. Draining Carburetor Float Chamber
ing fuel bowl drain screw (1) one full turn; gasoline
will drain through overflow/drain hose. Retighten
drain screw after all gasoline has been drained from
carburetor.
b. Drain all gasoline from the fuel tank. Spray the
inside of the fuel tank with a commercially available
rust preventative. Follow the manufacturer’s instruc-
tions.
2.
Fill the oil tank. Locate the hose leading from the oil tank
bottom to the oil pump feed fitting. Remove and plug the
oil pump end of this hose. This prevents oil from seeping
past the check ball into the oil pump and filling the engine
flywheel compartment.
3.
Remove the spark plugs, inject a few squirts of engine oil
into each cylinder and crank the engine 5-6 revolutions.
Reinstall spark plugs.
4.
Grease wheel bearings and install new seals.
5.
Adjust primary chain.
6.
Check tire inflation. If the motorcycle will be stored for an
extended period of time, securely support the motorcycle
under the frame so that all weight is off the tires.
7.
Wash painted and chrome-plated surfaces. Apply a light
film of oil to exposed unpainted surfaces.
1-64
2006 Sportster: Maintenance
HOME
REMOVAL FROM STORAGE
1WARNING
Do not apply any oil to brake discs or brake pads. Oil on
disc pads degrades braking efficiency and can result in
1WARNING
an accident resulting in death or serious injury.
The clutch failing to disengage can cause loss of control,
8.
Remove battery from vehicle. Charge battery until the
which could result in death or serious injury. Prior to
correct voltage is obtained. Charge the battery every
starting after extended periods of storage, place trans-
other month if it is stored at temperatures below 60˚ F
mission in gear and push vehicle back and forth several
(16˚ C). Charge battery once a month if it is stored at
times to assure proper clutch disengagement. (00075a)
temperatures above 60˚ F (16˚ C).
1. Charge and install battery.
2. Remove and inspect the spark plugs. Replace if neces-
1WARNING
sary.
Unplug or turn OFF battery charger before connecting
3. Clean the air cleaner element.
charger cables to battery. Connecting cables with
4. If fuel tank was drained, fill fuel tank with fresh gasoline.
charger ON can cause a spark and battery explosion,
5. If oil feed hose was plugged, unplug it and reconnect.
which could result in death or serious injury. (00066a)
6. Start the engine and run until it reaches normal operat-
ing temperature.
1WARNING
7. Check engine oil level. Check the transmission lubricant
level. Fill to proper levels with correct fluids, if required.
Unplug or turn OFF battery charger before disconnecting
charger cables from battery. Disconnecting clamps with
8. Perform all of the checks in the PRE-RIDING CHECK-
charger ON can cause a spark and battery explosion,
LIST in the Owner’s Manual.
which could result in death or serious injury. (00067a)
1WARNING
Store battery out of reach of children. Battery contains
sulfuric acid which can cause severe burns to eyes, skin
and clothing.
9.
If motorcycle is to be covered, use a material that will
breathe, such as light canvas. Plastic materials that do
not breathe promote the formation of condensation.
2006 Sportster: Maintenance
1-65
HOME
TROUBLESHOOTING
1.31
8.
Ignition timing incorrect due to faulty coil, ICM or sensors
GENERAL
(MAP, CKP and/or TSM/TSSM).
9. Loose wire connection at coil or battery connection or
1WARNING
plug between crank position sensor (CKP) and ignition
control module (ICM).
The troubleshooting section of this manual is intended
10. Ignition coil not functioning.
solely as a guide to diagnosing problems. Carefully read
11. Ignition control module (ICM) not functioning.
the appropriate sections of this manual before perform-
ing any work. Observe all cautions and warnings. Failure
12. Crank position sensor (CKP) not functioning.
to observe cautions and warnings could result in death
13. Sticking or damaged valve or valves.
or serious injury.
14. Engine oil too heavy (winter operation).
The following check list can be helpful in locating most oper-
NOTE
ating troubles. Refer to the appropriate sections in this Ser-
For cold weather starts, always disengage clutch.
vice Manual for detailed procedures.
Starts Hard
ENGINE
1.
Spark plugs in poor condition, have improper gap or are
partially fouled.
2.
Spark plug cables in poor condition.
Starting Motor Does Not Operate or Does
3.
Battery nearly discharged.
Not Turn Engine Over
4.
Loose wire connection at one of the battery terminals, at
1.
Engine run switch in OFF position.
coil, or at plug between crank position sensor (CKP) and
2.
Ignition switch not ON.
ignition control module (ICM).
3.
Discharged battery, loose or corroded connections (sole-
5.
Carburetor controls not adjusted correctly.
noid chatters).
6.
Ignition coil not functioning.
4.
Starter control circuit, relay or solenoid not functioning.
7.
Engine oil too heavy (winter operation).
5.
Electric starter shaft pinion gear not engaging or over-
8.
Fuel tank filler cap vent plugged, or carburetor fuel line
running clutch slipping.
closed off restricting fuel flow.
6.
TSM/TSSM bank angle sensor tripped and ignition
9.
Water or dirt in fuel system and carburetor.
switch not cycled OFF then ON.
10.
Enrichener valve inoperative.
Engine Turns Over But Does Not Start
11.
Air leak at intake manifold.
12.
Valves sticking.
1.
Fuel tank empty or fuel valve turned off.
13.
Air cleaner EVAP flapper (if equipped) stuck closed or
2.
Fuel valve or fuel strainer clogged.
inoperative.
3.
Engine flooded with gasoline as a result of overuse of
enrichener.
4.
Vacuum hose to fuel supply valve disconnected, leaking
or pinched.
5.
Discharged battery, loose or broken battery terminal con-
nections.
6.
Fouled spark plugs.
7.
Spark plug cables in poor condition and shorting, cable
connections loose or cables connected to incorrect cylin-
ders.
1-66
2006 Sportster: Maintenance
HOME
Starts But Runs Irregularly or Misses
Overheating
1.
Spark plugs in poor condition or partially fouled.
1. Insufficient oil supply, or oil not circulating.
2.
Spark plug cables in poor condition and shorting or leak-
2. Insufficient air flow over engine.
ing.
3. Leaking valves.
3.
Spark plug gap too close or too wide.
4. Heavy carbon deposit.
4.
Ignition coil, ignition control module (ICM) or crank posi-
5. Ignition timing retarded. Ignition control module (ICM) or
tion sensor (CKP) not functioning properly.
crank position sensor (CKP) defective.
5.
Battery nearly discharged.
Valve Train Noise
6.
Damaged wire or loose connection at battery terminals
or coil.
1. Low oil pressure caused by oil feed pump not functioning
7.
Intermittent short circuit due to damaged wire insulation.
properly or oil passages obstructed.
8.
Water or dirt in fuel system and carburetor or fuel
2. Hydraulic lifter not functioning properly.
strainer.
3. Bent push rod.
9.
Fuel tank filler cap vent plugged or carburetor float bowl
4. Cam, cam gears, or cam bushings worn.
vent closed off.
5. Rocker arm binding on shaft.
10. Carburetor controls improperly adjusted.
6. Valve sticking in guide.
11. Air leak at intake manifold or air cleaner.
12. Damaged intake or exhaust valve.
Excessive Vibration
13. Weak or broken valve springs.
1. Stabilizer links worn or loose, or stabilizer link brackets
loose or broken.
14. Incorrect valve timing.
15. Air cleaner EVAP flapper (if equipped) stuck closed or
2. Isolators worn or isolator bolts loose or broken.
inoperative.
3. Isolator mounting brackets (left side of vehicle) loose or
broken.
Spark Plug Fouls Repeatedly
4. Broken frame.
1.
Incorrect spark plug.
5. Primary chain badly worn or links tight as a result of
2.
Piston rings badly worn or broken.
insufficient lubrication.
3.
Fuel mixture too rich (see 4.3 TROUBLESHOOTING).
6. Wheels not aligned, rim(s) bent and/or tires worn.
4.
Valve guides or seals badly worn or damaged.
7. Internal engine problem.
Pre-Ignition or Detonation
(Knocks or Pings)
1.
Excessive carbon deposit on piston head or combustion
chamber.
2.
Incorrect heat range spark plug.
3.
Spark plugs not firing.
4.
Ignition timing advanced. Ignition control module (ICM)
or crank position sensor (CKP) defective.
5.
Fuel octane rating too low.
6.
Intake manifold vacuum leak.
2006 Sportster: Maintenance
1-67
HOME
ENGINE LUBRICATION SYSTEM
ELECTRICAL SYSTEM
Oil Does Not Return To Oil Tank
Alternator Does Not Charge
1.
Oil tank empty.
1. Voltage regulator-rectifier module not functioning.
2.
Return pump gears damaged.
2. Voltage regulator-rectifier not grounded.
3.
Oil feed pump not functioning.
3. Engine ground wire loose or broken.
4.
Restricted oil lines or fittings.
4. Loose or broken wires in charging circuit.
5.
Restricted oil filter.
5. Stator and/or rotor not functioning.
Engine Uses Too Much Oil or
Alternator Charge Rate Is Below Normal
Smokes Excessively
1. Voltage regulator-rectifier module not functioning.
1.
Piston rings badly worn or broken.
2. Stator and/or rotor not functioning.
2.
Valve guides or seals worn or damaged.
3. Weak or damaged battery.
3.
Restricted oil filter.
4. Loose connections.
Engine Leaks Oil From Cases, Push Rods,
Speedometer Operates Erratically
Hoses, Etc.
1. Contaminated speedometer sensor (remove sensor and
clean off metal particles).
1.
Loose parts.
2. Loose connections.
2.
Imperfect seal at gaskets, push rod covers, washers, etc.
To aid locating leaks, use BLACK LIGHT LEAK DETEC-
TOR (Part No. HD-35457).
TRANSMISSION
3.
Restricted oil return line to tank.
4.
Restricted breather passage(s) to air cleaner.
Shifts Hard
5.
Restricted oil filter.
1. Clutch dragging slightly.
2. Shifter forks (inside transmission) damaged.
FUEL
3. Corners worn off shifter clutch dogs (inside transmis-
sion).
Carburetor Floods
Jumps Out of Gear
1.
Excessive “pumping” of hand throttle grip.
1. Shifter pawl improperly adjusted.
2.
Inlet valve sticking.
2. Shifter engaging parts (inside transmission) badly worn
3.
Inlet valve and/or valve seat worn or damaged.
and rounded.
4.
Dirt or other foreign matter between valve and its seat.
3. Shifter forks bent.
5.
Float misadjusted.
4. Damaged gears.
6.
Leaky or damaged float.
1-68
2006 Sportster: Maintenance
HOME
CLUTCH
Handling Irregularities
1.
Tires improperly inflated. Check TIRE DATA Section. Do
not overinflate.
Slips
2.
Loose wheel axle nuts. Tighten front nut to 50-55 ft-lbs
1.
Clutch controls improperly adjusted.
(68-75 Nm). Tighten rear nut to 72-78 ft-lbs (98-106 Nm).
2.
Worn friction plates.
3.
Excessive wheel hub bearing play.
3.
Insufficient clutch spring tension.
4.
Rear wheel out of alignment with frame and front wheel.
5.
Rims and tires out-of-true sideways. Tire runout should
Drags or Does Not Release
not be more than 5/64 in. (2.0 mm).
1.
Clutch controls improperly adjusted.
6.
Rims and tires out-of-round or eccentric with hub. Tire
2.
Clutch plates excessively warped.
runout should not be more than 3/32 in. (2.4 mm).
7.
Loose spokes (laced wheel vehicles only).
Chatters
8.
Irregular or peaked front tire tread wear.
Friction or steel plates worn, warped, or dragging.
9.
Tire and wheel unbalanced.
10.
Steering head bearings improperly adjusted. Correct
CHASSIS
adjustment, and replace pitted or worn bearings and
races. See 2.18 FORK STEM AND BRACKET ASSEM-
BLY.
Irregular/Inadequate Brake Action
11.
Shock absorbers not functioning normally.
1.
Master cylinder reservoir low on fluid.
12.
Heavy front end loading. Non-standard equipment on the
front end (such as heavy radio receivers, extra lighting
2.
Brake system contains air bubbles.
equipment, or luggage) tends to cause unstable han-
3.
Master cylinder or brake caliper piston(s) worn or parts
dling.
damaged.
13.
Engine mounts and/or stabilizer links loose, worn or
4.
Brake pads contaminated with grease or oil.
damaged.
5.
Brake pads badly worn. Minimum lining thickness is 0.04
in. (1.02 mm).
6.
Brake disc badly worn or warped.
7.
Brake pads dragging or excessive braking (brake fades
due to heat buildup).
8.
Insufficient brake pedal or hand lever free play (brake
drags).
2006 Sportster: Maintenance
1-69
HOME
NOTES
1-70
2006 Sportster: Maintenance
HOME
SPECIFICATIONS
2.1
Table 2-1. Dimensions
OVERALL
OVERALL
SADDLE
OVERALL
ROAD
WHEELBASE
MODEL
LENGTH
WIDTH
HEIGHT
HEIGHT
CLEARANCE
IN. / MM.
IN. / MM.
IN. / MM.
IN./MM.*
IN. / MM.
IN. / MM.
XL 883
60.0 / 1524.0
90.1 / 2288.5
32.7 / 830.6
27.3 / 693.4
44.8 / 1137.9
5.6 / 141.0
XL 883L
60.0 / 1524.0
90.1 / 2288.5
32.7 / 830.6
26.0 / 660.4
44.8 / 1137.9
4.4 / 111.8
XL 883R
60.0 / 1524.0
90.1 / 2288.5
32.7 / 830.6
28.1 / 713.7
44.8 / 1137.9
5.6 / 141.0
XL 1200R
60.0 / 1524.0
90.1 / 2288.5
36.7 / 932.2
28.1 / 713.7
49.2 / 1249.7
5.6 / 141.0
XL 883C
60.4 / 1534.2
90.3 / 2293.6
32.7 / 830.6
26.5 / 673.1
45.7 / 1160.8
4.4 / 111.8
XL 1200C
60.4 / 1534.2
90.3 / 2293.6
32.7 / 830.6
26.5 / 673.1
45.7 / 1160.8
4.4 / 111.8
* Laden saddle height with 180 lb (81.6 Kg) rider.
Table 2-2. Weights
WEIGHT (AS
GVWR
GAWR-FRONT
GAWR-REAR
MODEL
SHIPPED)
LBS / KG
LBS / KG
LBS / KG
LBS / KG
XL 883
553.0 / 251.0
1000.0 / 454.0
335.0 / 152.0
665.0 / 302.0
XL 883L
553.0 / 251.0
1000.0 / 454.0
335.0 / 152.0
665.0 / 302.0
XL 883R
560.0 / 254.0
1000.0 / 454.0
335.0 / 152.0
665.0 / 302.0
XL 1200R
553.0 / 251.0
1000.0 / 454.0
335.0 / 152.0
665.0 / 302.0
XL 883C
562.0 / 255.0
1000.0 / 454.0
335.0 / 152.0
665.0 / 302.0
XL 1200C
562.0 / 255.0
1000.0 / 454.0
335.0 / 152.0
665.0 / 302.0
Table 2-3. Capacities
FRONT FORK
FUEL TANK
FUEL TANK
OIL TANK
TRANSMISSION
(PER FORK SIDE)
TOTAL
RESERVE
WITH FILTER
MODEL
OZ
ML
IN
MM
GAL
LITER
GAL
LITER
QT
LITER
OZ
ML
XL 883
11.6
342
5.75
146
3.3
12.5
0.8
3.03
3.6
3.41
32
946
XL 883L
12.3
364
4.80
122
3.3
12.5
0.8
3.03
3.6
3.41
32
946
XL 883R
11.6
342
5.75
146
3.3
12.5
0.8
3.03
3.6
3.41
32
946
XL 1200R
11.6
342
5.75
146
3.3
12.5
0.8
3.03
3.6
3.41
32
946
XL 883C
11.6
342
5.75
146
4.5
17.0
1.0
3.79
3.6
3.41
32
946
XL 1200C
11.6
342
5.75
146
4.5
17.0
1.0
3.79
3.6
3.41
32
946
Table 2-4. Brake Disc
SPECIFICATION
IN
MM
Diameter: front, rear
11.5
292
Front minimum thickness
0.200
5.08
Rear minimum thickness
0.230
5.84
Maximum disc runout (front and rear)
0.008
0.20
2006 Sportster: Chassis
2-1
HOME
Tire sizes are molded on the sidewall. Refer to the tire fitment
TIRES
tables below. Rim size and contour are cast or stamped into
the exterior surface of the rim.
Example: T19 x 2.15 MT DOT. “T” indicates that the rim con-
1WARNING
forms to Tire and Rim Association standards. The “19” is the
normal diameter of the rim in inches, measured at the bead
Use only Harley-Davidson approved tires. See a Harley-
seat diameter. The “2.15” is the width of the bead seat mea-
Davidson dealer. Using non-approved tires can adversely
sured in inches. “MT” designates the rim contour. “DOT”
affect stability, which could result in death or serious
means that the rim meets Department of Transportation Fed-
injury. (00024a)
eral Motor Vehicle Safety Standards.
Table 2-5. Tire Fitment-Tubeless Cast Wheels
RIM VALVE HOLE DIA.
TIRE
WHEEL SIZE
RIM SIZE
AND POSITION
AND CONTOUR
IN
MM
TYPE
SIZE
19 in. - Front
T19 x 2.15 MT
0.45
11.4
Dunlop D401F
100/90-19 57H
16 in. - Rear
T16 x 3.00 D
0.35
8.89
Dunlop D401
150/80B16 71H
Table 2-6. Tire Fitment-Tube Type Steel Laced Wheels
TIRE
WHEEL SIZE
RIM SIZE
TUBE SIZE
AND POSITION
AND CONTOUR
TYPE
SIZE
21 in. - Front
T21 x 2.15 TLA
MH90-21
Dunlop D402F
MH90-21 54H
19 in. - Front
T19 x 2.50 TLA
MJ90-19
Dunlop D401F
100/90-19 57H
16 in. - Rear
T16 x 3.00 D
MT90-16
Dunlop D401
150/80B16 71H
Table 2-7. Tire Fitment-Tube Type Chrome Aluminum Profile Laced Wheels
TIRE
WHEEL SIZE
RIM SIZE
TUBE SIZE
AND POSITION
AND CONTOUR
TYPE
SIZE
21 in. - Front
T21 x 2.15 MT
MH90-21
Dunlop D402F
MH90-21 54H
16 in. - Rear
T16 x 3.00 MT
MT90-16
Dunlop D401
150/80B16 71H
Table 2-8. Tire Pressure-All Models
COLD - UP TO 300 LB (136 KG) LOAD
UP TO GVWR MAXIMUM LOAD
(INCLUDES RIDER, PASSENGER AND CARGO)
TIRE
PSI
KPA
PSI
KPA
Front
30
207
30
207
Rear
36
248
40
276
2-2
2006 Sportster: Chassis
HOME
TORQUE VALUES
2.2
ITEM
TORQUE
NOTES
Brake caliper bleeder valve
35-61 in-lbs
4.0-6.9 Nm
front and rear, page 2-48, 2-64, 2-79, 2-80
Brake line banjo bolt
20-25 ft-lbs
27.1-33.9 Nm
page 2-47, 2-57, 2-66, 2-74, 2-79, 2-80
Brake pad pin plug
18-25 in-lbs
2.0-2.9 Nm
Page 2-65, 2-75
Brake pad pin
131-173 in-lbs
14.8-19.6 Nm
Page 2-65, 2-75
Brake pedal clevis screw
96-156 in-lbs
10.9-17.6 Nm
page 2-117, 2-119
Brake rod-to-bell crank screw
120-180 in-lbs
13.6-20.4 Nm
page 2-106, 2-117, 2-119
Brake rod-to-brake pedal screw
96-144 in-lbs
10.9-16.3 Nm
page 2-117, 2-119
Clutch cable end fitting
36-60 in-lbs
4.1-6.8 Nm
page 2-103
Clutch inspection cover screw
84-108 in-lbs
9.5-12.2 Nm
page 2-103
Clutch lever anti-rattle spring
8-13 in-lbs
0.9-1.5 Nm
page 2-103
screw
Clutch lever handlebar clamp
108-132 in-lbs
12.2-14.9 Nm
page 2-100, 2-102
screw
Cylinder head exhaust port nut
96-120 in-lbs
10.9-13.6 Nm
page 2-106
Debris deflector screw
36-60 in-lbs
4.1-6.8 Nm
page 2-112
Exhaust pipe clamp bracket screw
30-33 ft-lbs
40.7-44.8 Nm
page 2-95, 2-106
Fender mounting screw
132-216 in-lbs
14.9-24.4 Nm
page 2-111
Footrest bracket mounting bolt
45-50 ft-lbs
61.1-67.9 Nm
page 2-103
23-27 ft-lbs,
31.2-36.6 Nm,
Fork stem bolt
loosen,
loosen, 8.1-
page 2-84
72-96 in-lbs
10.9 Nm
Front axle nut
50-55 ft-lbs
67.9-74.6 Nm
page 2-8, 2-14, 2-65
Front axle pinch screw
21-27 ft-lbs
28.5-36.6 Nm
page 2-14, 2-65
Front belt guard screw
120-180 in-lbs
13.6-20.4 Nm
page 2-112
Front brake caliper mounting bolt
28-38 ft-lbs
38.0-51.6 Nm
page 2-66
Front brake disc mounting screw
16-24 ft-lbs
21.7-32.6 Nm
LOCTITE 243, page 2-11
Front brake line-to-front fork lower
120-168 in-lbs
13.6-19.0 Nm
page 2-78
bracket clamp screw
Front brake line-to-front fork upper
45-65 in-lbs
5.1-7.4 Nm
page 2-79
bracket clamp screw
Front brake master cylinder clamp
108-132 in-lbs
12.2-14.9 Nm
page 2-47
screw
Front brake reservoir cover screw
9-17 in-lbs
1.0-2.0 Nm
page 2-48, 2-67
Front fender mounting screw
96-156 in-lbs
10.9-17.6 Nm
page 2-83, 2-107
Front fork lower bracket pinch
30-35 ft-lbs
40.7-47.5 Nm
page 2-83
screw
Front fork slider tube cap
22-58 ft-lbs
29.9-78.7 Nm
page 2-83
Front fork upper bracket pinch
30-35 ft-lbs
40.7-47.5 Nm
page 2-83
screw
Front isolator mount-to-frame
25-35 ft-lbs
33.9-47.5 Nm
page 2-92
screw
2006 Sportster: Chassis
2-3
HOME
ITEM
TORQUE
NOTES
Front isolator/engine mount
60-70 ft-lbs
81.4-95.0 Nm
page 2-92
through-bolt
Front turn signal clamp screw
96-120 in-lbs
10.9-13.6 Nm
page 2-48, 2-102
Gear shift lever pinch screw
16-20 ft-lbs
21.7-27.1 Nm
page 2-117, 2-121
Handlebar switch housing screw
35-45 in-lbs
4.0-5.1 Nm
page 2-97, 2-100, 2-102
Ignition Control Module lock nut
12-20 in-lbs
1.4-2.3 Nm
page 2-111
License plate bracket mounting
20-25 in-lbs
2.3-2.8 Nm
page 2-110
screw
Lower front stabilizer link bracket-
25-35 ft-lbs
33.9-47.5 Nm
page 2-90
to-frame screw
Lower shock absorber mounting
45-50 ft-lbs
61.1-67.9 Nm
page 2-18, 2-88, 2-112
screw
Mirror stem lock nut
96-144 in-lbs
10.9-16.3 Nm
page 2-48, 2-102
Muffler interconnect bracket
30-33 ft-lbs
40.7-44.8 Nm
page 2-106
screw
Muffler Torca clamp nut
45-65 ft-lbs
61.1-88.2 Nm
page 2-106
Muffler-to-interconnect bracket
15-19 ft-lbs
20.4-25.8 Nm
page 2-106
screw
Passenger footrest support
45-50 ft-lbs
61.1-67.9 Nm
page 2-87, 2-123
bracket screw
Rear axle nut
72-78 ft-lbs
98-106 Nm
page 2-8, 2-18
Rear brake disc screw
30-45 ft-lbs
40.7-61.1 Nm
LOCTITE 243, page 2-16
Rear brake lamp switch
80-123 in-lbs
9.0-13.9 Nm
page 2-80
Rear brake line clamp-to-battery
30-40 in-lbs
3.4-4.5 Nm
page 2-80
tray bracket screw
Rear brake line clamp-to-rear fork
30-40 in-lbs
3.4-4.5 Nm
page 2-80
screw
Rear brake line/switch tee bracket
72-120 in-lbs
8.14-13.6 Nm
page 2-80
screw
Rear brake master cylinder
130-173 in-lbs
14.7-19.6 Nm
page 2-56
pushrod shoulder nut
Rear caliper bolt pin
15-18 ft-lbs
20.4-24.6 Nm
LOCTITE 272, page 2-74
Rear caliper mounting bracket
87-130 in-lbs
9.8-14.7 Nm
page 2-74
bolt pin
Rear exhaust pipe clamp nut
15-19 ft-lbs
20.4-25.8 Nm
page 2-106
Rear fork pivot/engine mount bolt
60-70 ft-lbs
81.4-95.0 Nm
page 2-87, 2-95
Rear isolator mount screw
25-35 ft-lbs
33.9-47.5 Nm
page 2-95
Rear Master Cylinder Mounting
17-22 ft-lbs
23.1-29.9 Nm
page 2-57
Bracket Screw (bottom)
Rear Master Cylinder Mounting
17-22 ft-lbs
23.1-29.9 Nm
page 2-57
Bracket Screw (top)
Rear master cylinder mounting
15-20 ft-lbs
20.4-27.1 Nm
Page 2-57
screw
Rear master cylinder reservoir
20-25 in-lbs
2.3-2.8 Nm
page 2-59
mounting screw
Rear pivot lockplate screw
80-120 in-lbs
9.05-13.6 Nm
page 2-95
Rear sprocket screw (cast wheel)
55-65 ft-lbs
74.6-88.2 Nm
LOCTITE 262, page 2-16
2-4
2006 Sportster: Chassis
HOME
ITEM
TORQUE
NOTES
Rider footrest support bracket
screw (XL 883/XL 883L/XL 883R/
45-50 ft-lbs
61.1-67.9 Nm
page 2-117
XL 1200R)
Rider footrest/brake pedal support
bracket screw (XL 883/XL 883L/
45-50 ft-lbs
61.1-67.9 Nm
page 2-117
XL 883R/XL 1200R)
Rider footrest/brake pedal support
bracket screw (XL 883C/XL
45-50 ft-lbs
61.1-67.9 Nm
page 2-119
1200C)
Rider footrest/shift lever support
bracket screw (XL 883C/XL
45-50 ft-lbs
61.1-67.9 Nm
page 2-121
1200C)
Seat post screw
96-156 in-lbs
10.9-17.6 Nm
page 2-111
Shift pedal clevis screw
18-22 ft-lbs
24.4-29.9 Nm
page 2-121
Shifter rod-to-shift lever assembly
120-180 in-lbs
13.6-20.4 Nm
page 2-121, 2-122
screw
Shifter rod-to-shift lever screw
120-180 in-lbs
13.6-20.4 Nm
page 2-121
Single Caliper Cast Front Wheel
16-24 ft-lbs
21.7-32.6 Nm
page 2-21
Hub Plate Screw
Spoke nipples
40-50 in-lbs
4.5-5.7 Nm
16 in., page 2-24, 19 in., page 2-28, 21 in., page 2-32
Sprocket cover screw
80-120 in-lbs
9.0-13.6 Nm
page 2-95, 2-106
Stabilizer link bracket-to-frame
25-35 ft-lbs
33.9-47.5 Nm
page 2-89
screw
Stabilizer link engine bracket
55-65 ft-lbs
74.6-88.2 Nm
page 2-89
screw
Stabilizer link screw
25-35 ft-lbs
33.9-47.5 Nm
page 2-89, 2-90, 2-92, 2-95
Tail lamp base screw
45-48 in-lbs
5.1-5.4 Nm
page 2-111
Turn signal stud nut
132-216 in-lbs
14.9-24.4 Nm
page 2-111
Upper shock absorber mounting
45-50 ft-lbs
61.1-67.9 Nm
page 2-88
screw
Valve stem nut
12-15 in-lbs
1.4-1.7 Nm
page 2-39
XL 883/XL 883L/XL 883R/XL
1200R Handlebar upper clamp
12-18 ft-lbs
16.3-24.4 Nm
page 2-99
screw
XL 883/XL 883L/XL 883R/XL
1200R Lower handlebar clamp
30-40 ft-lbs
40.7-54.3 Nm
page 2-99
bolt
XL 883C/XL 1200C Lower han-
30-40 ft-lbs
40.7-54.3 Nm
page 2-99
dlebar clamp bolt
XL 883C/XL 1200C Lower han-
8-12 in-lbs
0.9-1.4 Nm
page 2-99
dlebar clamp cover screw
XL 883C/XL 1200C upper handle-
bar clamp/speedometer housing
12-18 ft-lbs
16.3-24.4 Nm
page 2-99
screw
2006 Sportster: Chassis
2-5
HOME
VEHICLE IDENTIFICATION NUMBER (VIN)
2.3
See Figure 2-2. An abbreviated V.I.N. is stamped on the left
GENERAL
side crankcase at the base between the cylinders.
See Figure 2-1. The full 17 digit serial, or Vehicle Identifica-
tion Number (V.I.N.) is stamped on the right side of the steer-
ing head and on a label located on the right side down tube.
11468
11467
Figure 2-2. VIN Location, Engine Crankcase
Sample V.I.N. as it appears on the steering head:
1HD1CGP166K400000.
Sample abbreviated V.I.N. as it appears on the left crankcase:
CGP6400000.
NOTE
Always give the full 17 digit Vehicle Identification Number
Figure 2-1. VIN Locations, Frame
when ordering parts or making any inquiry about your motor-
cycle.
1
2
3
4
5
6
7
8
9
10
1
HD
1
CG P
1
6
6
K
400000
Figure 2-3. Sportster Vehicle Identification Number (typical)
2-6
2006 Sportster: Chassis
HOME
Table 2-9. Harley-Davidson 2006 Sportster Model V.I.N. Description
ITEM
DESCRIPTION
POSSIBLE VALUES
1
Market destination
1=Originally manufactured for sale within the United States
5=Originally manufactured for sale outside the United States
2
Manufacturer
HD=Harley-Davidson
3
Motorcycle type
1=Heavyweight motorcycle, 901 cc or larger
4=Middleweight motorcycle, 351 cc to 900 cc
4
Model
see Sportster model V.I.N. codes table
5
Engine type
M=Evolution, 883 cc air-cooled, carbureted
P=Evolution, 1200 cc air-cooled, carbureted
6
Introduction date
1=Regular
2=Mid-year
3=California/regular
4=Cosmetic changes and/or special introductory date
5=California/cosmetic changes and/or special introductory date
6=California/mid-year
7
VIN check digit
Can be 0-9 or X
8
Model year
6=2006
9
Plant of manufacture
K=Kansas City, MO., U.S.A.
10
Sequential number (last 6 digits)
varies
Table 2-10. 2006 Sportster Model V.I.N.
Codes
CODE
MODEL NAME
CA
XL 883
CM
XL 883L
CK
XL 883R
CJ
XL 883C
CG
XL 1200C
CL
XL 1200R
2006 Sportster: Chassis
2-7
HOME
WHEELS
2.4
Keep tires inflated to the recommended air pressure. Always
GENERAL
balance the wheel after replacing a tube or tire.
Good handling and maximum tire mileage are directly related
to the care of wheels and tires. Regularly inspect wheels and
1WARNING
tires for damage and wear. If handling problems occur, see
1.31 TROUBLESHOOTING or refer to Table 2-11. for a list of
Do not inflate tire beyond maximum pressure as speci-
fied on sidewall. Over inflated tires can blow out, which
probable causes.
could result in death or serious injury. (00027a)
Table 2-11. Wheel Service Chart
CHECK FOR
REMEDY
Loose axle nuts.
Tighten front axle nut to 50-55 ft-lbs (67.9-74.6 Nm). Tighten rear axle nut to
72-78 ft-lbs (98-106 Nm).
Excessive side-play or radial (up-and-down)
Replace wheel hub bearings. See SEALED WHEEL BEARINGS later in this
play in wheel hubs.
section.
Loose spokes.
Tighten or replace spokes. See 2.8 TRUING LACED WHEELS and 2.5
WHEEL LACING: 16 INCH RIM, 2.6 WHEEL LACING: 19 INCH RIM or 2.7
WHEEL LACING: 21 INCH RIM.
Alignment of rear wheel in frame or with
Check rear wheel alignment as described in this section or repair rear fork
front wheel.
as described in 2.19 REAR FORK.
Rims and tires out-of-true sideways; should
True wheels, replace rims or replace spokes. See 2.8 TRUING LACED
not be more than 5/64 in. (2.0 mm).
WHEELS and 2.5 WHEEL LACING: 16 INCH RIM, 2.6 WHEEL LACING: 19
INCH RIM or 2.7 WHEEL LACING: 21 INCH RIM.
Rims and tires out-of-round or eccentric
See Item 5 above.
with hub; should not be more than 3/32 in.
(2.4 mm).
Irregular or peaked front tire wear.
Replace as described in 2.4 WHEELS and 2.10 TIRES.
Correct tire inflation.
Inflate tires to correct pressure. See 2.1 SPECIFICATIONS.
Correct tire and wheel balance.
Static balance may be satisfactory if dynamic balancing facilities are not
available. However, dynamic balancing is strongly recommended.
Steering head bearings.
Correct adjustment and replace pitted or worn bearings. See 2.18 FORK
STEM AND BRACKET ASSEMBLY.
Damper tubes.
Check for leaks. See 2.17 FRONT FORK.
Shock absorbers.
Check damping action and mounting stud bushings. See 2.19 REAR FORK.
Rear fork bearings.
Check for looseness. See 2.19 REAR FORK.
2-8
2006 Sportster: Chassis
HOME
At regular intervals of 5000 miles (8000 km), or whenever
TROUBLESHOOTING
handling irregularities are noted, see the chart on the preced-
ing page for the recommended service procedure.
See Figure 2-4. Check tire inflation pressure at least once
each week. At the same time, inspect tire tread for punctures,
If tires must be replaced, same as original equipment tires
cuts, breaks and other damage. Repeat the inspection before
must be used. Other tires may not fit correctly and may be
road trips.
hazardous to use.
1WARNING
Use the following guidelines when installing a new tire or
repairing a flat. Failure to comply with the guidelines
below could result in death or serious injury.
1. Always locate and eliminate the cause of the original tire
failure.
2. Do not patch or vulcanize a tire casing. These proce-
dures weaken the casing and increase the risk of a blow-
out.
3. Only patch an inner tube as an emergency measure.
Replace the damaged tube as soon as possible.
4. Be sure the inner tube is the correct size for the tire cas-
x0142a2x
ing. Any stretching or wrinkling within the casing will
weaken the tube and result in premature failure.
Figure 2-4. Checking Tire Pressure
5. The use of tires other than those specified can adversely
affect handling resulting in death or serious injury.
6. Tires, tubes and wheels are critical safety items. Since
1WARNING
the servicing of these components requires special tools
Be sure tires are properly inflated, balanced and have
and skills, Harley-Davidson recommends that you see
adequate tread. Inspect your tires regularly and see a
your dealer for these services.
Harley-Davidson dealer for replacements. Riding with
excessively worn, unbalanced or under-inflated tires can
adversely affect stability and handling, which could
result in death or serious injury. (00014a)
2006 Sportster: Chassis
2-9
Большое спасибо!
Ваше мнение очень важно для нас.
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст