2006 Harley-Davidson XL 883 Sportster 883, 2006 Harley-Davidson XL 883L Sportster 883 Low, 2006 Harley, Davidson XL 883C Sportster 883C Custom , 2006 Harley-Davidson XL 883R Sportster 883R, 2006 Harley-Davidson XL 1200C Sportster 1200 Custom, 2006 Harley-Davidson XL 1200R Sportster 1200 Roadster, 2006 Harley-Davidson XL 1200L Sportster 1200 Low.
This service manual covers all the following Sportster Models: XL883, XL1200, XL883L, XL883C, XL883R, XL1200, XL1200L, XL1200C, XL1200R Including Domestic and International Models.
TIRES AND WHEELS 1.11
Match tires, tubes, air valves and caps to the correct
wheel rim. Contact a Harley-Davidson dealer. Mismatching
can result in damage to the tire bead, allow tire slippage
on the rim or cause tire failure, which could result
in death or serious injury. (00023a)
adversely affect motorcycle handling.
In addition, using tires other than those specified may
be used on all Harley-Davidson laced (wire spoked)
wheels. Protective rubber rim strips must be used with
tubeless tires (fitted with correct size inner tubes) when
mounted on laced (wire spoked) wheels.
Tubeless tires fitted with the correct size inner tubes may
tires must not be used on laced (wire spoked) wheels.
Inner tubes must not be used in radial tires and radial
Tubeless tires are used on all Harley-Davidson cast and
sizes are printed on the tube.
Check tire pressure and tread as follows:
1. Inspect each tire for punctures, cuts, and breaks.
2. Inspect each tire for wear. Replace tires when the tread
wear indicator bars become visible. See TIRE WEAR
INDICATORS which follows.
Tire sizes are molded on the tire sidewall. Inner tube
Do not inflate tire beyond maximum pressure as specified
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.
TIRE WEAR INDICATORS
See Figure 1-41. Tread wear indicator bars appear on tire
tread surfaces when 1/32 inch (0.8 mm) or less tire tread
remains. Arrows on tire sidewalls pinpoint location of wear
bar indicators. Always remove tires from service when the
tread wear indicator bars become visible, indicating 1/32 inch
(0.8 mm) tread pattern depth remaining.
New tires are needed if any of the following conditions exist.
Tread wear indicator bars become visible on the tread
snags or deep cuts.
Tire cords or fabric become visible through cracked sidewalls,
A bump, bulge or split in the tire is found.
Puncture, cut or other damage to the tire that cannot be
Table 1-8. Tire Pressures
Service wheel bearings:
Inspect any time the wheels are removed.
they are in the wheel. Rotate the inner bearing race and
check for abnormal noise. Make sure bearing rotates
Inspect the play of the wheel bearings by finger while
corrosion. Excessive play or roughness indicates worn
bearings. Replace bearings in sets only. See SEALED
Check wheel bearings and axle spacers for wear and
Inspect vehicles with wheel spokes as follows:
1. Raise motorcycle wheel off the ground.
If nipples require more than one full turn to tighten
spoke, remove tire to check that spoke is not protruding
far enough through rim to damage tube.
2. Lightly tap each spoke with a spoke wrench. Loose
spokes will sound dull and must be tightened. Tighten
spokes to 40-50
(4.5-5.6 Nm). If more than a few
spokes are loose, true the entire wheel following procedure
under 2.8 TRUING LACED WHEELS.
If necessary, remove tire. See 2.10 TIRES.
Cast Front Wheel
Label all components as they are removed so they may be
returned to their original locations.
1. See Figure 2-6. Remove bearing spacers (10, 12) from
right and left sides of wheel.
2. If necessary, remove five screws (1) and left side brake
3. If necessary, remove five screws and right side brake
disc (15) (XL 883R and XL 1200R only) or hub plate (9)
(all models except XL 883R and XL 1200R).
4. If necessary, remove roller bearings (5) and hub spacer
(11). See SEALED WHEEL BEARINGS later in this section
for removal procedure.
Laced Front Wheel
Cast Front Wheel
Be sure that brake fluid or other lubricants do not contact
brake pads or discs. Such contact can adversely
affect braking ability, which could cause loss of control,
resulting in death or serious injury. (00290a)
1. See Figure 2-6. Install hub spacer (11) and wheel bearings
(5) if removed. See SEALED WHEEL BEARINGS,
later in this section for installation procedure.
2. If necessary, install brake disc(s) as follows:
a. Apply two drops of LOCTITE THREADLOCKER 243
(blue) to five screws (1). Install right side brake disc
(15) (XL 883R and XL 1200R only) or hub plate (9)
(all models except XL 883R and XL 1200R). Secure
with screws and tighten to 16-24 ft-lbs (21.7-32.6