2006 TOURING MODELS
SERVICE MANUAL
Part Number 99483-06
Section 1: Maintenance
Section 2: Chassis
Section 3: Engine
Section 4: Fuel System
Section 5: Starter
Section 6: Drive
Section 7: Transmission
Section 8: Electrical
Section 9: Fuel Injection
Appendix
FLHTCUSE SERVICE SUPPLEMENT
Part Number 99500-06
Section 1: Maintenance
Section 2: Chassis
Section 3: Engine
Section 4: Fuel System
Section 5: Starter
Section 6: Drive
Section 7: Transmission
Section 8: Electrical
Section 9: Fuel Injection (No content)
Appendix
ELECTRICAL DIAGNOSTICS
Part Number 99497-06
Section 1: Starting & Charging
Section 2: Instruments
Section 3: TSM & TSSM
Section 4: Engine Management
Section 5: Engine Management (EFI)
Section 6: Sound System
Section 7: Cruise Control
Section 8: Wiring
SUBJECT PAGE NO.
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.3 Engine Oil/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.4 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.6 Wheel Spokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.7 Primary Chain/Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.8 Clutch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.9 Transmission Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.10 Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.11 Throttle Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.12 Enrichener Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1.13 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1.14 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
1.15 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
1.16 Engine Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
1.17 Front Fork Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
1.18 Steering Head Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
1.19 Critical Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
1.20 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
1.21 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
MAINTENANCE 1
T ab le Of Contents
2006 Touring: Maintenance 1-1
HOME
GENERAL 1.1
REPAIR NOTES
General maintenance practices are given in this section. All
special tools and torque values are noted at the point of use
and all required parts or materials can be found in the appro-
priate PARTS CATALOG.
Safety
Safety is always the most important consideration when per-
forming any job. Be sure you have a complete understanding
of the task to be performed. Use common sense. Use the
proper tools. Don’t just do the job – do the job safely.
Removing Parts
Always consider the weight of a part when lifting. Use a hoist
whenever necessary. Do not lift heavy parts by hand. A hoist
and adjustable lifting beam or sling are needed to remove
some parts. The lengths of chains or cables from the hoist to
the part should be equal and parallel, and should be posi-
tioned directly over the center of the part. Be sure that no
obstructions will interfere with the lifting operation. Never
leave a part suspended in mid-air.
Always use blocking or proper stands to support the part that
has been hoisted. If a part cannot be removed, verify that all
bolts and attaching hardware have been removed. Check to
see if any parts are in the way of the part being removed.
When removing hoses, wiring or tubes, always tag each part
to ensure proper installation.
Cleaning
If you intend to reuse parts, follow good shop practice and
thoroughly clean the parts before assembly. Keep all dirt out
of parts; the unit will perform better and last longer. Seals, fil-
ters and covers are used in this motorcycle to keep out envi-
ronmental dirt and dust. These items must be kept in good
condition to ensure satisfactory operation.
Clean and inspect all parts as they are removed. Be sure all
holes and passages are clean and open. After cleaning,
cover all parts with clean lint-free cloth, paper or other mate-
rial. Be sure the part is clean when it is installed.
Always clean around lines or covers before they are
removed. Plug, tape or cap holes and openings to keep out
dirt, dust and debris.
Always verify cleanliness of blind holes before assembly.
Tightening screws with dirt, water or oil in the holes can
cause castings to crack or break.
Disassembly and Assembly
Always assemble or disassemble one part at a time. Do not
work on two assemblies simultaneously. Be sure to make all
necessary adjustments. Recheck your work when finished.
Be sure that everything is done.
Operate the motorcycle to perform any final check or adjust-
ments. If all is correct, the motorcycle is ready to go back to
the customer.
Checking Torques on Fasteners with Lock
Patches
To check the torque on a fastener that has a lock patch:
1. Set the torque wrench for the lowest setting in the speci-
fied torque range.
2. Attempt to tighten fastener to set torque. If fastener does
not move and lowest setting is satisfied (torque wrench
clicks), then the proper torque has been maintained.
REPAIR AND REPLACEMENT
PROCEDURES
Hardware and Threaded Parts
Install helical thread inserts when inside threads in castings
are stripped, damaged or not capable of withstanding speci-
fied torque.
Replace bolts, nuts, studs, washers, spacers and small com-
mon hardware if missing or in any way damaged. Clean up or
repair minor thread damage with a suitable tap or die.
Replace all damaged or missing lubrication fittings.
Use Teflon tape on pipe fitting threads.
Wiring, Hoses and Lines
Replace hoses, clamps, electrical wiring, electrical switches
or fuel lines if they do not meet specifications.
Instruments and Gauges
Replace broken or defective instruments and gauges.
Replace dials and glass that are so scratched or discolored
that reading is difficult.
1-2 2006 Touring: Maintenance
HOME
Bearings
Anti-friction bearings must be handled in a special way. To
keep out dirt and abrasives, cover the bearings as soon as
they are removed from the package.
Wash bearings in a non-flammable cleaning solution. Knock
out packed lubricant inside by tapping the bearing against a
wooden block. Wash bearings again. Cover bearings with
clean material after setting them down to dry. Never use com-
pressed air to dry bearings.
Coat bearings with clean oil. Wrap bearings in clean paper.
Be sure that the chamfered side of the bearing always faces
the shoulder (when bearings installed against shoulders).
Lubricate bearings and all metal contact surfaces before
pressing into place. Only apply pressure on the part of the
bearing that makes direct contact with the mating part.
Always use the proper tools and fixtures for removing and
installing bearings.
Bearings do not usually need to be removed. Only remove
bearings if necessary.
Bushings
Do not remove a bushing unless damaged, excessively worn
or loose in its bore. Press out bushings that must be
replaced.
When pressing or driving bushings, be sure to apply pres-
sure in line with the bushing bore. Use a bearing/bushing
driver or a bar with a smooth, flat end. Never use a hammer
to drive bushings.
Inspect the bushing and the mated part for oil holes. Be sure
all oil holes are properly aligned.
Gaskets
Always discard gaskets after removal. Replace with new gas-
kets. Never use the same gasket twice (unless instructed
otherwise). Be sure that gasket holes match up with holes in
the mating part.
If a gasket must be made, be sure to cut holes that match up
with the mating part. Serious damage can occur if any flange
holes are blocked by the gasket. Use material that is the right
type and thickness.
Lip Type Seals
Lip seals are used to seal oil or grease and are usually
installed with the sealing lip facing the contained lubricant.
Seal orientation, however, may vary under different applica-
tions.
Seals should not be removed unless necessary. Only remove
seals if required to gain access to other parts or if seal dam-
age or wear dictates replacement.
Leaking oil or grease usually means that a seal is damaged.
Replace leaking seals to prevent overheated bearings.
Always discard seals after removal. Do not use the same
seal twice.
O-Rings (Preformed Packings)
Always discard O-rings after removal. Replace with new O-
rings. To prevent leaks, lubricate the O-rings before installa-
tion. Apply the same type of lubricant as that being sealed.
Be sure that all gasket, O-ring and seal mating surfaces are
thoroughly clean before installation.
Gears
Always check gears for damaged or worn teeth.
Remove burrs and rough spots with a honing stone or crocus
cloth before installation. Lubricate mating surfaces before
pressing gears on shafts.
Shafts
If a shaft does not come out easily, check that all nuts, bolts
or retaining rings have been removed. Check to see if other
parts are in the way before using force.
Shafts fitted to tapered splines should be very tight. If shafts
are not tight, disassemble and inspect tapered splines. Dis-
card parts that are worn. Be sure tapered splines are clean,
dry and free of burrs before putting them in place. Press mat-
ing parts together tightly.
Clean all rust from the machined surfaces of new parts.
Part Replacement
Always replace worn or damaged parts with new parts.
CLEANING
Part Protection
Before cleaning, protect rubber parts (such as hoses, boots
and electrical insulation) from cleaning solutions. Use a
grease-proof barrier material. Remove the rubber part if it
cannot be properly protected.
Cleaning Process
Any cleaning method may be used as long as it does not
result in parts damage. Thorough cleaning is necessary for
proper parts inspection. Strip rusted paint areas to bare
metal before repainting.
2006 Touring: Maintenance 1-3
HOME
Rust or Corrosion Removal
Remove rust and corrosion with a wire brush, abrasive cloth,
sand blasting, vapor blasting or rust remover. Use buffing
crocus cloth on highly polished parts that are rusted.
Bearings
Remove shields and seals from bearings before cleaning.
Clean bearings with permanent shields and seals in solution.
Clean open bearings by soaking them in a petroleum clean-
ing solution. Never use a solution that contains chlorine.
Let bearings stand and dry. Do not dry using compressed air.
Do not spin bearings while they are drying.
1-4 2006 Touring: Maintenance
HOME
TOOL SAFETY
AIR TOOLS
● Always use approved eye protection equipment when
performing any task using air-operated tools.
● On all power tools, use only recommended accessories
with proper capacity ratings.
● Do not exceed air pressure ratings of any power tools.
● Bits should be placed against work surface before air
hammers are operated.
● Disconnect the air supply line to an air hammer before
attaching a bit.
● Never point an air tool at yourself or another person.
● Protect bystanders with approved eye protection.
WRENCHES
● Never use an extension on a wrench handle.
● If possible, always pull on a wrench handle and adjust
your stance to prevent a fall if something lets go.
● Never cock a wrench.
● Never use a hammer on any wrench other than a Strik-
ing Face wrench.
● Discard any wrench with broken or battered points.
● Never use a pipe wrench to bend, raise, or lift a pipe.
PLIERS/CUTTERS/PRYBARS
● Plastic or vinyl covered pliers handles are not intended
to act as insulation; don’t use on live electrical circuits.
● Don’t use pliers or cutters for cutting hardened wire
unless they were designed for that purpose.
● Always cut at right angles.
● Don’t use any prybar as a chisel, punch, or hammer.
HAMMERS
● Never strike one hammer against a hardened object,
such as another hammer.
● Always grasp a hammer handle firmly, close to the end.
● Strike the object with the full face of the hammer.
● Never work with a hammer which has a loose head.
● Discard hammer if face is chipped or mushroomed.
● Wear approved eye protection when using striking tools.
● Protect bystanders with approved eye protection.
PUNCHES/CHISELS
● Never use a punch or chisel with a chipped or mush-
roomed end; dress mushroomed chisels and punches
with a file.
● Hold a chisel or a punch with a tool holder if possible.
● When using a chisel on a small piece, clamp the piece
firmly in a vise, and chip toward the stationary jaw.
● Wear approved eye protection when using these tools.
● Protect bystanders with approved eye protection.
SCREWDRIVERS
● Don’t use a screwdriver for prying, punching, chiseling,
scoring, or scraping.
● Use the right type of screwdriver for the job; match the
tip to the fastener.
● Don’t interchange POZIDRIV®, PHILLIPS®, or REED
AND PRINCE screwdrivers.
● Screwdriver handles are not intended to act as insula-
tion; don’t use on live electrical circuits.
● Don’t use a screwdriver with rounded edges because it
will slip – redress with a file.
RATCHETS AND HANDLES
● Periodically clean and lubricate ratchet mechanisms with
a light grade oil. Do not replace parts individually; ratch-
ets should be rebuilt with the entire contents of service
kit.
● Never hammer or put a pipe extension on a ratchet or
handle for added leverage.
● Always support the ratchet head when using socket
extensions, but do not put your hand on the head or you
may interfere with the action of its reversing mechanism.
● When breaking loose a fastener, apply a small amount
of pressure as a test to be sure the ratchet’s gear wheel
is engaged with the pawl.
SOCKETS
● Never use hand sockets on power or impact wrenches.
● Select the right size socket for the job.
● Never cock any wrench or socket.
● Select only impact sockets for use with air or electric
impact wrenches.
● Replace sockets showing cracks or wear.
● Keep sockets clean.
● Always use approved eye protection when using power
or impact sockets.
2006 Touring: Maintenance 1-5
HOME
STORAGE UNITS
● Don’t open more than one loaded drawer at a time.
Close each drawer before opening up another.
● Close lids and lock drawers and doors before moving
storage units.
● Don’t pull on a tool cabinet; push it in front of you.
● Set the brakes on the locking casters after the cabinet
has been rolled to your work.
1-6 2006 Touring: Maintenance
HOME
MAINTENANCE SCHEDULE 1.2
GENERAL
The table below lists the maintenance requirements for Tour-
ing models. If you are familiar with the procedures, just refer
to the table for the recommended service interval. If neces-
sary, see the quick reference table on the next page for the
required specifications. If more detailed information is
needed, turn to the sections which follow for step-by-step
instructions.
Table 1-1. Scheduled Maintenance Intervals
ITEM PROCEDURE
1000
mi
1600
km
5000
mi
8000
km
10,000
mi
16,000
km
15,000
mi
24,000
km
20,000
mi
32,000
km
25,000
mi
40,000
km
NOTES
Engine oil and filter Replace X X X X X X
Oil lines and brake system Inspect for leaks X X X X X X 1
Air cleaner Inspect, service as required X X X X X X
Tires Check pressure, inspect tread X X X X X X
Wheel spokes Check tightness X X X 1, 4
Primary chain tension Check adjustment X X X X X X
Primary chaincase lubricant Replace X X X
Clutch Check adjustment X X X X X X 1
Transmission lubricant Replace X X
Drive belt and sprockets Inspect, adjust belt X X X X X X 1
Throttle, brake, clutch and
enrichener controls
Check, adjust and lubricate X X X X X X 1, 4
Jiffy stand Inspect and lubricate X X X X X X 1
Fuel valve, lines and fittings Inspect for leaks X X X X X X 1, 4
Fuel filter Clean (EFI: replace) X 1
Brake fluid Check levels and condition X X X X X X 5
Brake pads and discs Inspect for wear X X X X X X
Spark plugs
Inspect X X X X
Replace X X
Electrical equipment and switches Check operation X X X X X X
Engine idle speed Check adjustment X X X X X X 1
Front fork oil Replace 1, 2
Steering head bearings
Lubricate X X X 2
Adjust X 1
Air suspension Check pressure, operation and leakage X X X X X X 1
Windshield bushings Inspect X X 1
Cruise control Inspect disengage switch and components X X X X X X 1
Fuel door, Tour-pak, saddlebags Lubricate hinges and latches X X X X X X
Critical fasteners Check tightness X X X 1
Engine mounts and
stabilizer links
Inspect X X 1
Battery Check battery and clean connections 3
Road test Verify component and system functions X X X X X X
NOTES:
1. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically
qualified.
2. Disassemble, lubricate and inspect every 50,000 miles (80,000 km).
3. Perform annually.
4. Not all vehicles are equipped with enrichener, fuel valve or spoke wheels.
5. Change DOT 4 brake fluid and flush every two years.
2006 Touring: Maintenance 1-7
HOME
Table 1-2. Quick Reference Data
ITEM SPECIFICATION DATA
Engine oil and filter
Drain plug torque 14-21 ft-lbs (19-28 Nm)
Oil capacity 4 qt. (3.8 L)
Filter Hand tighten 1/2-3/4 turn after gasket contact
Chrome filter part number 63798-99
Black filter part number 63731-99
Air cleaner
Air cleaner cover bracket screw torque 40-60 in-lbs (5-7 Nm)
Air cleaner cover screw torque 36-60 in-lbs (4-7 Nm)
Air cleaner cover screw threadlocker
Loctite Medium Strength Threadlocker 243
(blue), Part No. 99642-97 (6 ml)
Tire condition and pressure
Pressure: solo rider Front: 36 psi (2.5 bar), Rear: 36 psi (2.5 bar)
Pressure: rider with passenger Front: 36 psi (2.5 bar), Rear: 40 psi (2.8 bar)
Wear
Replace tire if 1/32 in. (0.8 mm) or less
of tread pattern remains
Wheel spokes Spoke nipple torque 40-50 in-lbs (4.5-5.6 Nm)
Primary chain tension
Deflection with engine cold 5/8-7/8 in. (15.9-22.2 mm)
Deflection with engine hot 3/8-5/8 in. (9.5-15.9 mm)
Chain tensioner nut torque 21-29 ft-lbs (29-39 Nm)
Primary chain inspection cover torque 84-108 in-lbs (10-12 Nm)
Primary chaincase lubricant
Lubricant capacity 32 oz (946 mL)
Primary chaincase drain plug torque 36-60 in-lbs (4-7 Nm)
FORMULA+ TRANSMISSION AND
PRIMARY CHAINCASE LUBRICANT
part number
99851-05 (qt)
Clutch adjustment
Free play at adjuster screw 1/2-1 turn
Free play at hand lever 1/16-1/8 in. (1.6-3.2 mm)
Adjuster screw locknut torque 72-120 in-lbs (8-14 Nm)
Clutch inspection cover torque 84-108 in-lbs (10-12 Nm)
Transmission lubricant
Lubricant level
Dipstick at FULL with motorcycle level
and filler plug resting on threads
Lubricant capacity 20-24 oz (590-710 mL)
FORMULA+ TRANSMISSION AND
PRIMARY CHAINCASE LUBRICANT
part number
99851-05 (qt)
Transmission drain plug torque 14-21 ft-lbs (19-28 Nm)
Filler plug torque 25-75 in-lbs (3-9 Nm)
Drive belt
Upward force at midpoint of bottom belt
strand
10 lb. (4.5 kg)
Deflection with motorcycle on jiffy stand
without rider or luggage and 10 psi (69
kPa) in rear shocks
1/4 - 5/16 in. (6.4-7.9 mm)
Deflection with motorcycle upright and
rear wheel in the air
3/16 - 1/4 in. (4.8-6.4 mm)
Throttle and clutch cables
Lubricant part number Super Oil , 94968-85TV (1/4 fl. oz)
Handlebar clamp screw torque 60-80 in-lbs (6.8-9.0 Nm)
Handlebar switch housing screw torque 35-45 in-lbs (4-5 Nm)
Enrichener control Hex nut torque 20-35 in-lbs (2-4 Nm)
Fuel filter Hex jam nut torque 15-20 ft-lbs (20-27 Nm)
Brake Fluid Reservoir Level
DOT 4 Brake Fluid part number 99953-99A (12 oz)
Level 1/ 8 inch (3.2 mm) from the top
Master cylinder reservoir cover torque 6-8 in-lbs (0.7-0.9 Nm)
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2006 Harley-Davidson FLHRI Road King Service & Repair Manual
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Description
This is the complete official full factory service repair manual for the Harley Davidson FLHRI Road King 2006. It covers all styles and contains hundreds of pages that can be printed in its entirety or selectively. The manual provides actual genuine repair service factory manuals, not third-party manuals.
The Harley Davidson FLHRI Road King 2006 Factory Service Repair Manual is designed to guide both professional mechanics and DIY enthusiasts through the fundamentals of maintenance and repair. It covers every detail relating to the Harley Davidson FLHRI Road King 2006, including engine fault symptom diagnosis, research and evaluation of repair approaches, testing of suspected parts, wiring diagrams, engine management systems, and common fixes.
The manual covers general information, maintenance, chassis, fuel system, cooling system, engine, clutch, engine lubrication system, engine removal/installation, drive, transmission, wheels/tires, final drive, brakes, suspension, steering, frame, electrical system, wiring diagrams, and more.
It contains necessary illustrations, diagrams, and specifications to guide the mechanic through any repair procedure. Additionally, an advanced troubleshooting guide is included to help diagnose and correct any problem.
This highly detailed manual contains everything needed to repair, maintain, rebuild, refurbish, or restore the vehicle. It covers all diagnostic and repair procedures in great detail, providing step-by-step instructions and photos to guide through all service, maintenance, repairs, and tuning.
The manual is available in English and can be printed without any restriction. It is delivered in a format that can work under all PC-based Windows operating systems and Mac. The manual is fully printable, and all pages are printable, eliminating the need for shipping and waiting for physical copies.
With detailed substeps, notes, cautions, warnings, numbered instructions, bold figure numbers, detailed illustrations, and a numbered table of contents, the manual is designed for easy use and quick access to the required information.
It also makes it easy to diagnose and repair problems with the machine's electrical system, as troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
Overall, this Harley Davidson FLHRI Road King 2006 Factory Service Repair Manual is an indispensable resource for anyone looking to service their vehicle themselves, saving on shop labor costs and providing a wealth of detailed information for any serious owner.
