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Harley Davidson 2006 Sportster XLH MODELS. Service Manual - page 13

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6.

See Figure 2-159. Remove rear turn signal stalk nuts (1)

INSTALLATION

from inside rear fender on both sides.

7.

Remove forward fender support screw with washer (2)

NOTE

and nut (4), and aft fender support screw with washer (3)

If a new fender is being installed, complete steps 1-7. Other-

and nut plate (5) on both sides.

wise proceed directly to step 8.

8.

Pull turn signal wiring harnesses through holes in tail

1.

See Figure 2-156. Remove three screws (3), three nuts

lamp base and rear fender. Disengage turn signal wiring

(4) and one washer (5) securing license plate bracket

harnesses from wire retention brackets (6).

assembly (2) and rear fender brace (25) to old fender (1).

9.

See Figure 2-156. Remove rear fender strut covers (21)

Position assembly on new fender and secure with

with attached turn signal assemblies

(16) from rear

screws, nuts and washer. Align remaining holes in rear

fender struts.

fender brace with aft fender support screw holes in

10. Remove screw (13), seat post (14) and flat washer (15)

fender. Tighten license plate bracket mounting screws to

to detach top of rear fender (1) from frame cross member

20-25 in-lbs (2.3-2.8 Nm).

tab.

2.

Carefully drill out pop rivets securing rear fender exten-

11. Carefully remove rear fender with attached tail/brake

sion (26) to old fender with a 1/4-in. (6.35 mm) diameter

lamp assembly from motorcycle.

drill bit. Rivet rear fender extension to new fender.

12. See Figure 2-157. Depress latch on rear lighting power

3.

Carefully drill out pop rivets securing wire retention

connector [94] (3) and unplug connector from rear light-

brackets (28) to old fender with a 1/4-in (6.35 mm) diam-

ing circuit board.

eter drill bit. Rivet brackets to new fender.

13. Remove screw with washer (5) and lift tail/brake lamp

4.

Remove fender seat nut kit (24) from old fender and

base from fender.

install on new fender.

5.

Place fender upside down on clean, soft towel or mat to

protect the finish. Clean inside area of fender where wir-

10506

ing harness/conduit will be placed, with a mixture of alco-

2

hol and water. Allow to air-dry thoroughly.

6.

Position new wire harness and conduit inside fender at

the same approximate position where harness/conduit

assembly is located in old fender. Insert end of wiring

harness with ‘D’ plug through ‘D’ hole in front of fender.

Insert plug into hole.

7.

Slide conduit toward ‘D’ plug as far as it will go. Insert

other end of wiring harness through tail lamp housing

3

hole in rear of fender. Remove adhesive tape backing

from conduit and press conduit in place along right side

10507

curve of fender.

8.

Carefully install rear fender onto motorcycle. Align holes

in fender with those in struts. Temporarily install screws

6

(18, 20) through fender struts and fender to hold fender

5

in place. Route rear lighting harness connector

[7B]

between frame cross member and top of oil tank. Plug

connector into socket [7A].

7

4

1

1.

Rear turn signal stalk nut (2)

2.

Forward fender support screw with washer (2)

3.

Aft fender support screw with washer (2)

4.

Forward fender support nut (2)

5.

Aft fender support nut plate (2)

6.

Wire retention bracket

7.

Rear lighting wiring harness and conduit

Figure 2-159. Rear Fender, Strut Cover and

Turn Signal Lamp Assembly

2-110

2006 Sportster: Chassis

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BELT GUARD AND DEBRIS DEFLECTOR

2.30

REMOVAL

x0578b2x

Belt Guard

4

1

1.

See Figure

2-160. Unthread right side lower shock

absorber mount nut (1). Pull shock absorber mounting

6

bolt (2) out slightly until it clears mounting hole in belt

guard (4).

5

7

2.

Remove screw (5), washer (6) and nut (7) securing front

3

of belt guard to rear fork (10).

3.

Remove belt guard from vehicle.

Debris Deflector

1.

See Figure 2-160. Loosen, but do not remove, three

screws with captive washers (9) securing debris deflec-

tor (8) to underside of rear fork (10).

2.

Slide debris deflector forward until keyway slots in deflec-

tor clear screw heads. Remove debris deflector.

2

10

8

INSTALLATION

9

1.

Nut

2.

Screw

Belt Guard

3.

Washer

1.

See Figure 2-160. Slide belt guard (4) into place on vehi-

4.

Belt guard

cle. Tab on front of belt guard mounts outboard of mount-

5.

Screw

ing bracket on rear fork.

6.

Washer

7.

Nut

2.

Secure front of belt guard to rear fork (10) with screw (5),

8.

Debris deflector

washer (6) and nut (7). Tighten to 120-180 in-lbs (13.6-

9.

Screw with captive washer (3)

20.4 Nm).

10. Rear fork

3.

Push lower shock absorber mounting screw (2) through

rear belt guard mounting hole. Thread nut (1) on screw.

Figure 2-160. Belt Guard/Debris Deflector

Tighten to 45-50 ft-lbs (61.1-67.9 Nm).

Debris Deflector

1.

See Figure 2-160. Position debris deflector (8) in place

on underside of rear fork (10).

2.

Fit large end of keyway slots in deflector over screw

heads and captive washers (9). Slide deflector rearward

to lock screws in slots. Tighten screws to 36-60 in-lbs

(4.1-6.8 Nm).

2-112

2006 Sportster: Chassis

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JIFFY STAND

2.31

GENERAL

WARNING

1

The vehicle is equipped with a jiffy stand (or side stand) that

Always park motorcycle on a level, firm surface. An

locks when placed in the full forward position (down) with the

unbalanced motorcycle can fall over, which could result

full weight of the vehicle resting on it.

in death or serious injury. (00039a)

1WARNING

1WARNING

The jiffy stand locks when placed in the full forward

Be sure jiffy stand is fully retracted before riding. If jiffy

(down) position with vehicle weight on it. If the jiffy stand

stand is not fully retracted, it can contact the road sur-

is not in the full forward (down) position with vehicle

face causing a loss of vehicle control, which could result

weight on it, the vehicle can fall over which could result

in death or serious injury. (00007a)

in death or serious injury. (00006a)

10129

1

2

5

4

3

3

6

7

1.

Clevis pin

2.

Cotter pin

3.

Bushing (2)

4.

Jiffy stand leg

5.

Rubber bumper

6.

Spring

7.

Jiffy stand yoke

Figure 2-161. Jiffy Stand (Retracted Position)

2006 Sportster: Chassis

2-113

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REMOVAL

INSTALLATION

1WARNING

1WARNING

Wear gloves and protective eyeglasses (or face shield)

Wear gloves and protective eyeglasses (or face shield)

when performing the following procedure. The jiffy stand

when performing the following procedure. The jiffy stand

spring tension could cause the spring, attached compo-

spring tension could cause the spring, attached compo-

nents and/or hand tools to fly outward at great speed and

nents and/or hand tools to fly outward at great speed and

could cause death or serious injury.

possibly cause death or serious injury.

1.

Block motorcycle under frame so that motorcycle is

1.

Clean and lubricate jiffy stand components according to

securely upright and jiffy stand may be moved through its

procedure listed in CLEANING AND LUBRICATION

full range of travel.

above.

2.

See Figure 2-161. Remove rubber bumper (5) from

2.

See Figure 2-162. Hook either end of spring (6) into

frame to permit further retraction of jiffy stand leg (4).

spring mounting hole on jiffy stand leg (5). Install other

Additional spring tension relief allows for easier spring

end of spring over frame mounted anchor pin.

removal.

3.

While holding end of spring in groove of anchor pin and

3.

Place jiffy stand leg in retracted position. Remove and

holding jiffy stand leg in its retracted position, position

discard cotter pin (2).

pivot end of jiffy stand leg within yoke (4) on motorcycle

frame. Insert clevis pin (1) through lower pivot hole of

4.

See Figure 2-162. While firmly holding jiffy stand leg (5)

yoke and halfway into pivot hole of jiffy stand leg.

in fully retracted position, withdraw clevis pin (1) until it

disengages with the upper pivot hole of jiffy stand yoke

4.

See Figure 2-161. Lift jiffy stand leg (4) upward, aligning

(4).

pivot hole of jiffy stand leg with slotted upper hole of yoke

(7). With shoulder down, position bottom bushing (3),

5.

Detach spring (6) from anchor pin using pliers. Unhook

over clevis pin (1). Insert clevis pin through holes in jiffy

other end of spring from jiffy stand leg.

stand leg and yoke.

6.

Remove clevis pin from lower pivot hole of jiffy stand

5.

Install upper bushing

(3) over end of clevis pin and

yoke. Remove jiffy stand leg. Remove upper and lower

against upper surface of yoke. Insert new cotter pin (2)

bushings (2).

through hole in end of clevis pin. Bend ends of cotter pin

apart to secure.

CLEANING AND LUBRICATION

6.

Press rubber bumper (5) onto mounting stud on motorcy-

cle frame.

Clean and lubricate jiffy stand assembly every 5000 miles

7.

Extend and retract jiffy stand leg several times to check

(8000 km). Proceed as follows:

for proper operation. In retracted position (up), jiffy stand

1.

See Figure 2-162. See REMOVAL above to remove jiffy

leg should be securely seated against frame-mounted

stand from motorcycle frame.

rubber bumper.

2.

Thoroughly clean all jiffy stand components, including

8.

Place jiffy stand in its full forward position (down). Care-

frame-mounted anchor pin and jiffy stand yoke (4).

fully remove support blocking from beneath motorcycle

3.

Apply a small amount of wheel bearing grease to pivot

frame. Rest motorcycle on jiffy stand.

holes of jiffy stand leg (5) and yoke, groove of anchor pin

and O.D. of clevis pin (1).

x0148b2x

4.

See INSTALLATION which follows to install jiffy stand to

motorcycle frame.

2

4

2

1

6

5

3

1.

Clevis pin

2.

Bushing (2)

3.

Cotter pin

4.

Jiffy stand yoke

5.

Jiffy stand leg

6.

Spring

Figure 2-162. Jiffy Stand

2-114

2006 Sportster: Chassis

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SEAT

2.32

GENERAL

10499

The seat is attached to the vehicle at three points.

2

1

1.

See Figure 2-163. The tongue (1) fits under the rear fuel

tank bracket.

2.

The keyhole (2) locks into the seat post (see Figure 2-

164.).

3.

See Figure 2-165. The mounting bracket (2) bolts to the

seat with two screws (5) and lock washers (6), and

attaches to a seat nut (4) in the rear fender with a screw

(1).

3

REMOVAL

1.

Tongue

1.

See Figure 2-165. Remove screw (1) to detach seat from

2.

Keyhole bracket

rear fender.

3.

Passenger strap

2.

Slide seat forward and lift up slightly to detach keyhole

Figure 2-163. Seat

bracket from seat post. Then slide seat rearward to

detach seat tongue from rear fuel tank bracket.

3.

If dual seat (7, 8, 10), inspect passenger strap (12) for

10057

damage or excessive wear.

NOTE

The passenger strap is not sold separately. If it is damaged,

excessively worn or otherwise unusable, the entire seat

assembly must be replaced.

INSTALLATION

1.

See Figure 2-163. Verify that tongue (1) and keyhole

bracket (2) are tightly secured to seat bottom and that no

rivets are loose or missing. Position seat on frame with

mounting bracket (item 2, Figure 2-165.) at rear.

2.

See Figure 2-163. Slide seat forward until the tongue fits

snugly under rear fuel tank bracket.

3.

Push seat forward, engage keyhole onto seat post (see

Figure 2-164.), then pull seat back slightly.

Figure 2-164. Seat Post

4.

See Figure 2-165. Install seat mounting screw with cap-

tive washer (1) to fasten seat mounting bracket (2) to top

of rear fender. Mounting bracket of solo seat uses for-

ward hole in rear fender; dual seat uses rearward hole.

5.

Pull up on seat to verify that it is locked in place.

6.

Tighten seat mounting screw.

1WARNING

After installing seat, pull upward on front of seat to be

sure it is in locked position. While riding, a loose seat can

shift causing loss of control, which could result in death

or serious injury. (00070a)

7.

Pull up on seat again to verify that it is properly secured

at all three points.

2006 Sportster: Chassis

2-115

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x0076d2x

13

11

7

13

13

12

8

13

10

9

1

2

3

6

4

5

1.

Seat mounting screw with captive washer

NOTE

2.

Mounting bracket

Seat nut (4) is inserted from under side of fender

3.

Retaining clip

and retaining clip (3) is located on top side.

4.

Seat nut

5.

Screw (2)

6.

Lockwasher

7.

Seat assembly, XL 1200C

8.

Seat assembly, XL 883C

9.

Seat assembly, XL 883

10. Seat assembly, XL 1200R

11. Seat assembly, XL 883L

12. Seat assembly, XL 883R

13. Passenger strap (not sold separately)

Figure 2-165. Seat Assembly

2-116

2006 Sportster: Chassis

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x0584x2x

24

22

16

23

25

21

18

15

20

14

17

19

13

7

4

3

26

11

1

12

9

10

8

6

2

5

1.

Footrest

14.

Screw (2)

2.

Spring washer

15.

Retaining ring

3.

Retaining ring

16.

Spring washer

4.

Rider footrest clevis

17.

Clevis pin

5.

Clevis pin

18.

Footrest

6.

Bushing

19.

Bell crank

7.

Rear brake rod assembly

20.

Rear brake master cylinder and bracket assembly

8.

Rear brake pedal

21.

Rubber washer

9.

Screw (2)

22.

Pinch screw

10.

Right rider footrest/brake pedal support bracket

23.

Washer

11.

Screw

24.

Shift lever

12.

Frame

25.

Shifter peg

13.

Left rider footrest support bracket

26.

Retaining ring

Figure 2-166. XL 883/XL 883L/XL 883R/XL 1200R Rider Footrests/Foot Controls

2-118

2006 Sportster: Chassis

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x0184a2x

13

15

14

8

7

16

11

6

4

2

1

12

10

9

5

3

1.

Footrest

9.

Screw (2)

2.

Retaining ring

10. Footrest/brake pedal support bracket

3.

Spring washer

11. Screw

4.

Clevis

12. J-clip

5.

Clevis pin

13. Frame

6.

Bushing

14. Bell crank

7.

Brake pedal

15. Rear brake master cylinder and bracket assembly

8.

Brake rod assembly

16. Retaining ring

Figure 2-167. XL 883C/XL 1200C Forward Controls-Brake Side

2-120

2006 Sportster: Chassis

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LEFT FOOTREST AND

Installation

SHIFT LEVER ASSEMBLY

1.

See Figure 2-168. Install rubber washer (19) and shift

lever (3) onto transmission shifter shaft, with shift lever

arm pointing straight down. Secure with pinch screw (1)

Removal

and washer (2). Tighten pinch screw to

16-20 ft-lbs

(21.7-27.1 Nm).

1.

See Figure 2-168. Remove retaining ring (13), clevis pin

2.

Mount j-clip (7) and footrest/shift lever support bracket

(17), footrest (16) and spring washer (15). Discard retain-

(8) to frame with two screws (9). Tighten to 45-50 ft-lbs

ing ring.

(61.1-67.9 Nm).

2.

Unscrew shifter rod assembly

(4) from shifter lever

3.

Slide shifter lever assembly (12) onto clevis (14). Mount

assembly (12) and shift lever (3).

clevis on footrest/shifter lever support bracket. Line up

3.

Remove retaining ring (20), screw (10) and clevis (14).

hole in clevis with hole in support bracket. Secure with

Slide shifter lever assembly off clevis. Discard retaining

screw (10). Tighten to 18-22 ft-lbs (24.4-29.9 Nm). Install

ring.

retaining ring (20) on end of clevis.

4.

Remove two screws (9), footrest/shifter lever support

4.

Mount footrest (16) on clevis with spring washer (15).

bracket (8) and j-clip (7) from frame.

Make sure spring washer is positioned inside clevis with

5.

Remove pinch screw (1), washer (2), shift lever (3) and

the square edge toward the inside. Align holes and push

rubber washer (19) from transmission shift shaft.

clevis pin

(17) from top down through hole in clevis.

Secure with new retaining ring (13).

5.

Thread screw (5) in one end of shifter rod assembly (4)

into shift lever (3). Tighten to 120-180 in-lbs (13.6-20.4

Nm).

6.

Thread screw (6) in other end of shifter rod into shift lever

assembly. Tighten to 120-180 in-lbs (13.6-20.4 Nm).

x0185c2x

17

1

3

18

2

5

4

6

19

10

16

20

15

14

12

13

11

9

7

8

1.

Pinch screw

11. Bushing

2.

Washer

12. Shifter lever assembly

3.

Shift lever

13. Retaining ring

4.

Shifter rod assembly

14. Clevis

5.

Screw

15. Spring washer

6.

Screw

16. Footrest

7.

J-clip

17. Clevis pin

8.

Footrest/shifter lever support bracket

18. Shifter pedal peg

9.

Screw (2)

19. Rubber washer

10. Screw

20. Retaining ring

Figure 2-168. XL 883C/XL 1200C Forward Controls-Shifter Side

2006 Sportster: Chassis

2-121

HOME

ADJUSTING SHIFT PEDAL

10505

5

The foot shift linkage is set at the factory and normally should

need no adjustment. However, if gears do not engage fully or

toe shifter travel is incorrect, adjust linkage rod as follows.

4

3

See Figure 2-169. Adjust shifter rod assembly (4) length until

45°

shifter lever assembly (5) is at 45° as shown in the figure.

1.

Loosen locknuts (3) on both ends of shifter rod.

2.

Remove screw (1) securing ball joint (2) to shifter lever

assembly.

1

2

3.

Turn ball joint or shifter rod to adjust rod length. Tempo-

rarily attach ball joint to shifter lever assembly and check

1.

Screw (2)

angle. Make sure an equal number of threads are visible

2.

Ball joint (2)

on both ends of shifter rod.

3.

Locknut (2)

4.

Shifter rod assembly

4.

When angle of shift lever assembly is at 45°, Install

5.

Shifter lever assembly

screw (1). Tighten to 120-180 in-lbs (13.6-20.4 Nm).

Figure 2-169. XL 883C/XL 1200C: Adjusting Shift Pedal

5.

Holding shifter rod so that it does not turn, tighten lock-

nuts on both ends.

2-122

2006 Sportster: Chassis

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PASSENGER FOOTRESTS

2.35

GENERAL

x0585x2x

3

Passenger footrest assemblies are standard equipment on

1

XL 883C, XL 1200C, XL 883R and XL 1200R models only.

2

REMOVAL

4

1.

See Figure 2-170. Remove retaining ring (1), clevis pin

(2), footrest (3) and spring washer (4). Discard retaining

5

ring.

2.

Remove two screws (5) and footrest support bracket (6)

6

from frame (7).

8

INSTALLATION

7

NOTE

See Figure 2-170. On left side of vehicle, a B-clip (8) is posi-

tioned between footrest support bracket (6) and lower support

1.

Retaining ring

bracket hole on frame (7). Make sure this clip is positioned

2.

Clevis pin

between footrest support bracket and frame when attaching

3.

Footrest

support bracket in the next step.

4.

Spring washer

1.

See Figure 2-170. Attach footrest support bracket (6) to

5.

Screw (2)

frame (7) with two screws (5). Tighten to 45-50 ft-lbs

6.

Footrest support bracket

(61.1-67.9 Nm).

7.

Frame

8.

B-clip (left side only)

2.

Install footrest (3) on footrest support bracket with spring

washer (4). Make sure spring washer is positioned inside

Figure 2-170. Passenger Footrest Assembly

support bracket mounting boss with the square edge

(Not Standard Equipment on XL 883 and XL 883L)

toward the inside. Align holes and push clevis pin (2)

from top down through hole in support bracket. Secure

with new retaining ring (1).

2006 Sportster: Chassis

2-123

HOME

FORK LOCK

2.36

REMOVAL

10573

1WARNING

To prevent accidental vehicle start-up, which could

cause death or serious injury, remove maxi-fuse before

proceeding. (00251a)

1.

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

side cover. See 7.25 MAXI-FUSE.

2.

Prepare vehicle for fork lock replacement.

● All models: remove fuel tank. See 4.8 FUEL TANK.

Turn front forks fully to the left.

● XL 883C and XL 1200C models: remove handlebar

upper clamp/speedometer housing. See 2.25 HAN-

DLEBARS. Secure handlebar assembly out of the

way.

3.

See Figure 2-171. See Figure 2-172. Using a 5/64 inch

Figure 2-171. Fork Lock Pin

(2 mm) drill bit, carefully drill a hole in the center of the

lock pin.

NOTE

10574

Take time to carefully orient drill bit to center of lock pin. If drill

bit “walks” off-center, removal of lock pin will be difficult.

4.

See Figure 2-173. To remove lock pin, insert a screw

extractor into the 5/64 in. (2 mm) hole. Hold body of

screw extractor with a pliers or tap handle and using a

small hammer gently “tap” on the pliers or tap handle to

remove lock pin.

5.

Remove lock assembly.

Figure 2-172. Drilling Lock Pin

10575

Figure 2-173. Removing Lock Pin

2-124

2006 Sportster: Chassis

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SPECIFICATIONS

3.1

Table 3-1. General Specifications

GENERAL

883 CC

1200 CC

Number of Cylinders

2

2

Type

4-cycle, 45° V

4-cycle, 45° V

Bore

3.0005 in. (76.20 mm)

3.498 in. (88.85 mm)

Stroke

3.812 in. (96.82 mm)

3.812 in. (96.82 mm)

Piston Displacement

53.86 cu. in. (883 cc)

73.2 cu. in. (1203 cc)

Torque

51.0 ft-lbs (69.2 Nm) @ 4300 RPM

79.0 ft-lbs (107.2 Nm) @ 3500 RPM

Compression Ratio

8.9:1

9.7:1

Oil tank capacity with filter

3.6 qt. (3.4 Liters)

3.6 qt. (3.4 Liters)

Table 3-2. Rocker Arms-883/1200 cc

Table 3-5. Cylinder Heads-883/1200 cc

ITEM

INCHES

MM

ITEM

INCHES

MM

Shaft in bushing (loose)

0.0005-0.0020

0.013-0.051

Valve guide in head

0.0033-0.0020

0.084-0.051

(tight)

End Clearance

0.003-0.013

0.08-0.33

Valve seat in head

0.0035-0.0010

0.089-0.025

Bushing fit in rocker arm

0.004-0.002

0.10-0.05

Head gasket surface

0.006

0.15

(flatness)

Table 3-3. Rocker Arm Shafts-883/1200 cc

ITEM

INCHES

MM

Table 3-6. Valves-883/1200 cc

Shaft fit in rocker cover

0.0007-0.0022

0.018-0.056

ITEM

INCHES

MM

Exhaust fit in guide

0.001-0.003

0.0254-0.0762

Intake fit in guide

0.001-0.003

0.0254-0.0762

Table 3-4. Tappets-883/1200 cc

Seat Width

0.040-0.062

1.02-1.57

ITEM

INCHES

MM

Stem protrusion from

2.028-2.064

51.511-52.426

Fit in guide

0.0008-0.0023

0.020-0.058

cylinder valve pocket

Roller fit

0.0006-0.0013

0.015-0.033

Roller end clearance

0.008-0.022

0.203-0.559

2006 Sportster: Engine

3-1

HOME

Table 3-7. Valve Springs-883/1200 cc

Table 3-10. Pistons-883 cc

INTAKE/EXHAUST

ITEM

INCHES

MM

Closed

135 lbs @ 1.850 in.

Compression ring

0.010-0.023

0.25-0.58

(61.2 kg @ 47.0 mm)

gap (top and 2nd)

Open

312 lbs @ 1.300 in.

Oil control ring

0.010-0.053

0.25-1.35

(141.5 kg @ 33.0 mm)

rail gap

Free length

2.325 in. (59.1 mm)

Compression ring

0.0020-0.0045

0.051-0.114

side clearance top

Compression ring

0.0020-0.0045

0.051-0.114

Table 3-8. Cylinders-883 cc

side clearance 2nd

Oil control ring

0.0014-0.0074

0.036-0.188

BORE DIAMETER

INCHES

MM

side clearance

+ 0.0002 in. (0.0051 mm)

Piston pin fit (loose;

0.00005-0.00045

0.0013-0.0114

Standard

3.0005

76.213

room temperature)

0.005 in. O.S. (oversize)

3.0048

76.323

0.010 in. O.S.

3.0098

76.449

Table 3-11. Pistons-1200 cc

0.020 in. O.S.

3.0198

76.703

ITEM

INCHES

MM

Compression ring

0.007-0.020

0.18-0.51

Table 3-9. Cylinders-1200 cc

gap (top and 2nd)

Oil control ring

0.009-0.052

0.23-1.32

BORE DIAMETER

INCHES

MM

rail gap

+ 0.0002 in. (0.0051 mm)

Top compression ring

0.0020-0.0045

0.051-0.114

Standard

3.4978

88.844

side clearance

0.005 in. O.S. (oversize)

3.502

88.95

2nd compression ring

0.0016-0.0041

0.041-0.104

0.010 in. O.S.

3.507

89.08

side clearance

0.020 in. O.S.

3.517

89.33

Oil control ring

0.0016-0.0076

0.041-0.193

side clearance

Piston pin fit (loose;

0.00005-0.00045

0.0013-0.0114

room temperature)

Table 3-12. Connecting Rods-883/1200 cc

ITEM

INCHES

MM

Piston pin fit (loose)

0.00125-0.00175

0.0318-0.0445

Side play between

0.005-0.025

0.013-0.64

flywheels

Fit on Crankpin

0.0004-0.0017

0.010-0.043

3-2

2006 Sportster: Engine

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Table 3-13. Oil Pressure-883/1200 cc

Table 3-17. Sprocket Shaft Bearing-

883/1200 cc

ITEM

PSI

KN/CM²

ITEM

INCHES

MM

Oil pressure at normal operating temperature (pressure

reading taken at oil pressure switch fitting)

Outer race fit in

0.006

0.152

crankcase (tight)

interference fit

Engine speed 1000 RPM

7-12

0.5-0.8

Inner race fit on shaft

0.006

0.152

Engine speed 2500 RPM

10-17

0.7-1.2

(tight)

interference fit

Table 3-14. Oil Pump-883/1200 cc

Table 3-18. Pinion Shaft Bearing-

ITEM

INCHES

MM

883/1200 cc

Feed/scavenge inner/outer

0.003

0.08

ITEM

INCHES

MM

gerotor clearance

Pinion shaft

1.2500-1.2496

31.750-31.740

Shaft to pump clearance

0.0025

0.064

journal diameter

Outer race

1.5646-1.5652

39.741-39.756

diameter in right

Table 3-15. Gearcase-883/1200 cc

crankcase

Bearing running

0.00012-0.00088

0.0030-0.0224

ITEM

INCHES

MM

clearance

Cam gear shaft in

0.0007-0.0022

0.018-0.056

Fit in cover

0.0023-0.0043

0.058-0.109

bushing (loose)

bushing (loose)

Cam gear shaft end play

0.005-0.024

0.13-0.61

(min. except rear intake)

Rear intake cam gear

0.006-0.024

0.15-0.61

Table 3-19. Ignition System-883/1200 cc

shaft end play (min.)

ITEM

VALUE

Timing during engine

0° BTDC

Table 3-16. Flywheels-883/1200 cc

cranking

Timing with engine speed at

10° BTDC

ITEM

INCHES

MM

950-1050

Runout (flywheels at rim)

0.000-0.010

0.00-0.25

ITEM

INCHES

MM

Runout (shaft at flywheel

0.000-0.002

0.00-0.05

Spark plug gap (6R12) (in.)

0.038-0.043

0.97-1.09

end)

End play

0.003-0.010

0.076-0.254

Table 3-20. Engine Speed-883/1200 cc

ITEM

VALUE

Slow Idle (RPM)

950-1050

2006 Sportster: Engine

3-3

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