Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 12
HOME
LOWER FRONT STABILIZER LINK
REAR STABILIZER LINK
Removal
Removal
1.
Position motorcycle upright on suitable lift.
1. Position motorcycle upright on suitable lift.
2.
See Figure 2-137. Remove screws (3) and stabilizer link
2. California vehicles: remove EVAP canister and mounting
(1).
bracket. See REMOVAL under
4.9 EVAPORATIVE
EMISSIONS CONTROL-CA MODELS.
3.
Remove screws (4), washers
(5) and stabilizer link
bracket (2) from frame.
3. See Figure 2-138. Remove short screw (3), long screw
(4), ground strap (2), stabilizer link (1) and spacer (5).
Installation
Installation
1.
See Figure 2-137. Install screws (4), washers (5) and
stabilizer link bracket (2) to frame. Tighten to 25-35 ft-lbs
1. See Figure 2-138. Install short screw (3) through ground
(33.9-47.5 Nm).
strap (2) and stabilizer link (1). Thread screw into frame
on right side of motorcycle. Do not tighten at this time.
2.
Install stabilizer link (1). Secure with screws (3). Tighten
to 25-35 ft-lbs (33.9-47.5 Nm).
2. Install long screw (4) through ground strap, stabilizer link
and spacer (5) into engine case.
3. Tighten both screws to 25-35 ft-lbs (33.9-47.5 Nm).
x0593a2x
4. California vehicles: Install EVAP canister and mounting
bracket. See INSTALLATION under 4.9 EVAPORATIVE
EMISSIONS CONTROL-CA MODELS.
4
3
x0594a2x
5
2
1
1.
Stabilizer link
2.
Stabilizer link bracket
3.
Screw (2)
1
4.
Screw (2)
5.
Washer (2)
5
Figure 2-137. Lower Front Stabilizer Link Assembly
4
2
3
1.
Stabilizer link
2.
Grounding strap
3.
Screw
4.
Screw
5.
Spacer
Figure 2-138. Rear Stabilizer Link Assembly
2-90
2006 Sportster: Chassis
HOME
FRONT ENGINE MOUNT/ISOLATOR
2.22
5. See Figure 2-137. Remove screw (3) securing lower
GENERAL
front stabilizer link (1) to stabilizer link bracket (2).
6. See Figure 2-138. Remove screw (4) from left end of
rear stabilizer link
(1) and ground strap (2). Remove
PART NO.
SPECIALTY TOOL
spacer (5).
HD-45968
Fat Jack
NOTE
See Figure 2-139. In the next step, the engine may need to
REMOVAL
be jacked up or down slightly to aid in removing bolt (3).
7. See Figure 2-139. Remove nut (4) and bolt (3) from front
1.
Position motorcycle upright on a suitable lift.
engine mount/isolator assembly.
2.
Custom models: Remove both forward foot control
8. Remove screws (5) from front isolator mount (2) on left
assemblies. See 2.34 RIDER FOOT CONTROLS: XL
side of motorcycle. Remove isolator mount and left front
883C, XL 1200C.
isolator (1).
3.
Support front of engine with FAT JACK and suitable
blocks.
9. Carefully pry front end of engine to the left approximately
one inch. Remove right front isolator (1) from crankcase.
4.
See Figure 2-136. Remove screw (4) securing upper
front stabilizer link (2) to stabilizer link bracket (3).
x0595a2x
1
3
1
5
4
2
1.
Isolator (2)
2.
Front isolator mount
3.
Bolt
4.
Nut
5.
Screw (2)
Figure 2-139. Front Engine Mount/Isolator
2006 Sportster: Chassis
2-91
HOME
5. See Figure 2-137. Attach lower front stabilizer link (1) to
INSTALLATION
bracket (2) with screw (3). Tighten to 25-35 ft-lbs (33.9-
47.5 Nm).
1.
See Figure 2-139. Install both front isolators (1) in engine
mounting boss on front of crankcase. Note that each iso-
6. See Figure 2-136. Attach upper front stabilizer link (2) to
lator has a half-moon tab and fits into engine mounting
bracket (3) with screw (4). Tighten to 25-35 ft-lbs (33.9-
boss in only one way. Push engine to the right until right
47.5 Nm).
isolator contacts frame boss.
7. See Figure 2-138. Install screw (4) through free end of
2.
Install front isolator mount (2) over left front isolator.
ground strap (2), rear stabilizer link (1), spacer (5), and
into engine crankcase. Tighten to 25-35 ft-lbs (33.9-47.5
3.
Install screws (5) through front isolator mount and thread
Nm).
into frame. Tighten to 25-35 ft-lbs (33.9-47.5 Nm).
8. Remove FAT JACK and blocks from under engine.
4.
Insert bolt
(3) through front isolator/engine mount
assembly from left side. Thread nut (4) onto bolt. Tighten
9. Custom models: Install both forward foot control assem-
to 60-70 ft-lbs (81.4-95.0 Nm).
blies. See 2.34 RIDER FOOT CONTROLS: XL 883C, XL
1200C.
2-92
2006 Sportster: Chassis
HOME
REAR ENGINE MOUNT/ISOLATOR
2.23
GENERAL
x0256b6x
1
4
PART NO.
SPECIALTY TOOL
5
6
HD-45967
Shop Dolly
HD-45968
Fat Jack
REMOVAL
1.
Remove seat. See 2.32 SEAT.
3
2.
Open left side cover. No tools are required. See 1.6
LEFT SIDE COVER.
1.
Sprocket cover
2
2.
Screw
3.
Screw
1WARNING
4.
Exhaust pipe clamp bracket
Prevent accidental vehicle start-up, which could cause
5.
Washer
death or serious injury. First disconnect negative (-) bat-
6.
Screw
tery cable at engine and then positive (+) cable from bat-
tery. (00280a)
Figure 2-140. Sprocket Cover
3.
Disconnect both battery cables, negative cable first. See
7. Loosen rear axle and remove rear drive belt. See
BATTERY DISCONNECTION AND REMOVAL under 1.7
REMOVAL under 6.6 SECONDARY DRIVE BELT.
BATTERY MAINTENANCE.
8. All models except XL 883 and XL 883L: Remove left pas-
4.
Remove exhaust system. See 2.27 EXHAUST SYSTEM.
senger footrest assembly. See
2.35 PASSENGER
5.
With the aid of a FAT JACK, support motorcycle on
FOOTRESTS.
SHOP DOLLY.
9. Unbolt rear brake master cylinder remote reservoir. Do
NOTE
not disconnect hose from reservoir. Secure reservoir to
vehicle in an upright position, out of the way. See 2.13
Position vehicle on SHOP DOLLY so that FAT JACK may be
REAR BRAKE MASTER CYLINDER RESERVOIR.
used (with the aid of suitable blocks) to support engine when
rear engine mount is removed.
10. Support rear fork assembly using vehicle tiedown straps.
6.
See Figure 2-140. Remove screw (6), washer (5) and
exhaust pipe clamp bracket (4). Remove two screws (2,
3). Remove sprocket cover (1).
2006 Sportster: Chassis
2-93
HOME
11. See Figure 2-141. Remove rear fork pivot bolts (1).
17. Support rear of engine with FAT JACK and suitable
blocks.
12. Pull rear fork back far enough to clear rear engine
18. See Figure 2-141. Remove two screws (7) securing rear
mounts and isolators.
isolator mount (2) to left side of frame. Remove isolator
13. California vehicles: remove EVAP canister and mounting
mount and left isolator (3).
bracket See REMOVAL under
4.9 EVAPORATIVE
19. Remove three screws (6) securing rear pivot lockplate
EMISSIONS CONTROL-CA MODELS.
(5) to rear of engine case. Remove lockplate and swing
14. See Figure 2-138. Remove screws (3, 4) securing rear
arm pivot shaft (4).
stabilizer link
(1). Remove stabilizer link, ground strap
NOTE
(2), and spacer (5).
Engine may need to be jacked up or down slightly to aid in
15. See Figure 2-136. Remove screw (4) securing upper
removing pivot shaft.
front stabilizer link (2) to stabilizer link bracket (3).
20. Carefully pry rear end of engine to the left approximately
one inch. Remove right rear isolator (3) from frame.
16. See Figure 2-137. Remove screw (3) securing lower
front stabilizer link (1) to stabilizer link bracket (2).
x0596b2x
1
1
2
7
6
3
5
4
1.
Bolt (2)
2.
Rear isolator mount
3.
Isolator (2)
3
4.
Swing arm pivot shaft
5.
Rear pivot lockplate
6.
Screw (3)
7.
Screw (2)
Figure 2-141. Rear Engine Mount/Isolator
2-94
2006 Sportster: Chassis
HOME
12. Install rear brake master cylinder remote reservoir. See
INSTALLATION
2.13 REAR BRAKE MASTER CYLINDER RESERVOIR.
1.
See Figure 2-141. Install new right rear isolator (3) into
13. All models except XL 883 and XL 883L: install left pas-
frame, lining up tabs on isolator with slots in frame. Slide
senger footpeg assembly. See
2.35 PASSENGER
rear end of engine to the right until engine mounting boss
FOOTRESTS.
on rear of crankcase contacts right isolator.
14. Install and adjust rear drive belt and tighten rear axle.
2.
Slide swing arm pivot shaft (4) through engine mounting
See INSTALLATION under 6.6 SECONDARY DRIVE
boss.
BELT.
15. See Figure 2-140. Install sprocket cover (1). Secure with
NOTE
two screws (2, 3). Note that long screw goes in top hole,
Engine may need to be moved slightly in one direction or
short screw in bottom hole. Do not tighten screws at this
another in order to line up pivot shaft with isolator.
time.
3.
Install rear pivot lockplate (5) over pivot shaft with ridges
16. Install exhaust pipe clamp bracket (4), washer (5) and
on lockplate engaging flats on pivot shaft flange. Secure
screw (6). Tighten to 30-33 ft-lbs (40.7-44.8 Nm). Now
to crankcase with three screws (6). Tighten to 80-120 in-
tighten screws (2, 3) to 80-120 in-lbs (9.0-13.6 Nm).
lbs (9.05-13.6 Nm).
17. Install exhaust system. See 2.27 EXHAUST SYSTEM.
4.
Install new left rear isolator (3) on swing arm pivot shaft.
5.
Place rear isolator mount (2) over left rear isolator, lining
1WARNING
up tabs on isolator with slots in isolator mount. Install
screws (7). Tighten to 25-35 ft-lbs (33.9-47.5 Nm).
Connect positive (+) battery cable first. If positive (+)
6.
Remove FAT JACK and blocks.
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explo-
7.
See Figure 2-136. Attach upper front stabilizer link (2) to
sion, which could result in death or serious injury.
bracket (3) with screw (4). Tighten to 25-35 ft-lbs (33.9-
(00068a)
47.5 Nm).
8.
See Figure 2-137. Attach lower front stabilizer link (1) to
18. Connect both battery cables, positive (+) cable first. See
bracket (2) with screw (3). Tighten to 25-35 ft-lbs (33.9-
BATTERY INSTALLATION AND CONNECTION under
47.5 Nm).
1.7 BATTERY MAINTENANCE.
9.
See Figure 2-138. Install short screw (3) through ground
19. Close left side cover. No tools are required. See 1.6
strap (2) and rear stabilizer link (1) into frame on right
LEFT SIDE COVER.
side of motorcycle. Install long screw (4) through free
20. Install seat. See 2.32 SEAT.
end of ground strap, stabilizer link and spacer (5) into
engine case. Tighten both screws to 25-35 ft-lbs (33.9-
47.5 Nm).
10.
California vehicles: Install EVAP canister and mounting
bracket. See INSTALLATION under 4.9 EVAPORATIVE
EMISSIONS CONTROL-CA MODELS.
11.
See Figure 2-141. Slide rear fork forward into position.
Install rear fork pivot bolts (1). Tighten to 60-70 ft-lbs
(81.4-95.0 Nm). Remove vehicle tiedown straps support-
ing rear fork.
2006 Sportster: Chassis
2-95
HOME
THROTTLE CONTROL
2.24
REMOVAL/DISASSEMBLY
x0427a2x
1.
See Figure 2-142. Slide rubber boot off each cable
adjuster
(4). Loosen jam nut on each adjuster. Turn
adjusters in direction which will shorten cable housings
to minimum length.
2.
Remove two screws (7) and separate upper housing (9)
10
from lower housing (11).
3.
Unhook ferrules (1) and cables (2, 3) from throttle control
grip (12) and lower housing (11).
4.
Remove air cleaner assembly. See 4.6 AIR CLEANER,
REMOVAL.
9
5.
Disconnect cables from carburetor.
6.
Remove friction spring (8), throttle friction screw (13) and
16
15
spring (5) from lower housing.
11
8
CLEANING, INSPECTION AND
REPAIR
4
6
5
1WARNING
13
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
14
safety glasses when working with compressed air. Never
7
use your hand to check for air leaks or to determine air
flow rates. (00061a)
Clean all parts in a non-flammable cleaning solvent. Blow dry
with low pressure compressed air. Replace cables if frayed,
2
1
3
kinked or bent.
12
ASSEMBLY/INSTALLATION
1.
Ferrule (2)
1.
See Figure 2-142. Apply a light coating of graphite to the
2.
Throttle control cable assembly
handlebar (10) and the inside surface of the upper and
3.
Idle control cable assembly
lower housings (9, 11).
4.
Cable adjuster (2)
2.
Install spring (5), throttle friction screw (13) and friction
5.
Spring
spring (8) in lower housing (11).
6.
Retaining ring
7.
Screw (2)
3.
Attach cable assemblies (2, 3) to lower housing. See Fig-
8.
Friction spring
ure 2-143. Throttle control cable (2) has a 5/16 in. (7.9
9.
Upper housing
mm) fitting end and is positioned to front of lower hous-
10. Handlebar
ing. Idle control cable (3) has a 1/4 in. (6.3 mm) fitting
11. Lower housing
end and is positioned to rear of lower housing.
12. Throttle control grip
4.
See Figure 2-142. Install throttle control grip (12) over
13. Throttle friction screw
end of right handlebar (10). Position lower housing (11)
14. Throttle cable clip
onto right handlebar, engaging lower housing with throt-
15. Throttle retaining ring
tle control grip. Position ferrules (1) over cable ball ends,
16. Idle retaining ring
then seat ferrules (with cables attached) in their respec-
tive notches of the throttle control grip.
Figure 2-142. Throttle Control, Right Handlebar
2-96
2006 Sportster: Chassis
HOME
5. Install upper housing (9) over right handlebar and secure
8340
to lower housing using screws (7). Tighten screws to 35-
45 in-lbs (4.0-5.1 Nm).
6. See Figure 2-144. Route control cables forward from
throttle control grip, forward of front fork upper bracket,
2
downward between right slider tube and headlamp, rear-
ward along right side of frame steering head and frame
backbone, over ignition switch housing, through throttle
cable guide between coil bracket and frame, and down-
5
ward to carburetor.
7. See Figure 2-143. Install idle control cable (3) housing
1
and spring into longer, inboard (idle) cable guide (8) on
carburetor.
8. Install throttle control cable (2) housing into shorter, out-
3
board cable guide (9) on carburetor.
1WARNING
4
Throttle cables must not pull tight when handlebars are
turned fully to left or right fork stops. Be sure wires and
x0506a1x
throttle cables are clear of fork stops at steering head so
they will not be pinched when fork is turned against
8
9
stops. Steering must be smooth and free with no binding
7
2
or interference. Improperly adjusted and/or positioned
throttle cables could result in loss of control of vehicle
and death or serious injury.
3
9. Adjust control cables. See CABLE INSPECTION,
LUBRICATION AND ADJUSTMENT under 1.24 THROT-
TLE CABLES AND ENRICHENER.
10413
6
1.
Throttle friction screw
2.
Throttle control (pull-open) cable
3.
Idle control (pull-close) cable
4.
Cable adjuster (2)
5.
Throttle control grip
6.
Throttle cam stop
7.
Carburetor stop plate
Figure 2-144. Throttle Control Cable Routing
8.
Idle control cable guide (on carburetor)
9.
Throttle control cable guide (on carburetor)
Figure 2-143. Throttle/Idle Control Cable
2006 Sportster: Chassis
2-97
HOME
HANDLEBARS
2.25
REMOVAL
x0597x2x
1
3
5
4
19
1WARNING
2
6
7
To prevent accidental vehicle start-up, which could
cause death or serious injury, remove maxi-fuse before
proceeding. (00251a)
8
All Models
18
9
1.
Remove Maxi-Fuse. See 7.25 MAXI-FUSE.
2.
Remove two screws securing clutch control assembly to
17
left side of handlebar. See 2.26 CLUTCH CONTROL.
3.
Remove two screws securing left handlebar switch
assembly to handlebar. See 7.23 LEFT HANDLEBAR
14
16
SWITCH. Let wires carefully support the switch assem-
10
bly.
13
4.
Remove left handlebar grip
12
11
15
5.
Remove front brake master cylinder assembly from right
1.
Handlebar grip
handlebar. See 2.11 FRONT BRAKE MASTER CYLIN-
2.
Upper handlebar clamp
DER.
3.
Screw (2)
4.
Screw (2)
XL 883, XL 883L, XL 883R, XL 1200R
5.
Washer (2)
1.
See Figure 2-145. Cut and remove four wiring harness
6.
Spacer (2) (XL 1200R only)
retainers (13). When cutting retainers, be careful not to
7.
Upper control housing
cut into wiring harnesses. Discard retainers.
8.
Handlebar
9.
Throttle grip and sleeve
2.
Loosen, but do not remove, two control housing screws
10.
Throttle adjusting assembly
(11).
11.
Screw (2)
3.
If removing lower handlebar clamps (14, 18), loosen, but
12.
Lower control housing
do not remove, two bolts (16) securing lower handlebar
13.
Wire harness retainer (4)
clamps to upper fork bracket (17).
14.
Lower right handlebar clamp
4.
Remove screws and washers (3, 4, 5), spacers (6 - XL
15.
Washer (2)
1200R only), upper handlebar clamp (2) and instrument
16.
Bolt (2)
bracket (19).
17.
Upper fork bracket
5.
Detach handlebar (8) from lower handlebar clamps.
18.
Lower left handlebar clamp
19.
Instrument bracket
6.
Slide right hand control housing and throttle assembly (7,
9, 12) off detached handlebar.
Figure 2-145. Handlebars: XL 883/XL 883L/
7.
If removing lower handlebar clamps (14, 18), remove two
XL 883R/XL 1200R
bolts
(16), washers (15) and lower handlebar clamps
from upper fork bracket.
2-98
2006 Sportster: Chassis
HOME
XL 883C, XL 1200C
INSTALLATION
1.
See Figure 2-146. Cut and remove four wiring harness
retainers (10). When cutting retainers, be careful not to
XL 883, XL 883L, XL 883R, XL 1200R
cut into wiring harnesses. Discard retainers.
2.
Loosen, but do not remove, two control housing screws
1. See Figure 2-145. If lower handlebar clamps (14, 18)
(8).
were removed, secure clamps to upper fork bracket (17)
with bolts (16) and washers (15). Finger tighten bolts
3.
Remove two screws (16) and lower clamp cover (15).
only at this time. Make sure wiring harnesses are routed
4.
Remove four screws (3) and upper handlebar clamp/
between lower handlebar clamps.
speedometer housing (2). Detach handlebar (5) from
2. Slide right handlebar control housing and throttle assem-
lower handlebar clamp.
bly (7, 9, 12) onto right end of handlebar (8). Position
5.
Slide right hand control and throttle assembly (4, 6, 9) off
handlebar on lower handlebar clamps.
detached handlebar.
3. Place upper handlebar clamp (2) in position and thread
6.
If removing lower handlebar clamp (14), remove bolts
the two rear screws (3) in place.
(11), washers
(12) and lower handlebar clamp from
4. XL
1200R models: place spacers (6) over two front
upper fork bracket.
mounting holes of upper handlebar clamp.
5. Position instrument bracket (19) over two front holes of
x0598x2x
upper handlebar clamp and thread two screws (4) and
3
1
washers (5) in place.
2
4
6. See Figure 2-147. Adjust handlebars to desired position
and tighten rear screws (3) to 12-18 ft-lbs (16.3-24.4 Nm)
until cast-in spacers of upper clamp contact lower
5
clamps.
14
7. See Figure 2-145. Finally, tighten front screws (4) to 12-
6
18 ft-lbs (16.3-24.4 Nm).
8. Tighten lower handlebar clamp bolts (16) to 30-40 ft-lbs
10
13
(40.7-54.3 Nm).
XL 883C, XL 1200C
12
1. See Figure 2-146. If lower handlebar clamp (14) was
9
8
removed, secure clamp to upper fork bracket with two
11
bolts (11) and washers (12). Make sure handlebar wiring
7
harnesses are routed behind and inside lower handlebar
clamp. Tighten bolts to 30-40 ft-lbs (40.7-54.3 Nm).
16
15
2. Slide right handlebar control housing and throttle assem-
bly (4, 6, 9) onto right end of handlebar (5). Position han-
1.
Handlebar grip
dlebar on lower handlebar clamp.
2.
Upper handlebar clamp/Speedometer housing
3.
Screw (4)
3. Place upper handlebar clamp/speedometer housing (2)
4.
Upper control housing
in position and thread four screws (3) in place.
5.
Handlebar
4. See Figure 2-147. Adjust handlebars to desired position.
6.
Throttle grip and sleeve
Tighten front screws first, to 12-18 ft-lbs (16.3-24.4 Nm).
7.
Throttle adjusting assembly
Then tighten rear screws to 12-18 ft-lbs (16.3-24.4 Nm).
8.
Screw (2)
5. Be sure handlebar wiring harnesses are routed properly
9.
Lower control housing
and are not pinched. Install lower clamp cover (15) and
10. Wire harness retainer (4)
screws (16). Tighten to 8-12 in-lbs (0.9-1.4 Nm).
11. Bolt (2)
12. Washer (2)
13. Upper fork bracket
14. Lower handlebar clamp
15. Lower clamp cover
16. Screw (2)
Figure 2-146. Handlebars: XL 883C/XL 1200C
2006 Sportster: Chassis
2-99
HOME
x0430b2x
All Models
4
1. Install front brake master cylinder assembly. See 2.11
FRONT BRAKE MASTER CYLINDER.
Tighten first
2. Install new left hand grip in place as follows:
a. Using a piece of emery cloth, rough grip end of left
5
handlebar.
3
NOTE
6
Before applying adhesive in the next step, clean the left han-
dlebar with acetone.
b. Apply LOCTITE PRISM PRIMER (770) to inside of
2
hand grip. Remove any excess PRISM PRIMER
with a clean cloth. Wait two minutes for PRISM
PRIMER to set before attempting the next step.
1
c. Apply LOCTITE PRISM SUPERBONDER (411) to
XL 883/XL 883L/XL 883R/XL 1200R
inside of hand grip. Install new hand grip on left han-
dlebar.
x0431b2x
4
NOTE
Tighten first
SUPERBONDER will set in four minutes and be fully cured in
24 hours.
3. Position left hand control and loosely install hand control
clamp screws. See 7.23 LEFT HANDLEBAR SWITCH.
1
3
4. Attach clutch control assembly to left side of handlebar.
Tighten screws to 108-132 in-lbs (12.2-14.9 Nm). See
2.26 CLUTCH CONTROL.
5. Tighten left hand control clamp screws to 35-45 in-lbs
(4.0-5.1 Nm).
6. Tighten right hand control clamp screws to 35-45 in-lbs
(4.0-5.1 Nm).
6
7. Wrap four new wiring harness retainers (item 12, Figure
2-145. or item 10, Figure 2-146.) around handlebar wir-
XL 883C/XL 1200C
ing harnesses and push retainers into holes in handle-
1.
Lower clamp (Customs: 1, all others: 2)
bar.
2.
Cast-in spacer (2)
8. Install Maxi-Fuse. See 7.25 MAXI-FUSE.
3.
Rear screw (2)
9. Verify the following:
4.
Front screw (2)
5.
Instrument bracket
a. Clutch cable adjustment/operation.
6.
Upper clamp
b. Proper throttle cable operation.
c. All electrical switch functions.
Figure 2-147. Handlebar Riser
d. Proper brake operation and brake lamp function.
2-100
2006 Sportster: Chassis
HOME
CLUTCH CONTROL
2.26
2.
See Figure 2-148. Slide rubber boot (1) on clutch cable
GENERAL
adjuster
(2) upward to expose adjuster mechanism.
Loosen jam nut
(3) from adjuster. Turn adjuster to
For clutch adjustment, see ADJUSTMENT under
1.13
shorten cable housing until there is a large amount of
CLUTCH.
freeplay at clutch hand lever. See ADJUSTMENT under
1.13 CLUTCH.
For clutch replacement, see 6.5 PRIMARY DRIVE/CLUTCH.
3.
See Figure 2-149. Remove six screws (1) and clutch
inspection cover (2). Exercise caution to avoid damaging
REMOVAL/DISASSEMBLY
or dislodging quad ring (7) from groove in primary cover
(9).
1WARNING
x0055x6x
To prevent accidental vehicle start-up, which could
1
cause death or serious injury, remove maxi-fuse before
2
proceeding. (00251a)
3
Open left side cover and remove Maxi-Fuse. Close left side
4
cover. See 7.25 MAXI-FUSE.
Clutch Cable-Lower
1.
Rubber boot
2.
Cable adjuster
1.
XL 883, XL 883L, XL 883R and XL 1200R models:
3.
Jam nut
remove left side rider footrest and mounting bracket
4.
Cable end
assembly. See LEFT FOOTREST AND SHIFT LEVER
ASSEMBLY under 2.33 RIDER FOOT CONTROLS: XL
Figure 2-148. Clutch Cable Adjuster Mechanism
883, XL 883L, XL 883R, XL 1200R for removal proce-
dure.
x0432a2x
1.
Screw (6)
15
14
16
2.
Clutch inspection cover
3.
Hex lockplate and spring
17
2
4.
Nut
5.
Ramp assembly (see items 14-17)
4
3
6.
Coupling
1
7.
Quad ring
8.
Clutch adjusting screw assembly
9.
Primary cover
10. O-ring
7
11. Clutch cable end
5
12. Cable end fitting
13. Clutch cable
14. Outer ramp
6
15. Ball (3)
16. Inner ramp
17. Retaining ring
13
8
10
11
12
9
Figure 2-149. Clutch Release Mechanism
2006 Sportster: Chassis
2-101
HOME
4.
Slide hex lockplate with attached spring (3) from flats of
x0075a2x
15
adjusting screw assembly (8).
7
6
5.
Turn adjusting screw assembly clockwise to release
9
ramp assembly (5) and coupling (6). As the adjusting
screw is turned, ramp assembly moves forward. Unscrew
nut (4) from end of adjusting screw.
8
6.
Remove hook of ramp from cable coupling. Remove
clutch cable end (11) from slot in coupling. Remove cou-
pling and ramp assembly.
4
7.
Unscrew cable end fitting (12) and remove clutch cable
1
(13) lower section from primary cover. Remove O-ring
(10) from cable end fitting. Discard O-ring.
11
8.
Clean all metal parts in a non-volatile cleaning solution
or solvent.
5
2
10
Clutch Lever and Clutch Cable-Upper
3
1.
See Figure 2-150. Remove retaining ring (3) and pivot
13
12
14
pin (6). Discard retaining ring.
2.
Remove clutch lever (1) from clutch lever bracket (5).
16
1.
Clutch lever
3.
Remove clutch cable pin (2). Disconnect clutch cable (4)
2.
Clutch cable pin
upper section from lever.
3.
Retaining ring
4.
Remove bushing (9) from clutch lever. Bushing has a col-
4.
Clutch cable
lar on one end and can only be removed from top of
5.
Clutch lever bracket
lever.
6.
Pivot pin
7.
Screw and retainer (2)
5.
Remove screw (10) and anti-rattle spring (11).
8.
Clutch control clamp
9.
Bushing
Clutch Hand Control
10.
Screw
1.
See Figure 2-150. Loosen set screw (12) and remove
11.
Anti-rattle spring
turn signal assembly (16) from clutch lever bracket (5).
12.
Set screw
2.
Loosen and remove lock nut (14) and lock washer (13),
13.
Lock washer
and lift mirror (15) from clutch lever bracket.
14.
Lock nut
15.
Mirror
3.
Remove two screws and retainers (7) from clutch control
16.
Turn signal assembly
clamp (8).
4.
Remove clutch control clamp (8) and clutch lever bracket
Figure 2-150. Clutch Hand Control
from left handlebar.
3. Install mirror
(15), secure with lock nut (14) and lock
NOTE
washer (13). Position mirror for best rearward visibility.
See Figure 2-150. You may need to loosen two screws of left
Tighten lock nut to 96-144 in-lbs (10.9-16.3 Nm).
handlebar switch housing to remove clutch control clamp (8)
4. Install turn signal (16) and secure with set screw (12).
and clutch lever bracket (5) from left handlebar.
Position so turn signal lens faces directly forward and
turn signal does not strike fuel tank when handlebars are
ASSEMBLY/INSTALLATION
turned full left. Tighten set screw to 96-120 in-lbs (10.9-
13.6 Nm).
NOTE
Clutch Hand Control
If two screws of left handlebar switch housing were loosened
1.
See Figure 2-150. Position clutch control clamp (8) and
during clutch hand control removal, tighten to 35-45 in-lbs
clutch lever bracket (5) onto left handlebar. Hold clamp
(4.0-5.1 Nm).
and bracket assembly firmly against left handlebar switch
housing.
2.
Secure components to left handlebar using two screws
and retainers
(7). Tighten to
108-132 in-lbs
(12.2-
14.9 Nm).
2-102
2006 Sportster: Chassis
HOME
4. Thread nut (4) on adjusting screw assembly (8) until slot
Clutch Lever and Clutch Cable-Upper
of screw is accessible with a screwdriver. Fit nut hex into
1.
See Figure 2-150. Install anti-rattle spring (11) and screw
recess of outer ramp (14). Turn adjusting screw counter-
(10) onto clutch lever (1). Tighten screw to 8-13 in-lbs
clockwise until resistance is felt. Then back off adjusting
(0.9-1.5 Nm).
screw 1/4 turn.
2.
Install bushing (9) in clutch lever. Bushing has a collar on
5. Install hex lockplate with spring (3) onto flats of adjusting
one end and must be installed from top of lever.
screw assembly (8). If necessary, turn adjusting screw
3.
Connect end of clutch cable (4) upper section to clutch
clockwise slightly so that lockplate slides onto flats while
lever (1) using clutch cable pin (2).
also fitting within recess of outer ramp.
4.
Position lever within clutch lever bracket (5), install pivot
6. Verify that quad ring (7) is fully seated in groove of pri-
pin (6) and secure with new retaining ring (3).
mary cover (9). Install clutch inspection cover (2) and
secure with six screws (1). Tighten screws in a crosswise
Clutch Cable-Lower
pattern to 84-108 in-lbs (9.5-12.2 Nm).
1.
See Figure 2-151. If not yet done, route clutch cable (3)
7. XL 883, XL 883L, XL 883R and XL 1200R models: install
forward from clutch lever (1), downward to outboard side
left side rider footrest and mounting bracket assembly.
of left front fork slider tube, through two clips (6) on left
Tighten footrest bracket mounting bolts to 45-50 ft-lbs
front frame downtube, and then rearward to primary
(61.1-67.9 Nm). See LEFT FOOTREST AND SHIFT
cover (4).
LEVER ASSEMBLY under 2.33 RIDER FOOT CON-
2.
See Figure 2-149. Install new O-ring (10) over cable end
TROLS: XL 883, XL 883L, XL 883R, XL 1200R for instal-
fitting (12) of clutch cable (13) lower section. Screw fitting
lation procedure.
into primary cover (9). Tighten to 36-60 in-lbs (4.1-6.8
Nm).
Finish
3.
Fit coupling (6) over cable end (11) with the rounded side
inboard, the ramp connector button outboard. With
Open left side cover and install Maxi-Fuse. Close left side
retaining ring side of ramp assembly (5) facing inward,
cover. See 7.25 MAXI-FUSE.
place hook of ramp around coupling button and rotate
assembly counterclockwise until tang on inner ramp (16)
fits in slot of primary cover.
x0205b2x
1.
Clutch lever
2.
Cable adjuster boot
3.
Clutch cable
1
4.
Primary cover
5.
Cable end fitting
6.
Clip (2)
8
7.
Front brake caliper
3
8.
Front brake line
7
2
4
6
5
Figure 2-151. Clutch Cable and Front Brake Line Routings - Left Side
2006 Sportster: Chassis
2-103
HOME
EXHAUST SYSTEM
2.27
1. See Figure 2-152. Remove heat shields:
REMOVAL
a. Open worm drive clamps (13) and remove exhaust
pipe heat shields (11, 12).
Mufflers and Exhaust Pipes
b. California, HDI and England models: open worm
drive clamps (15) and remove muffler heat shields
NOTE
(14).
To facilitate removing exhaust pipe header nuts, use Snap-On
tool (Part No. PFSX916).
2. Remove nuts (10) from front and
rear cylinder head
exhaust studs.
x0147c2x
13
4
22
12
24
2
20
21
7
23
26
8
25
15
1
5
9
10
16
11
18
15
17
6
14
15
19
13
16
15
14
6
3
1.
Muffler, front
14.
Muffler heat shield (2) *
2.
Muffler, rear
15.
Worm drive clamp (4) *
3.
Exhaust pipe, front
16.
Flanged bolt (4)
4.
Exhaust pipe, rear
17.
Bolt (3)
5.
Muffler interconnect bracket
18.
Washer (3)
6.
Torca muffler clamp assembly (2)
19.
Muffler interconnect gasket (2)
7.
Exhaust port gasket (2)
20.
Exhaust pipe clamp
8.
Exhaust gasket retaining ring (2)
21.
Exhaust pipe clamp bracket
9.
Exhaust pipe flange (2)
22.
Acorn nut
10. Nut (4)
23.
Screw
11. Heat shield, front exhaust pipe
24.
Engine sprocket cover
12. Heat shield, rear exhaust pipe
25.
Screw
13. Worm drive clamp (4)
26.
Washer
* California, HDI, England only
Figure 2-152. Exhaust System, All Models
2-104
2006 Sportster: Chassis
HOME
3.
Remove flanged bolts (16) securing front and rear muf-
x0256b6x
flers (1, 2) to muffler interconnect bracket (5).
1
4.
Loosen Torca muffler clamp assemblies (6) on front and
rear mufflers. Remove mufflers. Discard muffler intercon-
4
nect gaskets (19).
5
5.
Remove and discard Torca clamp assemblies; they are
6
one time usage only.
NOTE
New Torca muffler clamps have eliminated the need for sili-
cone or graphite tape during assembly. To ensure sealing
integrity of muffler clamps and prevent the possibility of leak-
age, Harley-Davidson recommends that torca muffler clamp
assemblies be discarded and replaced each time they are
3
removed.
6.
Remove nut (22) and screw (23) from exhaust pipe
1.
Sprocket cover
2
clamp (20). Separate exhaust pipe clamp from clamp
2.
Screw
bracket (21).
3.
Screw
7.
Remove front and rear exhaust pipes
(3,
4). Slide
4.
Exhaust pipe clamp bracket
exhaust pipe clamp off rear exhaust pipe.
5.
Washer
6.
Screw
8.
Remove exhaust port gasket (7), retaining ring (8) and
exhaust pipe flange (9) from each exhaust pipe. Discard
Figure 2-153. Sprocket Cover
gasket.
Muffler Interconnect Bracket
x0586x2x
1.
See Figure 2-153. Remove screw (6), washer (5) and
exhaust pipe clamp bracket (4). Remove two screws (2,
3
2
3). Remove sprocket cover (1).
2.
See Figure 2-154. Unscrew rear brake rod (1) at bell
crank (2).
3.
See Figure 2-152. Remove three bolts (17) and washers
(18) securing muffler interconnect bracket (5) to engine
crankcase. Remove muffler interconnect bracket.
4
5
1
1.
Rear brake rod
2.
Bell crank
3.
Rear brake master cylinder assembly
4.
Rear brake pedal
5.
Frame
Figure 2-154. Rear Brake Linkage
2006 Sportster: Chassis
2-105
HOME
4.
Install new muffler interconnect gaskets (19) in intercon-
INSTALLATION
nect mating holes in mufflers (1, 2).
5.
Place new Torca clamp assemblies (6) over slotted end
Muffler Interconnect Bracket
of each muffler. Install each muffler onto the end of its
respective exhaust pipe.
1.
See Figure 2-152. Install muffler interconnect bracket (5)
6.
Rotate both mufflers until their mounting bosses line up
to engine case with three bolts (17) and washers (18).
with holes in muffler interconnect bracket. Carefully mate
Tighten to 30-33 ft-lbs (40.7-44.8 Nm).
each muffler with exhaust port in interconnect bracket.
2.
See Figure 2-154. Apply two drops of LOCTITE 243
Loosely install flanged bolts (16). Do not tighten at this
(Part. No. 99642-97) to rear brake rod ball stud screw.
time.
Attach rear brake rod (1) to bell crank (2). Tighten screw
7.
Tighten exhaust system fasteners in the following
to 120-180 in-lbs (13.6-20.4 Nm).
sequence:
3.
See Figure 2-153. Install sprocket cover (1). Secure with
a. Tighten four flanged bolts securing mufflers to inter-
two screws (2, 3). Note that long screw goes in top hole,
connect bracket to 15-19 ft-lbs (20.4-25.8 Nm).
short screw in bottom hole. Do not tighten screws at this
time.
b. Tighten four nuts at cylinder head exhaust studs to
96-120 in-lbs (10.9-13.6 Nm).
4.
Install exhaust pipe clamp bracket (4), washer (5) and
screw (6). Tighten to 30-33 ft-lbs (40.7-44.8 Nm). Now
c. Tighten two Torca clamps to 45-65 ft-lbs (61.1-88.2
tighten screws (2, 3) to 80-120 in-lbs (9.0-13.6 Nm).
Nm).
d. Tighten rear exhaust pipe clamp nut (22) to 15-19 ft-
Exhaust Pipes and Mufflers
lbs (20.4-25.8 Nm).
NOTE
8.
Install heat shields:
To facilitate installing exhaust pipe header nuts, use Snap-On
a. Open worm drive clamps
(13) and install heat
tool (Part No. PFSX916).
shields
(11,
12) on exhaust pipes. Position each
clamp so that screw is on the outboard side in the
1.
See Figure 2-152. Place exhaust pipe flange (9), exhaust
most accessible position. Tighten clamps securely.
gasket retaining ring (8) and new exhaust port gasket (7)
over front end of each exhaust pipe (3, 4). Position flange
b. California, HDI and England models: open worm
so that inside counterbore faces cylinder head exhaust
drive clamps (15) and install muffler heat shields
port.
(14) on mufflers. Position each clamp so that screw
is on the outboard side in the most accessible posi-
2.
Position front ends of front and rear exhaust pipes into
tion. Tighten clamps securely.
front and rear cylinder heads, respectively. Position holes
in flanges over mounting studs and loosely install nuts
(10). Do not tighten nuts at this time.
3.
Install exhaust pipe clamp (20) on rear exhaust pipe (4)
with square hole facing down. Assemble exhaust pipe
clamp to exhaust pipe clamp bracket (21) with screw (23)
and acorn nut (22). Make sure bracket fits between ends
of clamp. Do not tighten at this time.
2-106
2006 Sportster: Chassis
HOME
FRONT FENDER
2.28
REMOVAL
x0433x2x
1.
See Figure 2-155. Remove four socket head screws (1)
and locknuts (2) to detach front fender (3) from front fork
sliders.
2
2.
Carefully remove fender from between front fork sliders.
INSTALLATION
1.
See Figure 2-155. Carefully position front fender
(3)
between right and left front fork sliders.
2.
Secure fender using four socket head screws (1) and
lock nuts (2). Tighten to 96-156 in-lbs (10.9-17.6 Nm).
1
3
1.
Screw (4)
2.
Locknuts (4)
3.
Front fender
Figure 2-155. Front Fender
2006 Sportster: Chassis
2-107
HOME
REAR FENDER
2.29
2. Open left side cover and remove Maxi-Fuse. See 7.25
REMOVAL
MAXI-FUSE. Close left side cover.
1.
Remove seat. See REMOVAL under 2.32 SEAT.
3. See Figure 2-156. Remove two screws (6) and tail lamp
lens (7) from tail lamp base assembly (11). Twist tail lamp
bulb socket (9) 1/4 turn counterclockwise *and remove
1WARNING
from lens.
To prevent accidental vehicle start-up, which could
cause death or serious injury, remove maxi-fuse before
proceeding. (00251a)
x0589x2x
3
2
24
8
9
1
15
14
10
6
7
23
22
11
12
19
13
18
28
17
21
27
19
20
5
16
26
25
4
1.
Rear fender
15. Washer
2.
License plate bracket assembly
16. Turn signal assembly
3.
Screw (3)
17. Turn signal stalk (2)
4.
Nut (3)
18. Screw (2)
5.
Washer
19. washer (4)
6.
Screw (2)
20. Screw (2)
7.
Tail lamp lens
21. Rear fender strut cover (2)
8.
Bulb
22. Nut (4)
9.
Socket assembly
23. Nut plate (2)
10. Screw w/captive washer
24. Fender seat nut kit
11. Tail lamp base assembly
25. Rear fender brace
12. Clip nut
26. Rear fender extension
13. Screw
27. Frame
14. Seat post
28. Wire retention bracket (2)
Figure 2-156. Rear Fender Assembly
2-108
2006 Sportster: Chassis
HOME
4.
See Figure 2-157. Note the electrical connectors located
10057
on tail lamp circuit board. Depress latches on turn signal
connectors (1, 2) and tail lamp connector (4). Unplug
3
5
1
connectors from rear lighting circuit board.
5.
See Figure 2-158. Remove two locknuts (1) securing
ICM (2) to frame. Lift ICM off studs to expose rear light-
ing connector assembly
[7]. Unplug connector
[7B].
Depress external latch and use a rocking motion to sepa-
rate connector.
10056
4
5
1
2
6
1.
Lock nut (2)
2.
ICM
3.
Seat post
3
4.
Flat washer
2
5.
Frame crossmember tab
6.
Rear fender
4
Figure 2-158. Rear Fender Removal
1.
Left turn signal connector [18]
2.
Right turn signal connector [19]
3.
Rear lighting power connector [94]
4.
Tail lamp connector [93]
5.
Screw with washer
x0190x2x
Secondary lock open
6-Pin Black [94]
- AMP
1
2
3
4
5
6
1.
Orange w/white tracer
2.
Brown
3.
Blue
4.
Red w/yellow tracer
5.
Violet
6.
Black
Figure 2-157. Tail Lamp Connectors
2006 Sportster: Chassis
2-109
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