Harley-Davidson Softail 2006 Service Manual (P/N 99482-06)

Harley-Davidson’s 2006 Softail Service Manual, P/N 99482-06, documents maintenance and repair for the carbureted and fuel-injected Softail variants listed above, including the Springer-equipped models.

PDF Search, Bookmarks and Circuit Detail

Text access and wiring detail: OCR text supports searches throughout most of the manual, but the starting-circuit sheets have no searchable text. Embedded bookmarks provide chapter, appendix and index access. Small wiring labels require zooming; some circuit lines are faint.

One English-language, printable 653-page PDF includes the title page, two foreword pages and 12 opening contents pages. Section dividers, four notes pages, one blank page, appendices and the index are also included in that total.

Engine Overhaul, Drivetrain and Electrical Service

These highlights are selected repair topics, rather than a complete table of contents. Vehicle-alignment checks and handlebar-switch repair are further examples of the work covered.

• Engine repair: Step-by-step top- and bottom-end overhaul, compression and cylinder-leakage testing, cam-support-plate service, and counterbalancer inspection and assembly.

• Primary drive: Clutch-pack and bearing replacement, compensating-sprocket alignment, primary-chain service, and drive-belt replacement.

• Transmission: Internal disassembly, inspection and reassembly, with shifter-cam, fork, mainshaft, countershaft and main-drive-gear bearing procedures.

• Fuel systems: C.V. carburetor overhaul, intake-leak testing, EFI fuel-pressure testing, and fuel-pump/fuel-gauge-sender removal and installation.

• Chassis and brakes: Hydraulic-fork disassembly, Springer fork and rocker-bearing service, brake-caliper and master-cylinder repair, and bleeding procedures.

• Electrical components: Starter armature and field-winding tests, battery load and conductance tests, component replacement, and connector repair.

• Electrical scope: Chapter circuit drawings are included. Appendix B wiring-diagram sheets and the separate Softail Models Electrical Diagnostic Manual are not included.

The major repair material is written for professional Harley-Davidson technicians, while the basic maintenance sections also assist users servicing their motorcycles.

Maintenance and Twin Cam 88B Repair

Routine servicing covers pre-ride inspections, seasonal storage and return to service. Oil changes, primary chaincase servicing, transmission lubrication, and clutch and throttle cable adjustments are supported by the Quick Reference Maintenance Chart.

For the air-cooled, counterbalanced Twin Cam 88B, separate in-chassis and engine-removed repair paths help establish the extent of disassembly a job requires.

Dedicated sections address rocker assemblies and hydraulic lifters. Cylinder-head procedures extend to valve-guide replacement and seat refacing; cylinder service includes boring and honing. Oil-pump inspection and oil-pressure testing cover lubrication problems.

Component torque tables and wear limits accompany the repair material. Illustrations include the Cylinder Head Bolt Torque Sequence and Cam Chain Tensioner Shoe Wear. Cam service identifies the HD-42313 tensioner unloader and explains how uncontrolled tensioner release can stretch the spring or crack the shoe.

Clutch and Transmission Repair

Clutch instructions distinguish partial pack disassembly on the motorcycle from complete shell, hub and bearing work. Transmission inspection also covers side-door bearings.

Appendix D provides separate Japan-market mainshaft/countershaft procedures. Its case-number identification helps distinguish those assemblies before selecting the applicable internal service instructions.

Springer Suspension and Chassis Work

FLSTSC/FXSTS procedures distinguish steering-head fall-away checks and rocker-bearing work from conventional hydraulic-fork service. The Front Fork: FLSTSC/FXSTS exploded view identifies the spring fork, rigid fork and front shock components. Tool references include the HD-47255 Springer steering-head bearing tool.

Wheel service includes sealed-bearing replacement and laced-wheel truing. Rear-caliper instructions distinguish FXST/FXSTB/FXSTS assemblies from those fitted to the other models.

Carburetor and EFI Components

Carburetor coverage follows the vacuum piston, float and needle valve, accelerator pump and enrichener, supported by hard-starting and poor-idling symptom tables. The float-pin section warns that breaking a mounting pedestal can require replacement of the carburetor body.

EFI component procedures address the induction module, injectors and idle-air control, plus the in-tank pump, filter and pressure regulator. California evaporative-emissions layouts distinguish carbureted and EFI plumbing.

EFI idle-speed setting requires Digital Technician, HD-44750. Detailed fault-code troubleshooting and several electronic component tests are referred to the separate electrical diagnostic manual.

Circuit References and Security Modules

Chapter drawings include starting and ignition circuits, the Charging System Circuit and the EFI System Circuit. Connector sections explain terminal removal, crimping and sealed splices for AMP Multilock, Deutsch, Delphi and Packard connections.

TSM/TSSM material covers replacement-module password learning, key-fob assignment and personal-code entry. Password-learning procedures include options with and without Digital Technician.

A Preview of Oil and Fuel Pressure Specifications

The engine oil-pressure check specifies 30–38 psi (207–262 kPa) at 2,000 rpm, with engine oil at its normal operating temperature of 230°F (110°C).

During the EFI fuel-pressure test, the gauge reading should remain steady at 55–62 psi (380–425 kPa) as engine speed changes.

Follow the complete manufacturer procedures and safety precautions for motorcycle lifting, spring-loaded suspension, brake work and pressurized fuel-system service.