2006 Harley-Davidson Touring FLHT, FLHR, FLTR, and FLHX Factory Service Manual (P/N 99483-06)

• 1,418-page PDF factory manual set for 2006 Touring models: 713-page Service Manual P/N 99483-06; 154-page FLHTCUSE Service Supplement P/N 99500-06; 550-page Electrical Diagnostic Manual P/N 99497-06; and a one-page set contents sheet.
• Powertrain repair coverage includes engine removal and installation, top- and bottom-end overhaul, cylinder head and piston service, cam and oil-pump work, primary drive and clutch service, and internal transmission repair.
• Chassis procedures cover wheel bearing replacement, wheel lacing and truing, brake master cylinders and calipers, hydraulic brake bleeding, fork and steering-head service, rear air suspension, swingarm work, and powertrain-to-frame alignment.
• Factory electrical diagnosis addresses starting and charging, instruments, turn-signal/security modules, carbureted ICM and EFI ECM systems, fuel-pressure and intake-leak testing, cruise control, serial data, and Advanced Audio faults.
• FLHTCUSE-specific material adds hydraulic clutch service and bleeding, model-specific engine and oil-cooler work, unique controls and trim, XM/audio equipment, garage-door opener service, and dedicated wiring diagrams.
• Shop-reference content includes model-specific harness diagrams, connector service, diagnostic charts, special-tool identification, torque tables, fluid data, wear limits, clearances, and electrical test specifications.

Exact Model and Variant Coverage

The base manual's VIN table covers the 2006 FLHT/FLHTI; FLHTCI; FLHTCUI, FLHTCUI Shrine, and FLHTCUI with sidecar; FLHR/FLHRI/FLHRCI/FLHRS/FLHRSI, including FLHRI Shrine; FLTRI; and FLHX/FLHXI. Engine-code V identifies carbureted versions and W identifies fuel-injected versions. The separate FLHTCUSE supplement covers VIN model PR and engine type E, denoting its fuel-injected Twin Cam powertrain.

This is a working shop set rather than a maintenance-only booklet. It is best suited to professional technicians and mechanically qualified owners who have the specified lifting equipment, test gear, and specialty tools; the advanced electrical sections assume familiarity with DTC-based fault isolation, breakout boxes, and Digital Technician.

Mechanical Repair Depth

The standard Touring engine section is built around the Twin Cam 88, while the FLHTCUSE supplement adds the model's 103 cu. in. engine differences. Coverage reaches beyond removal and replacement into cylinder-head inspection, valve and guide work, cylinder boring and honing, piston service, cam timing, cam-support-plate and oil-pump repair, crankcase work, and flywheel/connecting-rod inspection. Manufacturing tolerances, service wear limits, lubrication data, and component-specific torque sequences are placed with the related procedures.

Drive and transmission chapters cover the primary chain and sprockets, clutch, secondary belt, primary chaincase, shift linkage, shifter cam and forks, mainshaft/countershaft assemblies, main-drive gear and bearing, and transmission case/oil pan. A separate appendix distinguishes transmissions by the third digit of the eight-digit case number: 9 is Japan-only and 0 is for all other countries, with a different shaft assembly procedure.

Chassis content includes cast and laced wheels, rim runout, wheel truing, front and rear brake overhaul, suspension, steering, bodywork, fairings, Tour-Pak, saddlebags, and exhaust. Vehicle alignment is documented two ways: with Vehicle Alignment Tool HD-46247 after major disassembly or engine replacement, and with the factory straightedge method for locating alignment and clearance problems.

Diagnostics, Wiring, and Special Tools

The Electrical Diagnostic Manual provides symptom charts and circuit tests for no-crank and charging faults, speedometer self-diagnostics, TSM/TSSM security and turn-signal functions, password learn, carbureted-engine ICM faults, EFI sensor and injector DTCs, fuel-system electrical tests, radio and speaker DTCs, serial-data-bus faults, and cruise dropout diagnosis. The service appendix identifies tools such as the HD-44060 wheel-bearing remover/installer, HD-42313 cam-chain tensioner unloader, HD-43644 camshaft-bearing tool, carbureted and EFI breakout boxes HD-42682/HD-43876, and HD-44750 Digital Technician.

Named schematic coverage includes the Main Harness, Starting and Charging, Tail/Auxiliary/Fender/Directional/Tour-Pak Lighting, Radio/CB/Intercom/Rear Speakers, XM/Hands Free Phone/Navigation, and the FLHTCUSE EFI Harness. Deutsch, Multilock, Delphi, Packard, Autofuse, and sealed-splice connector service is also included. Coverage of the TLE and TLE-U sidecar units themselves is limited to amplifier, speaker, and switch wiring; this is not a full sidecar mechanical manual.

The FLHTCUSE book is a supplement, so procedures not unique to that model remain in the base Touring manual. Its fuel-injection section contains no separate repair chapter and directs the user to the main service and electrical-diagnostic material.

Two assembly cautions show the level of shop detail. Using the wrong Japan-market mainshaft first gear or reusing shaft retaining rings can damage or lock the transmission, while displacement of the lifter anti-rotation pin during engine assembly can cause severe engine damage. Brake repair, vehicle alignment, and engine removal directly affect safe control and stability, so the factory support, torque, bleeding, and final-check requirements should be followed closely.

This set is a service and diagnostic reference, not a parts catalog; it directs parts identification and ordering to the appropriate catalog.