Introduction to Your Service Manual
This document is the official service manual for 2006 Harley-Davidson Softail models. It is designed to provide authorized service personnel and experienced mechanics with detailed procedures for the inspection, maintenance, and repair of these motorcycles. The manual contains essential information, including specifications, diagnostic procedures, and step-by-step instructions to ensure proper service and optimal performance.
Adherence to the procedures outlined in this manual is crucial for maintaining the safety, reliability, and longevity of your Harley-Davidson Softail motorcycle. Always prioritize safety and use appropriate tools and equipment.
This image displays the front cover of the official service manual. The cover features a red background with a partial view of a motorcycle engine and exhaust system at the top. The Harley-Davidson logo is visible on the left, and the title 'SOFTAIL® MODELS 2006 HARLEY-DAVIDSON® SERVICE MANUAL' is prominently displayed in white text. The manual's part number, 99482-06, is located in the bottom right corner.
General Information and Safety
Before commencing any service or repair work, it is imperative to review the safety warnings and general information sections of this manual. These sections provide critical guidelines to prevent injury to personnel and damage to the motorcycle.
- Safety Precautions: Always wear appropriate personal protective equipment (PPE) such as safety glasses, gloves, and sturdy footwear.
- Tool Usage: Use only the correct tools for each task. Improper tool usage can lead to damage or injury.
- Environmental Considerations: Dispose of fluids and parts responsibly according to local regulations.
- Torque Specifications: Adhere strictly to all specified torque values to ensure proper assembly and prevent component failure.
Maintenance Procedures
This section details the recommended maintenance schedule and procedures for 2006 Softail models. Regular maintenance is essential for optimal performance and longevity.
Scheduled Maintenance Intervals
Refer to the specific chapter for detailed instructions on each maintenance task. Intervals are typically based on mileage or time, whichever comes first.
- Engine Oil and Filter Change
- Transmission Fluid Check/Change
- Primary Chain Case Lubrication
- Spark Plug Inspection/Replacement
- Brake System Inspection
- Tire Pressure and Wear Check
Engine Service
This chapter provides comprehensive instructions for servicing the Twin Cam 88B engine found in 2006 Softail models. It covers everything from routine adjustments to complete engine overhaul.
Key Engine Service Areas:
- Top End (Cylinders, Pistons, Valves)
- Bottom End (Crankshaft, Connecting Rods)
- Camshafts and Valve Train
- Fuel System (Carburetor/EFI)
- Exhaust System
Chassis and Suspension
Detailed procedures for the frame, suspension components, wheels, tires, and braking system are included in this section. Proper chassis maintenance is vital for handling and rider safety.
Chassis Components Covered:
- Front Forks and Triple Trees
- Rear Suspension (Softail Hidden Shocks)
- Wheels, Hubs, and Bearings
- Brake Calipers, Discs, and Lines
- Steering Head Adjustment
Electrical System
This section provides comprehensive information on the electrical system, including wiring diagrams, component testing, and diagnostic procedures for electrical faults.
Electrical System Topics:
- Battery and Charging System
- Ignition System
- Lighting and Instrumentation
- Switches and Sensors
- Wiring Diagrams and Harness Routing
Troubleshooting Guide
This section assists in diagnosing common operational issues. It provides systematic approaches to identify the root cause of problems based on symptoms.
Common Troubleshooting Categories:
- Engine Starting Issues
- Poor Engine Performance
- Brake System Malfunctions
- Electrical System Failures
- Unusual Noises or Vibrations
Always consult the relevant chapters for detailed repair procedures once a problem has been identified.
Specifications
This section contains critical technical specifications, including torque values, fluid capacities, and component dimensions, necessary for accurate service and assembly.
Example Specifications Table:
| Component | Specification | Unit |
|---|---|---|
| Engine Oil Capacity | 3.0 | Quarts |
| Spark Plug Gap | 0.040 | Inches |
| Front Axle Nut Torque | 50-55 | ft-lbs |
Always refer to the complete specifications tables within the manual for precise values for all components.
Warranty and Support
This service manual provides technical repair information and does not include details regarding product warranties. For warranty information pertaining to your 2006 Harley-Davidson Softail motorcycle, please consult your original purchase documentation or contact an authorized Harley-Davidson dealership.
For additional support or specific technical inquiries not covered in this manual, it is recommended to contact an authorized Harley-Davidson service center. They have access to the latest service bulletins and specialized tools.
