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Harley Davidson 2006 Sportster XLH MODELS. Service Manual - page 5

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BLEEDING HYDRAULIC BRAKE SYSTEM

1.9

GENERAL

8966

2

Bleed the hydraulic brake system any time a hydraulic brake

3

line, brake master cylinder or brake caliper has been opened,

or whenever brake lever/pedal operation feels

“spongy.”

Bleeding evacuates air from the system leaving only incom-

pressible hydraulic fluid.

1WARNING

1

Direct contact of D.O.T. 5 brake fluid with eyes can cause

eye irritation, swelling, and redness. Avoid eye contact.

In case of eye contact flush with large amounts of water

and get medical attention. Swallowing large amounts of

D.O.T. 5 brake fluid can cause digestive discomfort. If

1.

Front brake master cylinder and reservoir

swallowed, obtain medical attention. Use in well venti-

2.

Cover screw (2)

lated area. KEEP OUT OF REACH OF CHILDREN.

3.

Top cover

(00144a)

Figure 1-21. Front Brake Master Cylinder Reservoir

NOTE

Hydraulic brake fluid bladder-type pressure equipment can be

used to fill brake master cylinders through the bleeder valve.

Remove master cylinder reservoir cover so that system can-

1.

Front brake master cylinder assembly

not pressurize. Do not use pressure bleeding equipment

2.

Diaphragm

when the hydraulic system is sealed with master cylinder res-

3.

Diaphragm plate

ervoir cover and diaphragm in place.

4.

Reservoir cover

5.

Screw (2)

5

BLEEDING FRONT BRAKE

1.

See Figure 1-21. Position motorcycle so that top of front

4

master cylinder reservoir (1) is level.

2.

See Figure 1-22. Remove reservoir cover (4) with two

captive screws (5), diaphragm plate (3) and diaphragm

3

(2) from master cylinder reservoir (1).

2

1

x0601x1x

Figure 1-22. Front Brake Master Cylinder Cover Assembly

2006 Sportster: Maintenance

1-21

HOME

NOTES

11. If bleeding dual front disc brake system (XL 883R and XL

● See Figure 1-23. Do not use sight glass (2) to determine

1200R only), repeat this procedure for other caliper.

maximum fluid level. Sight glass should only be used as

12. See Figure 1-22. Replace diaphragm (2), diaphragm

a visual indicator that fluid level is low and needs atten-

plate (3) and reservoir cover (4) with captive screws (5).

tion. A ridge (1) is cast into the inside of the reservoir to

Tighten to 9-17 in-lbs (1.0-2.0 Nm).

assist you in determining the correct level.

13. Wipe up any brake fluid spills.

● Use only HARLEY-DAVIDSON D.O.T. 5 BRAKE FLUID

from a sealed container.

1WARNING

● Do not overfill reservoir. Do not reuse old brake fluid.

After repairing the brake system, test brakes at low

speed. If brakes are not operating properly, testing at

high speeds can cause loss of control, which could

result in death or serious injury. (00289a)

10444

1

14. Test ride motorcycle at low speed. Repeat the above

bleeding procedure if front brake feels spongy.

10336

3

2

2

1.

Cast-in ridge

2.

Sight glass

Figure 1-23. Filling Front Master Cylinder Reservoir

1

3.

See Figure

1-23. Add enough HARLEY-DAVIDSON

D.O.T. 5 BRAKE FLUID to reservoir to bring fluid level

1.

Front brake caliper

even with ridge (1) cast into inside of reservoir, about 1/

2.

Bleeder valve

4-inch (6 mm) below top edge.

3.

Bleeder cap

4.

See Figure 1-24. Remove bleeder cap (3) from bleeder

valve (2) on front caliper (1).

Figure 1-24. Front Brake Caliper

5.

See Figure 1-25. Install end of a length of 5/16 in. (7.9

mm) I.D. clear plastic tubing over caliper bleeder valve.

Place free end of tube in a clean container.

x0419a2x

6.

Squeeze and hold brake lever to build up hydraulic pres-

sure. See Figure 1-24. Open bleeder valve (2) about 1/2-

turn. Brake fluid will flow from bleeder valve through tub-

ing. Observe fluid flowing through tubing. Check for air

bubbles.

7.

Close bleeder valve when brake lever has moved 1/2 to

3/4 of its full range of travel. Allow brake lever to return

slowly to its released position.

8.

Repeat Step 6 and 7 until all air bubbles are purged from

system.

9.

Final tighten bleeder valve to 35-61 in-lbs (3.9-6.9 Nm).

Remove plastic tubing and install bleeder cap (3).

10.

See Figure

1-23. Add enough HARLEY-DAVIDSON

D.O.T. 5 BRAKE FLUID to reservoir to bring fluid level

even with ridge cast into inside of reservoir, about 1/4-

Figure 1-25. Bleeding Hydraulic System

inch (6 mm) below top edge.

1-22

2006 Sportster: Maintenance

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BLEEDING REAR BRAKE

10335

3

NOTES

●

See Figure 1-26. Vehicle must be upright so that rear

2

brake master cylinder reservoir (1) is in a level position

when filling and checking fluid level.

4

●

Reservoir cover (5) may be removed from rear brake

master cylinder reservoir to more easily verify fluid level

5

in reservoir.

10333

●

Use only HARLEY-DAVIDSON D.O.T. 5 BRAKE FLUID

from a sealed container.

3

●

Do not overfill reservoir. Do not reuse old brake fluid.

1.

Position motorcycle upright (not resting on jiffy stand).

2

See Figure 1-26. Unscrew and remove reservoir cap (2).

2.

Add HARLEY-DAVIDSON D.O.T. 5 BRAKE FLUID to

master cylinder reservoir (1) until the fluid reaches the

4

upper fluid level (3).

3.

See Figure 1-27. Remove bleeder cap (3). Install end of

1

a length of 5/16 in. (7.9 mm) I.D. clear plastic tubing over

caliper bleeder valve (2). Place free end of tube in a

1.

Rear brake master cylinder reservoir

clean container.

2.

Reservoir cap

3.

Upper fluid level

4.

Depress and hold brake pedal to build up hydraulic pres-

4.

Lower fluid level

sure. Open bleeder valve about 1/2-turn. Brake fluid will

5.

Reservoir cover

flow from bleeder valve through tubing. Observe fluid

flowing through tubing. Check for air bubbles.

Figure 1-26. Rear Brake Master Cylinder Reservoir

5.

Close bleeder valve when brake pedal has moved 1/2 to

3/4 of its full range of travel. Allow brake pedal to return

slowly to its released position.

10623

6.

Repeat Step 4 and 5 until all air bubbles are purged.

7.

Final tighten bleeder valve to 35-61 in-lbs (3.9-6.9 Nm).

Remove plastic tubing and install bleeder cap.

2

8.

See Figure 1-26. Add HARLEY-DAVIDSON D.O.T. 5

BRAKE FLUID to master cylinder reservoir (1) until the

fluid reaches the upper fluid level (3).

3

9.

Replace reservoir cap (2). Replace reservoir cover (5) if

removed.

10.

Wipe up any brake fluid spills.

1

1WARNING

After repairing the brake system, test brakes at low

speed. If brakes are not operating properly, testing at

1.

Rear brake caliper

high speeds can cause loss of control, which could

2.

Bleeder valve

result in death or serious injury. (00289a)

3.

Bleeder cap

11. Test ride motorcycle at low speed. Repeat the above

Figure 1-27. Rear Brake Caliper

bleeding procedure if rear brake feels spongy.

2006 Sportster: Maintenance

1-23

HOME

BRAKE PADS AND DISCS

1.10

INSPECTION

10087

4

Check brake pads and discs:

4

Front brake

● At scheduled service intervals as specified in 1.3 MAIN-

TENANCE SCHEDULE. Refer to Table 1-1.

● Whenever the components are removed from the vehicle

during service procedures.

Brake Pads

1WARNING

1

3

Always replace brake pads in complete sets for correct

and safe brake operation. Improper brake operation

3

could result in death or serious injury. (00111a)

2

See Figure 1-28. Replace brake pads (3) if brake pad friction

material on either the front or rear caliper is worn to 0.04 in.

10088

(1.02 mm) or less above the backing plate (4). Always replace

4

both pads in a caliper as a set. See BRAKE PAD REPLACE-

MENT-FRONT or BRAKE PAD REPLACEMENT-REAR

4

later in this section.

When checking the brake pads and discs, inspect the brake

5

hoses for correct routing and any signs of damage.

Brake Disc Thickness, Lateral Runout

and Warpage

The minimum brake disc (2) thickness is stamped on the side

of the disc. Replace disc if worn past minimum thickness or

badly scored.

Maximum brake disc lateral runout and warpage is 0.008 in.

3

(0.2 mm) when measured near the outside diameter.

3

● To replace front brake disc(s), see FRONT WHEEL

under 2.4 WHEELS.

● To replace rear brake disc, see REAR WHEEL under 2.4

WHEELS.

2

Rear brake

1.

Front brake caliper (viewed from below)

2.

Brake disc

3.

Brake pad (2)

4.

Brake pad backing plate (2)

5.

Rear brake caliper (viewed from rear)

Figure 1-28. Brake Pad Inspection

1-24

2006 Sportster: Maintenance

HOME

BRAKE PAD REPLACEMENT-

1.

Front brake master cylinder assembly

FRONT

2.

Diaphragm

3.

Diaphragm plate

4.

Reservoir cover

5.

Screw (2)

5

CAUTION

Do not remove front caliper(s) from mounting bracket

unless caliper mounting pins require service. Removing

caliper from mounting bracket unnecessarily increases

4

the risk of contaminates falling into mounting pin holes

and damaging caliper during vehicle operation.

3

1.

See Figure 1-29. Position motorcycle so that front master

cylinder reservoir (1) is level.

2

2.

See Figure 1-30. Remove two screws (5), reservoir cover

(4), diaphragm plate (3) and diaphragm (2) from master

cylinder reservoir (1).

8966

2

3

1

x0601x1x

1

Figure 1-30. Front Brake Master Cylinder Cover Assembly

8971

1.

Front brake master cylinder and reservoir

2.

Cover screw (2)

3.

Top cover

Figure 1-29. Front Brake Master Cylinder Reservoir

NOTE

As the pistons are pushed back into the caliper, fluid level

may rise higher than fluid level mark at about 1/4-inch (6 mm)

below top of reservoir. You may have to remove fluid to allow

for this.

3.

Press against the side of the brake caliper body to push

the outside brake pad (pad closest to caliper pistons)

back. This pushes the caliper pistons back into their

bores.

NOTES

Figure 1-31. Front Caliper Pad Spring

● See Figure 1-31. When replacing front brake pads, make

sure pad spring does not become dislodged and fall out.

If it does, you will have to reinstall it before installing new

pads.

● The front left and front right (not present on all vehicles)

calipers do NOT use the same brake pad set as the rear

brake caliper.

2006 Sportster: Maintenance

1-25

HOME

4.

See Figure 1-32. Remove pad pin plug (3).

7. See Figure 1-34. Install new inside brake pad (1) using

same orientation as pad previously removed. Make sure

5.

See Figure 1-33. Loosen, but do not remove, brake pad

front mounting tab (2) is seated in slot (5) in caliper

pin.

mounting bracket (4) and pad friction material faces

brake disc.

CAUTION

8. While holding new inside pad in place, pull pad pin out

Do not completely remove brake pad pin from caliper

and remove outside brake pad. Note the pad’s original

during the next step. Completely removing pad pin at this

orientation for replacement purposes.

time may cause difficulty during assembly.

9. Install new outside brake pad using the same orientation

6.

Once the pistons have been fully retracted into their

as pad previously removed. Make sure front mounting

bores, pull pad pin part way until inside pad drops free.

tab is seated in slot in caliper mounting bracket and pad

Note the pad’s original orientation for replacement pur-

friction material faces brake disc.

poses.

8972

10340

2

3

3

4

1

1

10344

2

5

2

1

3

4

1.

Front brake caliper

2.

Caliper mounting bracket

1.

Brake pad

3.

Pad pin plug

2.

Front mounting tab

4.

Caliper mounting pins

3.

Pad pin hole

4.

Front caliper mounting bracket

Figure 1-32. Front Caliper Assembly

5.

Slot

Figure 1-34. Front Brake Pads

10341

10. Temporarily insert a 1/8-in (3.175 mm) drill bit in caliper

pad pin hole to hold both pads in place.

11. Inspect pad pin for grooving and wear. Measure pad pin

diameter in an unworn area, and then in the area of any

grooving or wear. If wear is more than 0.011 in. (0.28

mm), replace pin.

Figure 1-33. Brake Pad Pin (Plug Removed)

1-26

2006 Sportster: Maintenance

HOME

12. Press brake pads firmly up against pad spring, remove

10444

drill bit and install pad pin. Tighten to 131-173 in-lbs

1

(14.8-19.6 Nm).

NOTES

If pad pin does not fit, check the following:

● You are using a set of pads, not two identical pads.

● Pad spring orientation must match Figure 1-31.

● See Figure 1-34. Pad front mounting tabs (2) must be

fully seated in mounting bracket slot (5).

● Pads must be pushed tight up against pad spring before

pad pin is installed.

13. See Figure 1-32. Install pad pin plug (3). Tighten to 18-

2

25 in-lbs (2.0-2.9 Nm).

1WARNING

1.

Cast-in ridge

2.

Sight glass

After servicing brakes and before moving motorcycle,

pump brakes to build brake system pressure. Insufficient

Figure 1-35. Filling Front Master Cylinder Reservoir

pressure can adversely affect brake performance, which

could result in death or serious injury. (00279a)

16. See Figure 1-30. Install diaphragm (2), diaphragm plate

(3), reservoir cover (4) and screws (5) on front brake

14. Pump brake lever to move pistons out until they contact

master cylinder reservoir. Tighten screws to 9-17 in-lbs

outside brake pad. Verify piston location against pad.

(1.0-2.0 Nm).

1WARNING

1

WARNING

Direct contact of D.O.T. 5 brake fluid with eyes can cause

After repairing the brake system, test brakes at low

eye irritation, swelling, and redness. Avoid eye contact.

speed. If brakes are not operating properly, testing at

In case of eye contact flush with large amounts of water

high speeds can cause loss of control, which could

and get medical attention. Swallowing large amounts of

result in death or serious injury. (00289a)

D.O.T. 5 brake fluid can cause digestive discomfort. If

swallowed, obtain medical attention. Use in well venti-

17. Test brake system.

lated area. KEEP OUT OF REACH OF CHILDREN.

a. Turn ignition switch ON. Pump brake lever to verify

(00144a)

operation of the brake lamp.

15. See Figure 1-35. Check brake fluid level in master cylin-

b. Test ride the motorcycle. If the brakes feel spongy,

der. Add enough HARLEY-DAVIDSON D.O.T. 5 BRAKE

bleed the system. See 1.9 BLEEDING HYDRAULIC

FLUID to reservoir to bring fluid level even with ridge (1)

BRAKE SYSTEM.

cast into inside of reservoir, about 1/4-inch (6 mm) below

NOTE

top edge.

Avoid making hard stops for the first 100 miles (160 km). This

allows the new pads to become conditioned to the brake

discs.

2006 Sportster: Maintenance

1-27

HOME

NOTES

BRAKE PAD REPLACEMENT-REAR

● See Figure 1-37. When replacing rear brake pads, make

sure pad spring does not become dislodged and fall out.

If it does, you will have to reinstall it before installing new

CAUTION

pads. Installation of this spring may require removal of

Do not remove rear caliper from mounting bracket unless

caliper from mounting bracket.

caliper mounting pins require service. Removing caliper

● The rear brake caliper does NOT use the same brake

from mounting bracket unnecessarily increases the risk

pad set as the front left and front right (not present on all

of contaminates falling into caliper boots and bushings

vehicles) calipers.

which could damage caliper during vehicle operation.

1.

See Figure 1-36. Remove the rear master cylinder reser-

voir cap (2).

8964

NOTE

See Figure 1-36. As the piston is pushed back into the cali-

per, fluid level may rise higher than the upper fluid level (3) in

the reservoir (1). You may have to remove fluid to allow for

this.

10335

3

2

4

Figure 1-37. Rear Caliper Pad Spring

5

10333

3

2

4

1

1.

Rear brake master cylinder reservoir

2.

Reservoir cap

3.

Upper fluid level

4.

Lower fluid level

5.

Reservoir cover

Figure 1-36. Rear Brake Master Cylinder Reservoir

2.

Press against the side of the brake caliper body to push

the outside brake pad (pad closest to caliper piston)

back. This pushes the caliper piston back into its bore.

1-28

2006 Sportster: Maintenance

HOME

3.

See Figure 1-38. Remove pad pin plug (3).

CAUTION

4.

See Figure 1-39. Loosen, but do not remove, brake pad

pin.

Do not completely remove brake pad pin from caliper

during the next step. Completely removing pad pin at this

time may cause difficulty during assembly.

10624

5. Once the piston has been fully retracted into its bore, pull

3

pad pin part way until inside pad drops free. Note the

1

pad’s original orientation for replacement purposes.

6. See Figure 1-40. Install new inside brake pad (2) using

2

same orientation as pad previously removed. Make sure

front mounting tab (3) is seated in slot (6) in caliper

mounting bracket (5) and pad friction material faces

brake disc.

7. While holding new inside pad in place, pull pad pin out

and remove outside brake pad (1). Note the pad’s origi-

4

nal orientation for replacement purposes.

8963

1.

Rear brake caliper

3

4

4

2.

Caliper mounting bracket

3.

Pad pin plug

4.

Caliper mounting pins

Figure 1-38. Rear Caliper Assembly

1

2

10339

10346

3

5

6

Figure 1-39. Brake Pad Pin (Plug Removed)

1.

Outside brake pad

2.

Inside brake pad

3.

Front mounting tab

4.

Pad pin hole

5.

Rear caliper mounting bracket

6.

Slot

Figure 1-40. Rear Brake Pads

2006 Sportster: Maintenance

1-29

HOME

TIRES AND WHEELS

1.11

TIRES

TIRE WEAR INDICATORS

See Figure 1-41. Tread wear indicator bars appear on tire

1WARNING

tread surfaces when 1/32 inch (0.8 mm) or less tire tread

remains. Arrows on tire sidewalls pinpoint location of wear

Match tires, tubes, air valves and caps to the correct

bar indicators. Always remove tires from service when the

wheel rim. Contact a Harley-Davidson dealer. Mismatch-

tread wear indicator bars become visible, indicating 1/32 inch

ing can result in damage to the tire bead, allow tire slip-

(0.8 mm) tread pattern depth remaining.

page on the rim or cause tire failure, which could result

New tires are needed if any of the following conditions exist.

in death or serious injury. (00023a)

● Tread wear indicator bars become visible on the tread

● In addition, using tires other than those specified may

surfaces.

adversely affect motorcycle handling.

● Tire cords or fabric become visible through cracked side-

● Tubeless tires fitted with the correct size inner tubes may

walls, snags or deep cuts.

be used on all Harley-Davidson laced (wire spoked)

wheels. Protective rubber rim strips must be used with

● A bump, bulge or split in the tire is found.

tubeless tires (fitted with correct size inner tubes) when

● Puncture, cut or other damage to the tire that cannot be

mounted on laced (wire spoked) wheels.

repaired.

● Inner tubes must not be used in radial tires and radial

tires must not be used on laced (wire spoked) wheels.

o0250x0x

● Tubeless tires are used on all Harley-Davidson cast and

disc wheels.

● Tire sizes are molded on the tire sidewall. Inner tube

sizes are printed on the tube.

Check tire pressure and tread as follows:

1.

Inspect each tire for punctures, cuts, and breaks.

Sidewall

2.

Inspect each tire for wear. Replace tires when the tread

wear indicator bars become visible. See TIRE WEAR

INDICATORS which follows.

1WARNING

Do not inflate tire beyond maximum pressure as speci-

00249x0x

fied on sidewall. Over inflated tires can blow out, which

could result in death or serious injury. (00027a)

3.

Check for proper front and rear tire pressures when tires

are cold. Compare results against Table 1-8.

Tread

Table 1-8. Tire Pressures

surface

RIDER AND ONE

ALL MODELS

SOLO RIDER

PASSENGER

DUNLOP TIRES

ONLY

PSI

kPA

PSI

kPA

Front

30

207

30

207

Rear

36

248

40

276

Figure 1-41. Tread Wear Indicators

2006 Sportster: Maintenance

1-31

HOME

PRIMARY CHAIN

1.12

INSPECTION

8940

2

See Figure 1-42. Check the primary chain for correct tension

1

by measuring its vertical free play through the primary chain

inspection cover (1) opening located near the top of the pri-

3

mary cover (2).

NOTES

●

See Figure 1-43. Refer to Table 1-9. A properly adjusted

primary chain should have the specified vertical free play

in its upper strand. Be sure the measurement is taken

midway between engine and clutch sprockets with

sprockets rotated to the tightest chain position.

6

●

Always measure the vertical free play with the sprockets

4

5

rotated to several different positions. The tightest mea-

1.

Primary chain inspection cover

surement observed must be within specifications shown

2.

Primary cover

in Table 1-9.

3.

Clutch inspection cover

●

The initial primary chain vertical free play specification

4.

Drain plug

used at the Harley-Davidson assembly plant is 1/4-3/8 in.

5.

Primary chain adjuster screw

(6.35-9.53 mm) with a cold engine. The 1/4 in. (6.35 mm)

6.

Locknut

minimum is only allowed at the absolute tightest point in

the drive, as measured with precision factory equipment.

Figure 1-42. Primary Cover

If a chain has less than 1/4 in. (6.35 mm) vertical free

play (with a cold engine), adjust free play to the “field”

specification of 3/8-1/2 in. (9.53-12.70 mm). The looser

x0251x6x

specification will avoid overtightening, which might other-

Check free play at tightest point on

wise occur during adjustment using “non-factory” equip-

chain - midway between sprockets

ment and methods.

●

An opening between the primary drive and transmission

compartments allows the same lubricant supply to lubri-

cate moving parts in both compartments. For complete

lubrication service on the primary chain, see

1.14

TRANSMISSION LUBRICANT.

●

Since the primary chain runs in lubricant, little service

will be required other than checking lubricant level and

Figure 1-43. Primary Chain Vertical Free Play

chain tension. If, through hard usage, the primary chain

does become worn, it must be replaced. Remove and

install the chain following the procedure under 6.5 PRI-

MARY DRIVE/CLUTCH.

Table 1-9. Primary Chain

Specifications-All Models

ENGINE

MEASUREMENT “A”

Cold

3/8-1/2 in.

9.53-12.70 mm

Hot

1/4-3/8 in.

6.35-9.53 mm

2006 Sportster: Maintenance

1-33

HOME

CLUTCH

1.13

ADJUSTMENT

x0055x6x

1

All models feature a primary cover and a quick-release clutch

2

cable to simplify both clutch service and adjustment. See Fig-

3

ure 1-44. Clutch cable adjuster is located in middle of cable,

adjacent to left frame downtube.

4

11468

1.

Rubber boot

2.

Cable adjuster

3.

Jam nut

4.

Cable end

Figure 1-45. Clutch Cable Adjuster Mechanism

8.

See Figure 1-45. Turn cable adjuster (2) clockwise away

from jam nut (3) until slack is eliminated.

9.

See Figure 1-47. Pull clutch cable ferrule away from

clutch lever bracket to check free play. Turn cable

adjuster as necessary to obtain 1/16-1/8 in. (1.6-3.2 mm)

free play between end of cable ferrule and clutch lever

Figure 1-44. Clutch Cable Adjuster Location-All Models

bracket

1.

See Figure 1-45. Slide rubber boot (1) off cable adjuster

10.

See Figure 1-45. Hold adjuster (2) with 1/2 inch wrench.

(2).

Using 9/16 inch wrench, tighten jam nut (3) against cable

2.

Holding cable adjuster with 1/2 inch wrench, loosen jam

adjuster. Cover cable adjuster mechanism with rubber

nut (3) using a 9/16 inch wrench. Back jam nut away from

boot (1).

cable adjuster. Screw adjuster toward jam nut to intro-

11.

XL 883, XL 883L, XL 883R and XL 1200R models: install

duce a large amount of free play at hand lever.

left side rider footrest and mounting bracket assembly.

3.

XL 883, XL 883L, XL 883R and XL 1200R models:

Tighten footrest bracket mounting bolts to 45-50 ft-lbs

remove left side rider footrest and mounting bracket

(61.1-67.9 Nm). See LEFT FOOTREST AND SHIFT

assembly. See LEFT FOOTREST AND SHIFT LEVER

LEVER ASSEMBLY under 2.33 RIDER FOOT CON-

ASSEMBLY under 2.33 RIDER FOOT CONTROLS: XL

TROLS: XL 883, XL 883L, XL 883R, XL 1200R for

883, XL 883L, XL 883R, XL 1200R for REMOVAL.

INSTALLATION.

4.

See Figure 1-46. Remove six screws (1) and remove

clutch inspection cover (2). Exercise caution to avoid

damaging or dislodging quad ring (7) in primary cover

(9).

5.

Remove hex lockplate with attached spring (3) from flats

of adjusting screw assembly (8). Turn adjusting screw

counterclockwise until resistance is felt. Back off adjust-

ing screw 1/4 turn.

6.

Slide hex lockplate with spring onto flats of adjusting

screw. If necessary, turn adjusting screw clockwise

slightly so that lockplate slides onto flats while also fitting

within recess of outer ramp.

7.

Verify that quad ring is fully seated in groove of primary

cover. Install clutch inspection cover and secure with six

screws. Tighten screws in a crosswise pattern to 84-108

in-lbs (9.5-12.2 Nm).

2006 Sportster: Maintenance

1-35

HOME

x0588x1x

1.

Screw (6)

2

2.

Clutch inspection cover

3.

Hex lockplate and spring

4.

Nut

3

4

5.

Ramp assembly

1

6.

Coupling

5

7.

Quad ring

8.

Clutch adjusting screw assembly

7

9.

Primary cover

10. Clutch cable

6

10

8

9

Figure 1-46. Clutch Release Mechanism

x0257x6x

2

1

1.

Ferrule

2.

Clutch lever bracket

Figure 1-47. Clutch Freeplay: Adjust for 1/16-1/8 in.

(1.6-3.2 mm) gap between ferrule and bracket

1-36

2006 Sportster: Maintenance

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TRANSMISSION LUBRICANT

1.14

GENERAL

8940

2

Drain transmission and refill to correct level with fresh, clean

lubricant. For best results, drain lubricant while hot.

CAUTION

When draining or adding lubricant, do not allow dirt,

debris or other contaminants to enter the engine.

(00198a)

CAUTION

1

Be sure that no lubricant gets on tires, wheels or brakes

1.

Drain plug

when changing fluid. Traction can be adversely affected,

2.

Clutch inspection cover

which could result in loss of control of the motorcycle

and death or serious injury. (00047c)

Figure 1-48. Primary Cover

DRAINING LUBRICANT

REFILLING LUBRICANT

1.

Operate motorcycle until engine reaches operating tem-

1. XL 883, XL 883L, XL 883R and XL 1200R models:

perature.

remove left side rider footrest and mounting bracket

2.

On level surface, position motorcycle on jiffy stand.

assembly. See LEFT FOOTREST AND SHIFT LEVER

ASSEMBLY under 2.33 RIDER FOOT CONTROLS: XL

883, XL 883L, XL 883R, XL 1200R for REMOVAL.

1WARNING

2. See Figure 1-48. Remove six screws from clutch inspec-

To prevent accidental vehicle start-up, which could

tion cover (2). Remove clutch inspection cover from pri-

cause death or serious injury, remove maxi-fuse before

mary cover. Exercise caution to avoid damaging or

proceeding. (00251a)

dislodging quad ring (item 3, Figure 1-49.) in primary

cover.

3.

Open left side cover and remove Maxi-Fuse. Close left

side cover. See 7.25 MAXI-FUSE.

CAUTION

4.

See Figure 1-48. Position a suitable container under

transmission lubricant drain plug (1). Remove drain plug

Do not overfill the primary chaincase with lubricant.

and drain lubricant.

Overfilling can cause rough clutch engagement, incom-

5.

With drain plug still removed, position motorcycle

plete disengagement, clutch drag and/or difficulty in find-

STRAIGHT UP and LEVEL to allow any additional fluid

ing neutral at engine idle. (00199b)

to drain from clutch compartment.

3. With vehicle positioned upright

(not resting on jiffy

stand), add 32 fluid ounces (946 ml) of GENUINE HAR-

CAUTION

LEY-DAVIDSON FORMULA+ TRANSMISSION AND

PRIMARY CHAINCASE LUBRICANT through clutch

Do not over-tighten drain plug. Doing so could result in a

inspection cover opening.

lubricant leak. (00200a)

6.

Remove foreign material from magnetic drain plug. Rein-

stall plug and tighten to 14-30 ft-lbs (19.0-40.7 Nm).

2006 Sportster: Maintenance

1-37

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x0258a6x

CAUTION

2

3

Make certain primary chaincase is filled with proper

4

amount of lubricant with motorcycle upright. If under-

filled, transmission can be damaged during vehicle oper-

ation.

4.

See Figure 1-49. Verify that lubricant level (5) is even

with bottom of clutch diaphragm spring (1) with vehicle

upright.

5.

Verify that quad ring is fully seated in groove of primary

cover. Install clutch inspection cover on primary cover

using six screws. Tighten screws in a crosswise pattern

to 84-108 in-lbs (9.5-12.2 Nm).

6.

XL 883, XL 883L, XL 883R and XL 1200R models: install

1

5

left side rider footrest and mounting bracket assembly.

Tighten footrest bracket mounting bolts to 45-50 ft-lbs

1. Clutch diaphragm spring

(61.1-67.9 Nm). See LEFT FOOTREST AND SHIFT

2. Clutch adjusting screw

LEVER ASSEMBLY under 2.33 RIDER FOOT CON-

3. Quad ring

TROLS: XL 883, XL 883L, XL 883R, XL 1200R for

4. Primary cover

INSTALLATION.

5. Chaincase lubricant level

7.

Open left side cover and install Maxi-Fuse. Close left

Figure 1-49. Chaincase Lubricant Level

side cover. See 7.25 MAXI-FUSE.

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2006 Sportster: Maintenance

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REAR BELT DEFLECTION

1.15

INSPECTION

x0622a1x

PART NO.

SPECIALTY TOOL

HD-35381-A

Belt tension gauge

When checking belt deflection:

● Move vehicle forward or back, rotating rear wheel to find

tightest point in belt. Measure belt deflection at that point.

x0623a1x

2

3

● Measure belt deflection with no rider or cargo on motor-

cycle, transmission in neutral, belt and sprockets at

ambient temperature (cold engine) and motorcycle rest-

0

10

ing on jiffy stand.

1.

See Figure

1-50. Obtain HARLEY-DAVIDSON BELT

5

1

4

6

TENSION GAUGE.

NOTE

1.

Belt tension gauge

Customers may purchase belt tension gauge from an autho-

2.

Belt cradle

rized Harley-Davidson dealer.

3.

0 lbs (0 kg) mark

4.

O-ring

2.

To use the belt tension gauge:

5.

10 lbs (4.5 kg) mark

a. Slide O-ring (4) toward 0 ft-lbs (0 kg) mark (3).

6.

Knob

b. See Figure 1-51. Note belt position in viewing win-

dow (2) relative to deflection graduations (3).

Figure 1-50. Belt Tension Gauge (Part No. HD-35381-A)

c. See Figure 1-50. Fit belt cradle (2) against bottom of

drive belt under deflection window (approximately

half-way between drive sprockets).

8844

2

d. Press upward on knob (6) until O-ring slides down to

10 lbs (4.5 kg) mark (5).

e. See Figure 1-51. Note belt position in viewing win-

3

dow (2) relative to deflection graduations (3) while

holding gauge steady.

NOTE

4

1

Deflection graduations are 1/8 in. (3.2 mm) apart. To measure

belt deflection, count the number of graduations between

original belt position in step 2.-b. and the belt position in step

2.-e. Multiply this number by 1/8 in. (3.2 mm) to determine

1.

Debris deflector

actual belt deflection.

2.

Belt deflection viewing window

3.

Drive belt deflection graduations

4.

Drive belt

Figure 1-51. Belt Deflection Window

2006 Sportster: Maintenance

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