====== MiscRes: FSMs ======
\\
====== Factory Service Manual (FSM) for Sportsters ======
AKA Field Service Manual ((Sportsterdoc))
==== What manuals do you need to maintain your ride? ====
At minimum, you should have a Factory Service Manual (FSM) and a Parts Catalog made for your year model. \\
The FSM has the most accurate information on your year model. \\
The parts catalog has parts listings, of course, plus exploded diagrams to help understand how most of the parts go together. \\
Although, the parts books are not intended as assembly manuals and descrepancies do apply. \\
2001-up models also have an Electrical Diagnostic Manual, some models have an updated manual as well. \\
These manuals are important for diagnosing all the electrical doo-dads on 2001-up models. \\
On disassembly / reassembly, there are certain parts that are a no brainer. Take this bolt out and remove the part. \\
There are other parts that need further parts removed or retained before disassembly. \\
Failure to go through the proper steps can lead to engine failure. \\
So the service manual should be regarded as the FIRST TOOL that you'll need for your Sportster. \\
==== Purpose of the FSM ====
Quote from the Factory Service Manual: \\
This service and repair manual has been prepared with two purposes in mind. \\
First, it will acquaint the reader with the construction of the Harley-Davidson product and assist him in performing basic maintenance and repair. \\
Secondly, it will introduce to the professional Harley-Davidson mechanic the latest field-tested and factory-approved major repair methods. \\
We sincerely believe that this manual will make your association with Harley-Davidson products more pleasant and profitable. \\
The practices set out in these manuals is NOT necessarily the same procedures used to build the bike at the factory. \\
Hence the alternate name for the FSM being "Field Service Manual".
1959-1969 FSMs were basically the same exact book with some revision pages. \\
Example, a 1960 service manual IS a 1959 manual with the inside cover changed to show a 1960 Sportster on it. \\
The only thing that changed might be if a procedure or something changed. If so, the bottom of the page will have a revision date. \\
No revised date = the same exact page, from the year before, copied to the new manual. \\
That is apparent due to the body of illustrations hardly ever changing and degraded illustrations and / or text in each subsequent year manual. \\
It can seem as if nobody told the book maker to always use the original pages to make copies. \\
Older illustrations are much more clear than the newer ones. \\
What changed yearly / periodically was the outside and inside covers unless revision pages were needed. \\
==== Purpose of the OEM Electrical Diagnostics Manual (EDM) for 2001-up ====
For 2000 and previous models, the electrical diagnostics were a part of the FSM. \\
Starting in 2001, HD added another manual / publication to the list of service manuals. \\
The FSMs were getting thicker with more pages and the electrical diagnostics were expanded out into their own manual. \\
So the EDM is basically an extra FSM for specific electrical diagnostic and troubleshooting issues for each year model 2001-up. \\
Quote from the Factory EDM; \\
This electrical diagnostic service manual has been prepared with two purposes in mind. \\
First, it will acquaint the user with the construction of the Harley-Davidson product and assist in the performance of repair. \\
Secondly, it will introduce to the professional Harley-Davidson Technician the latest field tested and factory-approved diagnostic methods. \\
We sincerely believe that this manual will make your association with Harley-Davidson products more pleasant and profitable. \\
Diagnostics / troubleshooting for the starting system, charging system, turn signals, ECM, among others are now in the electronics manual. \\
The EDM also has diagnostic code troubleshooting along with related wiring connectors and wiring diagrams. \\
==== Which brand service manual should you buy? ====
Accurate information is the most important factor in owning a service manual. \\
All manuals (including HD manuals) have errors from time to time. \\
However and by far, HD manuals have the most accurate information available. So, in order below: \\
- Buy an HD service manual for your year model. \\ Buy an HD parts catalog for your year model.
- Buy an aftermarket service manual or even two different brand aftermarket manuals if desired, after you have the factory manual.
==== Where to buy HD service manuals? ====
* Go to your local dealership or visit Harley Davidson online. \\
* Links for ordering parts from HD: \\ If the manual(s) you want don't show up on the site, I'd ring them or email them. \\ Their site might not be updated yet, but they will be able to get the manuals for you. ((Folkie of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/174886-factory-service-manual-for-2015-48?t=1876604))
* [[http://www.manchesterharley-superstore.com/catalog_product_detail.asp?cat_8250-98111_product_1445214.Official_Harley_Davidson_Spo rt.htm|Manchester Harley-Davidson]]
* [[https://www.shopronniesharleydavidson.com/?_ga=2.174804962.1783235891.1643422688-848864980.1643422688|Ronnie's Harley-Davidson]]
* [[https://chester-harley-davidson.co.uk/|Chester Harley Davidson]] in the UK. (Stanney Mill Lane, Little Stanney, Chester, CH2 4HY) ((Folkie of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/174886-factory-service-manual-for-2015-48?t=1876604))
* [[https://www.jerseyh-d.com/|Jersey H-D]] Jersey, Channel Islands (no VAT!) ((Folkie of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/174886-factory-service-manual-for-2015-48?t=1876604))
* You can also buy new and used factory manuals on Ebay or online motorcycle shops etc. \\
==== HD manuals are generally more expensive than aftermarket manuals ====
There are those that believe that the MoCo is just out to make big money off their products. \\
And who's to say that isn't true. That is the goal of ALL businesses. And HD is a business. \\
HD prices their manuals based off the profit they need off the end sale. \\
So that argument is really rhetorical in nature. \\
Aftermarket manual companies are also a business. They price their manuals based on what they can get by listing. \\
But they also don't build and maintain motorcycles. So their overhead is significantly lower than HD. \\
Likewise they can sell their manuals cheaper than HD. \\
So you can "stick it to the man" purchasing an aftermarket manual instead. \\
But the information in it may just cost you a lot more than if you'd bought the factory manual. \\
No company is sanctioned to make / sell HD manuals without HD's approval. \\
So aftermarkets would have to get their "technical" information out of HD manuals. \\
But consider this, one visit to the dealership to get them to do something you could have done yourself, is going to cost you more than $100. \\
The factory manual is worth it. ((IXL2Relax of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/197107-service-manual-2019-xl1200x?t=2073700))
==== There is nothing wrong with buying a used factory manual ====
Unless you are buying a manual to resell it later, you can go to online retailors, Ebay or others to purchase used factory manuals. \\
There is also something to be said about a used manual. \\
Someone before you had it and put those smudge marks and oil stains on it while wrenching on their Sportster. \\
So in a way and besides it being cheaper than new, that book is retaining history. \\
As long as the pages aren't ripped or missing, it's the same as a new one..... without the new smell. \\
==== Anything wrong with having an HD manual as well as aftermarket manuals? ====
Absolutely not. As a matter of fact, that is the best possible place to be. \\
Having as much information as possible gives a person more pictures, examples, details and perspectives. \\
Sometimes it's just a bad angle of a picture or confused wording that may stumble you. \\
Or it may be missing or inferred information in one manual that is better explained in another. \\
Especially in the older HD manuals, some parts just appear off the bike and details emerge about that part. \\
Other manuals may go through all the steps to get the part off the bike and into your hand. \\
So yes, having aftermarket manuals as well as HD manuals can be a good thing. \\
But damages incurred because an aftermarket manual failed to mention something in the factory manual is not good. \\
Understandably, people who do not have access to a local or even mail order HD business do have problems geting factory manuals. \\
But they are worth holding out for instead of faltering to aftermarket manuals alone. \\
And for the most part, aftermarket manuals should get you by until you can come across a factory manual. \\
Just don't be surprised if you find more erroneous information in the aftermarkets. \\
==== Are aftermarket manuals the same as HD manuals? ====
No, AFTERMARKET MANUALS ARE NOT THE SAME AS HD MANUALS. \\
They are not a reprint of the factory manuals. They are someone else's interpretation of the factory manuals. \\
Wording is different, pictures are different and the specs do not always match HD manual specs. \\
Some aftermarket service manual providers include; Haynes, Clymer and Peterson's. \\
Yes the increased amount of pictures is definitely a bonus. \\
Yes, there are generally more pictures and references to other tools on the market that you can use. \\
Also beware that cheap tools sometimes yield cheap results. That's not to say they won't work or work well. \\
But HD doesn't get into listing all the tools on the market. \\
They would have to vet all of them on a weekly basis to keep up with all the pop-up tools on the market these days. \\
HD lists tools specific for the jobs at hand and a large part of those are specifically made by or for HD. \\
If a cheap wrench will do the job instead, there is no problem using it. \\
But the old saying still works, if you are gonna stay and play, you gotta pay. \\
If you are going to wrench on your ride, you have to buy or make the wrenches. \\
It's up to the individual to decide which to buy with the recommendations in the manuals being just that. \\
There is always another way to skin a cat. \\
Both the Clymer and Haynes manuals have some good tips that just are not in the FSM. ((OutlawTexan67 of the XLFORUM https://www.xlforum.net/showthread.php?t=49400&page=2)) \\
But do yourself a favor and have an HD manual on hand. \\
==== Beware of long year-span aftermarket manuals ====
Changes between two adjacent year models may not always be in them. \\
From 1986-2003, there were many changes made. \\
However, all of the changes most likely will not be listed in a Clymer 1986-2003 service manual. \\
Things like oil capacities, engine specs, torque specs and etc. will most likely be listed for the newer year models. \\
One year (only) information will most likely not be in long year-span manuals. \\
Having a manual that is written just for your year model should have the most accurate information for that year. \\
Haynes has a 1970-2001 Sportster service manual. \\
The manual mixes information from Ironheads and Evos into the same book when these are totally different animals. \\
====== Master Service Manuals (1959-1965) ======
In 1959, HD implemented a Service Manual program. \\ It consisted of a Master service manuals and Individual Model manuals. \\ Master FSMs covered the complete model line and was only sold to dealerships. \\ Customer service manuals for individual models were sold to the general public. ((HD Service Bulletin #403 dated December 15, 1958)) ((HD Service Bulletin #415 dated February 15, 1960 pg OA-1 ((HD Service Bulletin #456 dated December 7, 1961 pg OA-1)) ((HD Service Bulletin #470 dated January 31, 1963 pg OA-1)) ((HD Service Bulletin #495dated September 18, 1965 pg OA-1))
Prior to 1959, there were no service manuals published. \\ 1957-1958 owners were told through the first (1959) FSM that most of the information will be correct for 1957-1958 models as well.
Master Service Manuals were sold to dealerships from 1959-1965 (skipping the year 1961). \\ There were no list prices for these type manuals and they were restricted to HD dealers because they contained confidential information. \\ (read as service bulletins not available to the public) \\ Each master service manual contains maintenance and repair information for all models covered with card separators between different sections. \\ Pages were loose leaf bound to allow pages to be added or taken out. \\ The master service manuals were discontinued because the addition of more models to the Harley-Davidson line made the manuals too large. ((TSB #528 dated December 31, 1965)) \\
* __Master service manuals__ were divided into seven different informational sections including: ((HD Service Bulletin #403 dated December 15, 1958 pg OA-1))
* Dealer - section 0: This section is for Service Bulletins and updates from the MoCo (design changes, new tools, etc).
* Product - section 1
* Chassis - section 2
* Engine - section 3
* Transmission - section 4
* Electrical - section 5
* Miscellaneous - section 6
* __Supplemental master manuals__ were sold to dealerships from 1960-1965 (skipping 1961) \\ They could be purchased to update the previous year full service manual. \\ So the dealerships had the option of just buying the supplements instead of paying for a new full manual. \\ The supplement pages were to update any new changes / converting earlier service manuals to cover the current models. \\ They were all in loose leaf binders so updating a manual simply consisted of removing revised pages and inserting the respective new pages. \\ In 1966, the MoCo offered individual model supplements but no more all model master supplement packages.
^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&800|}}||||||
| **Factory Master Service Manuals** ||||||
|Catalog #|Year Span|Models Covered| Full Catalog | Use to Update \\ Catalog # | Dealer Price |
|99480-59|1957-1959|Duo Glide, Sportster, \\ Servi-Car, Model 165 and Hummer| Yes | X | $15.00 ((TSB #403 dated December 15, 1958)) |
|99480-60|1959-1960|All Models| Yes | X | $18.00 ((TSB #415 dated February 15, 1960)) |
|99481-60|1960|Supplement to 1959 FSM, all models| No | 99480-59 | $10.00 ((TSB #415 dated February 15, 1960)) |
|1961 service manuals were not published. See service bulletin #456||||||
|99480-62|1959-1962|All models| Yes | X | $21.00 ((TSB #456 dated December 7, 1961)) |
|99481-62|1962|Supplement to 1960 FSM, all models| No | 99480-60 | $10.00 ((TSB #456 dated December 7, 1961)) |
|99480-63|1959-1963|All models| Yes | X | $21.00 ((TSB #470 dated January 31, 1963)) |
|99481-63|1963|Supplement to 1962 FSM, all models| No | 99480-62 | $6.00 ((TSB #470 dated January 31, 1963)) |
|99480-64|1959-1964|All models| Yes | X | ? |
|99481-64|1964|Supplement to 1963 FSM, all models| No | 99480-63 | ? |
|99480-65|1959-1965|All models| Yes | X | $23.50 ((TSB #495 dated September 18, 1965)) |
|99481-65|1965|Supplement to 1964 FSM, all models| No | 99480-64 | $8.00 ((TSB #495 dated September 18, 1965)) |
====== Individual Model Service Manuals ======
Individual Model Service Manuals could be purchased by anyone from HD dealerships. \\
They were also recommended to have on hand in dealer service departments (instead of the master manuals) for quick reference. \\
These manuals cover maintenance and repair information for only one model. \\
They are also divided into sections like the Master Manual but do not have the Dealer section for Service Bulletin information. \\
These were also loose leaf bound until the mid 1970's and could be updated with new model year supplements or a new full manual could be purchased. \\
* __Early Individual service manuals__ were divided into six different informational sections including: ((HD Service Bulletin #403 dated December 15, 1958 pg OA-1))
* Product - section 1
* Chassis - section 2
* Engine - section 3
* Transmission - section 4
* Electrical - section 5
* Miscellaneous - section 6
Starting in 1970, the card stock dividers were deleted and the inside cover contained more of a menu with page numbers to the six different sections. \\
Later, the name of the sections were progressively changed into more of a detailed menu to the various subjects. \\
^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&800|}}||||||
| **Factory Individual Model Service Manuals for Sportsters** ||||||
|Catalog #|Year Span| Dealer Price | List Price | Notes |Pics of Covers \\ Click to View|
|99484-59|1957-1959|$4.00|$5.00|Complete loose leaf service manual|{{:sportster_history:l001-fsm-1959_edition_cover_1st_for_1957-1964_loose_leaf_binders.jpg?linkonly|Outside Cover}} \\ {{:sportster_history:l001-fsm-1959_edition_cover_99484-59_for_1957-1959_loose_leaf_inside.jpg?linkonly|Inside Cover}}|
|99484-60|1959-1960|$4.00|$5.00|Complete loose leaf service manual|{{:sportster_history:l001-fsm-1959_edition_cover_1st_for_1957-1964_loose_leaf_binders.jpg?linkonly|Outside Cover}} \\ {{:sportster_history:l001-fsm-1960_edition_cover_99484-60_for_1957-1960_loose_leaf_inside.jpg?linkonly|Inside Cover}}|
|99485-60|1960|$1.50|$2.00|Loose leaf supplement set \\ Updates service manual (99484-59)|
|1961 service manuals were not published. See service bulletin #456||||||
|99484-62|1959-1962|$4.00|$5.00|Complete loose leaf service manual|{{:sportster_history:l001-fsm-1959_edition_cover_1st_for_1957-1964_loose_leaf_binders.jpg?linkonly|Outside Cover}} \\ {{:sportster_history:l001-fsm-1962_edition_cover_99484-62_for_1957-1962_loose_leaf_inside.jpg?linkonly|Inside Cover}}|
|99485-62|1962|$1.00|$1.50|Loose leaf supplement set \\ Updates service manual (99484-60)|
|99484-63|1959-1963|$4.00|$5.00|Complete loose leaf service manual|{{:sportster_history:l001-fsm-1959_edition_cover_1st_for_1957-1964_loose_leaf_binders.jpg?linkonly|Outside Cover}} \\ {{:sportster_history:l001-fsm-1963_edition_cover_99484-63_for_1957-1963_loose_leaf_inside.jpg?linkonly|Inside Cover}}|
|99485-63|1963|$0.75|$1.00|Loose leaf supplement set \\ Updates service manual (99484-62)|
|99480-64|1959-1964| ? | ? |Complete loose leaf service manual|{{:sportster_history:l001-fsm-1959_edition_cover_1st_for_1957-1964_loose_leaf_binders.jpg?linkonly|Outside Cover}} \\ {{:sportster_history:l001-fsm-1964_edition_cover_99484-64_for_1957-1964_loose_leaf_inside.jpg?linkonly|Inside Cover}}|
|99485-64|1964| ? | ? |Loose leaf supplement set \\ Updates service manual (99484-63)|
|99484-65|1959-1965|$4.00|$5.00|Complete loose leaf service manual|{{:sportster_history:l001-fsm-1965_edition_cover_1st_for_1965-1969_loose_leaf_binders.jpg?linkonly|Outside Cover}} \\ inside cover needed|
|99485-65|1965|$1.70|$2.25|Loose leaf supplement set \\ Updates service manual (99484-64)|
|99484-66|1959-1966|$4.00|$5.00|Complete loose leaf service manual|{{:sportster_history:l001-fsm-1965_edition_cover_1st_for_1965-1969_loose_leaf_binders.jpg?linkonly|Outside Cover}} \\ {{:sportster_history:l001-fsm-1966_edition_cover_99484-66_for_1957-1966_loose_leaf_inside.jpg?linkonly|Inside Cover}}|
|99485-66|1966|$1.90|$2.50|Loose leaf supplement set \\ Updates service manual (99484-64)|
|Catalog #|Year Span|Notes |||
|99484-67|1959-1967|Complete original loose leaf service manual|||{{:sportster_history:l001-fsm-1965_edition_cover_1st_for_1965-1969_loose_leaf_binders.jpg?linkonly|Outside Cover}} \\ {{:sportster_history:l001-fsm-1967_edition_cover_99484-67_for_1957-1967_loose_leaf_inside.jpg?linkonly|Inside Cover}}|
|99484-68|1959-1968|Complete original loose leaf service manual|||{{:sportster_history:l001-fsm-1965_edition_cover_1st_for_1965-1969_loose_leaf_binders.jpg?linkonly|Outside Cover}} \\ inside cover needed|
|99484-69|1959-1969|Complete original loose leaf service manual|||{{:sportster_history:l001-fsm-1965_edition_cover_1st_for_1965-1969_loose_leaf_binders.jpg?linkonly|Outside Cover}} \\ {{:sportster_history:l001-fsm-1969_edition_cover_99484-69_for_1957-1969_loose_leaf_inside.jpg?linkonly|Inside Cover}}|
|99484-69|:::|Complete glued binder reprint service manual|||{{:sportster_history:l001-fsm-1969_edition_cover_99484-69_for_1957-1969_book_bound.jpg?linkonly|Latest Edition Cover}}|
|99484-70|1970|Complete original loose leaf service manual|||{{:sportster_history:l001-fsm-1970_edition_cover_99484-70_loose_leaf_1_outside.jpg?linkonly|Outside Cover}}|
|99484-71|1970-1971|Complete original service manual|||{{:sportster_history:l001-fsm-1971_edition_cover_99484-71_for_1970-1971_loose_leaf_1_outside.jpg?linkonly|Outside Cover}}|
|99484-72|1970-1972|Complete original service manual|||{{:sportster_history:l001-fsm-1972_edition_cover_99484-72_for_1970-1972_loose_leaf_1_outside.jpg?linkonly|Outside Cover}}|
|99484-73|1970-1973|Complete original service manual|||{{:sportster_history:l001-fsm-1973_edition_cover_99484-73_for_1970-1973_loose_leaf_1_outside.jpg?linkonly|Outside Cover}}|
|99484-74|1970-1974|Complete original service manual|||{{:sportster_history:l001-fsm-1974_edition_cover_99484-74_for_1970-1974_loose_leaf_1_outside.jpg?linkonly|Outside Cover}}|
|99484-75|1970-1975|Complete original service manual|||{{:sportster_history:l001-fsm-1975_edition_cover_99484-75_for_1970-1975_loose_leaf_1_outside.jpg?linkonly|Outside Cover}}|
|99484-76|1970-1976|Complete original service manual|||{{:sportster_history:l001-fsm-1976_edition_cover_99484-76_for_1970-1976_book_bound_pic1_outside.jpg?linkonly|Outside Cover}}|
|99484-77|1970-1977|Complete original service manual|||{{:sportster_history:l001-fsm-1977_edition_cover_99484-77_for_1970-1977.jpg?linkonly|Outside Cover}}|
|99484-78|1970-1978|Complete original service manual|||{{:sportster_history:l001-fsm-1978_edition_cover_99484-78_for_1970-1978.jpg?linkonly|Outside Cover}}|
|99484-79|1979|Complete original service manual|||{{:sportster_history:l001-fsm-1979_edition_cover_99484-79.jpg?linkonly|Outside Cover}}|
|99484-80|1979-1980|Complete original service manual|||{{:sportster_history:l001-fsm-1980_edition_cover_99484-80_for_1979-1980.jpg?linkonly|Outside Cover}}|
|99484-81|1979-1981|Complete original service manual|||{{:sportster_history:l001-fsm-1981_edition_cover_99484-81_for_1979-1981.jpg?linkonly|Outside Cover}}|
|99484-82|1979-1982|Complete original service manual|||{{:sportster_history:l001-fsm-1982_edition_cover_99484-82_for_1979-1982.jpg?linkonly|Outside Cover}}|
|99484-83|1979-1983|Complete original service manual|||{{:sportster_history:l001-fsm-1983_edition_cover_99484-83_for_1979-1983.jpg?linkonly|Outside Cover}}|
|99484-83S|L1983|Supplement service manual updates 1983 FSM (99484-83) \\ Includes changes for XR-1000|||{{:sportster_history:l001_fsm_1983_edition_cover_99484-83s_supplemental_service_manual.png?linkonly|Outside Cover}}|
|99484-84|1979-E1984|Complete original service manual \\ Does not include changes for L1984 alternator engine|||{{:sportster_history:l001-fsm-1984_edition_cover_99484-84_for_1979-1984.jpg?linkonly|Outside Cover}}|
|99484-84S|L1984|Supplement service manual updates 1984 FSM (99484-84) \\ Includes changes for L1984 alternator engine only|||{{:sportster_history:l001-fsm-1984_edition_cover_99484-84s_for_late_1984.jpg?linkonly|Outside Cover}} \\ {{:sportster_history:l001-fsm-1984_edition_cover_99484-84s_letter_for_l1984_fsm.jpg?linkonly|Supplement Letter}}|
|99484-85|1979-1985|Complete original service manual|||{{:sportster_history:l001-fsm-1985_edition_cover_99484-85_for_1979-1985.jpg?linkonly|Outside Cover}}|
|99484-86|1986|Complete original service manual|||{{:sportster_history:l001-fsm-1986_edition_cover_99484-86_for_1986.jpg?linkonly|Outside Cover}}|
|XXXXX-XX|:::|Complete (dealer only) edition, no part#|||{{:sportster_history:l001-fsm-1986_edition_cover_00000-00_for_1986_-_dealer_only.jpg?linkonly|Dealer (only) Cover}}|
|99484-87|1986-1987|Complete original service manual|||{{:sportster_history:l001-fsm-1987_edition_cover_99484-87_for_1986-1987.jpg?linkonly|Outside Cover}}|
|99484-88|1986-1988|Complete original service manual|||{{:sportster_history:l001-fsm-1988_edition_cover_99484-88_for_1986-1988.jpg?linkonly|Outside Cover}}|
|99484-89|1986-1989|Complete original service manual|||{{:sportster_history:l001-fsm-1989_edition_cover_99484-89_for_1986-1989.jpg?linkonly|Outside Cover}}|
|99484-90|1986-1990|Complete original service manual|||{{:sportster_history:l001-fsm-1990_edition_cover_99484-90_for_1986-1990.jpg?linkonly|Outside Cover}}|
|99948-90|:::|Electrical Wiring Diagrams (All Models)|||{{:sportster_history:l007-wdt-1990_edition_cover_99948-90_for_1986-1990.jpg?linkonly|Outside Cover}}|
|99484-91|1991|Complete original service manual|||{{:sportster_history:l001-fsm-1991_edition_cover_99484-91_for_1991.jpg?linkonly|Outside Cover}}|
|99484-92|1991-1992|Complete original service manual|||{{:sportster_history:l001-fsm-1992_edition_cover_99484-92_for_1991-1992.jpg?linkonly|Outside Cover}}|
|99948-92|:::|Electrical Wiring Diagrams & Troubleshooting Guide (All Models)|||{{:sportster_history:l007-wdt-1992_edition_cover_99948-92_for_1991-1992.jpg?linkonly|Outside Cover}}|
|99484-93|1993|Complete original service manual|||{{:sportster_history:l001-fsm-1993_edition_cover_99484-93_for_1993.jpg?linkonly|Outside Cover}}|
|99484-94|1993-1994|Complete original service manual|||{{:sportster_history:l001-fsm-1994_edition_cover_99484-94_for_1993-1994.jpg?linkonly|Outside Cover}}|
|99948-94|:::|Electrical Wiring Diagrams & Troubleshooting Guide (All Models)|||{{:sportster_history:l007-wdt-1994_edition_cover_99948-94_for_1993-1994.jpg?linkonly|Outside Cover}}|
|99484-95|1995|Complete original service manual|||{{:sportster_history:l001-fsm-1995_edition_cover_99484-95_for_1995.jpg?linkonly|Outside Cover}}|
|99484-95A|:::|Complete updated service manual|||{{:sportster_history:l001-fsm-1995_edition_cover_99484-95A_for_1995.jpg?linkonly|Outside Cover}}|
|99484-96|1995-1996|Complete original service manual|||{{:sportster_history:l001-fsm-1996_edition_cover_99484-96_for_1995-1996.jpg?linkonly|Outside Cover}}|
|99948-96|:::|Electrical Wiring Diagrams & Troubleshooting Guide (All Models)|||{{:sportster_history:l007-wdt-1996_edition_cover_99948-96_for_1995-1996.jpg?linkonly|Outside Cover}}|
|99484-97|1997|Complete original service manual|||{{:sportster_history:l001-fsm-1997_edition_cover_99484-97_for_1997.jpg?linkonly|Outside Cover}}|
|99948-97|:::|Electrical Wiring Diagrams & Troubleshooting Guide (All Models)|||{{:sportster_history:l007-wdt-1997_edition_cover_99948-97_for_1997.jpg?linkonly|Outside Cover}}|
|99484-98|1998|Complete original service manual|||{{:sportster_history:l001-fsm-1998_edition_cover_99484-98_for_1998.jpg?linkonly|Outside Cover}}|
|99948-98|:::|Electrical Wiring Diagrams & Troubleshooting Guide (All Models)|||{{:sportster_history:l007-wdt-1998_edition_cover_99948-98_for_1998.jpg?linkonly|Outside Cover}}|
|99484-99|1999|Complete original service manual|||{{:sportster_history:l001-fsm-1999_edition_cover_99484-99_for_1999.jpg?linkonly|Outside Cover}}|
|99484-00|2000|Complete original service manual|||{{:sportster_history:l001-fsm-2000_edition_cover_99484-00_for_2000.jpg?linkonly|Outside Cover}}|
|99484-01|2001|Complete service manual|||{{:sportster_history:l001-fsm-2001_edition_cover_99484-01_for_2001.jpg?linkonly|Outside Cover}}|
|99495-01|:::|Original electrical diagnostic two manual set \\ for XLH / Dyna / Softail / FLT models|||{{:sportster_history:l005-edm-2001_edition_cover_99495-01_v-i_for_2001_all_models.jpg?linkonly|V-I Outside Cover}} \\ {{:sportster_history:l005-edm-2001_edition_cover_99495-01_v-ii_for_2001_all_models.jpg?linkonly|V-II Outside Cover}}|
|99484-02|2002|Complete original service manual|||{{:sportster_history:l001-fsm-2002_edition_cover_99484-02_for_2002.jpg?linkonly|Outside Cover}}|
|99484-02A|:::|Complete updated service manual|||{{:sportster_history:l001-fsm-2002_edition_cover_99484-02A_for_2002.jpg?linkonly|Outside Cover}}|
|99495-02|:::|Original electrical diagnostic manual|||{{:sportster_history:l005-edm-2002_edition_cover_99495-02_for_2002.jpg?linkonly|Outside Cover}}|
|99484-03|2003|Complete original service manual|||{{:sportster_history:l001-fsm-2003_edition_cover_99484-03_for_2003.jpg?linkonly|Outside Cover}}|
|99495-03|:::|Original electrical diagnostic manual|||{{:sportster_history:l005-edm-2003_edition_cover_99495-03_for_2003.jpg?linkonly|Outside Cover}}|
|99484-04|2004|Complete original service manual|||{{:sportster_history:l001-fsm-2004_edition_cover_99484-04_for_2004.jpg?linkonly|Outside Cover}}|
|99495-04|:::|Original electrical diagnostic manual|||{{:sportster_history:l005-edm-2004_edition_cover_99495-04_for_2004.jpg?linkonly|Outside Cover}}|
|99495-04A|:::|Updated electrical diagnostic manual|||{{:sportster_history:l005-edm-2004_edition_cover_99495-04a_for_2004.jpg?linkonly|Outside Cover}}|
|99484-05|2005|Complete original service manual|||{{:sportster_history:l001-fsm-2005_edition_cover_99484-05_for_2005.jpg?linkonly|Outside Cover}}|
|99495-05|:::|Original electrical diagnostic manual|||{{:sportster_history:l005-edm-2005_edition_cover_99495-05_for_2005.jpg?linkonly|Outside Cover}}|
|99484-06|2006|Complete original service manual|||{{:sportster_history:l001-fsm-2006_edition_cover_99484-06_for_2006.jpg?linkonly|Outside Cover}}|
|99495-06|:::|Original electrical diagnostic manual|||{{:sportster_history:l005-edm-2006_edition_cover_99495-06_for_2006.jpg?linkonly|Outside Cover}}|
|99484-07|2007|Complete original service manual|||{{:sportster_history:l001-fsm-2007_edition_cover_99484-07_for_2007.jpg?linkonly|Outside Cover}}|
|99484-07A|:::|Complete updated service manual|||{{:sportster_history:l001-fsm-2007_edition_cover_99484-07A_for_2007.jpg?linkonly|Outside Cover}}|
|99495-07|:::|Original electrical diagnostic manual|||{{:sportster_history:l005-edm-2007_edition_cover_99495-07.jpg?linkonly|Outside Cover}}|
|99484-08|2008|Complete original service manual|||{{:sportster_history:l001-fsm-2008_edition_cover_99484-08_for_2008.jpg?linkonly|Outside Cover}}|
|99484-08A|:::|Complete updated service manual|||{{:sportster_history:l001-fsm-2008_edition_cover_99484-08A_for_2008.jpg?linkonly|Outside Cover}}|
|99495-08|:::|Original electrical diagnostic manual|||{{:sportster_history:l005-edm-2008_edition_cover_99495-08_for_2008.jpg?linkonly|Outside Cover}}|
|99484-09|2009|Complete original service manual|||{{:sportster_history:l001-fsm-2009_edition_cover_99484-09_for_2009.jpg?linkonly|Outside Cover}}|
|99495-09|:::|Original electrical diagnostic manual|||{{:sportster_history:l005-edm-2009_edition_cover_99495-09_for_2009.jpg?linkonly|Outside Cover}}|
|99484-10|2010|Complete original service manual|||{{:sportster_history:l001-fsm-2010_edition_cover_99484-10_for_2010.jpg?linkonly|Outside Cover}}|
|99484-10A|:::|Complete updated service manual|||{{:sportster_history:l001-fsm-2010_edition_cover_99484-10A_for_2010.jpg?linkonly|Outside Cover}}|
|99495-10|:::|Original electrical diagnostic manual|||{{:sportster_history:l005-edm-2010_edition_cover_99495-10_for_2010.jpg?linkonly|Outside Cover}}|
|99484-11|2011|Complete original service manual|||{{:sportster_history:l001-fsm-2011_edition_cover_99484-11_for_2011.jpg?linkonly|Outside Cover}}|
|99484-11A|:::|Complete updated service manual|||{{:sportster_history:l001-fsm-2011_edition_cover_99484-11A_for_2011.jpg?linkonly|Outside Cover}}|
|99495-11|:::|Original electrical diagnostic manual|||{{:sportster_history:l005-edm-2011_edition_cover_99495-11_for_2011.jpg?linkonly|Outside Cover}}|
|99484-12|2012|Complete original service manual|||{{:sportster_history:l001-fsm-2012_edition_cover_99484-12_for_2012.jpg?linkonly|Outside Cover}}|
|99484-12A|:::|Complete updated service manual|||{{:sportster_history:l001-fsm-2012_edition_cover_99484-12A_for_2012.jpg?linkonly|Outside Cover}}|
|99495-12|:::|Original electrical diagnostic manual|||{{:sportster_history:l005-edm-2012_edition_cover_99495-12_for_2012.jpg?linkonly|Outside Cover}}|
|99484-13|2013|Complete service manual|||{{:sportster_history:l001-fsm-2013_edition_cover_99484-13_for_2013.jpg?linkonly|Outside Cover}}|
|99495-13|:::|Original electrical diagnostic manual|||{{:sportster_history:l005-edm-2013_edition_cover_99495-13_for_2013.jpg?linkonly|Outside Cover}}|
|99484-14|2014|Complete service manual|||{{:sportster_history:l001-fsm-2014_edition_cover_99484-14_for_2014.jpg?linkonly|Outside Cover}}|
|99484-14A|:::|Complete updated service manual|||{{:sportster_history:l001-fsm-2014_edition_cover_99484-14A_for_2014.jpg?linkonly|Outside Cover}}|
|99495-14|:::|Original electrical diagnostic manual|||{{:sportster_history:l005-edm-2014_edition_cover_99495-14_for_2014.jpg?linkonly|Outside Cover}}|
|99484-15|2015|Complete service manual|||{{:sportster_history:l001-fsm-2015_edition_cover_99484-15_for_2015.jpg?linkonly|Outside Cover}}|
|99495-15|:::|Original electrical diagnostic manual|||{{:sportster_history:l005-edm-2015_edition_cover_99495-15_for_2015.jpg?linkonly|Outside Cover}}|
|99484-16|2016|Complete service manual|||{{:sportster_history:l001-fsm-2016_edition_cover_99484-16_for_2016.jpg?linkonly|Outside Cover}}|
|99484-16A|:::|Complete updated service manual|||{{:sportster_history:l001-fsm-2016_edition_cover_99484-16A_for_2016.jpg?linkonly|Outside Cover}}|
|99495-16|:::|Original electrical diagnostic manual|||{{:sportster_history:l005-edm-2016_edition_cover_99495-16_for_2016.jpg?linkonly|Outside Cover}}|
|94000384|2017|Complete service manual|||{{:sportster_history:l001-fsm-2017_edition_cover_94000384_for_2017.jpg?linkonly|Outside Cover}}|
|94000392|:::|Original electrical diagnostic manual|||{{:sportster_history:l005-edm-2017_edition_cover_94000392_for_2017.jpg?linkonly|Outside Cover}}|
|94000575|2018|Complete service manual|||{{:sportster_history:l001-fsm-2018_edition_cover_94000575_for_2018.jpg?linkonly|Outside Cover}}|
|94000504|:::|Original electrical diagnostic manual|||{{:sportster_history:l005-edm-2018_edition_cover_94000504_for_2018.jpg?linkonly|Outside Cover}}|
|94000546|2019|Complete service manual|||{{:sportster_history:l001-fsm-2019_edition_cover_94000546_for_2019.jpg?linkonly|Outside Cover}}|
|94000553|:::|Original electrical diagnostic manual|||{{:sportster_history:l005-edm-2019_edition_cover_94000553_for_2019.jpg?linkonly|Outside Cover}}|
|94000739|2020|Complete service manual|||{{ :sportster_history:l001-fsm-2020_edition_cover_94000739_for_2020.jpg?linkonly |Outside Cover}}|
|94000733|:::|Original electrical diagnostic manual|||{{:sportster_history:l005-edm-2020_edition_cover_94000733_for_2020.jpg?linkonly|Outside Cover}}|
====== 1959-1969 FSM Section Dividers ======
From 1959 to the sometime in the 1970s, FSMs were compiled of loose leaf pages. \\
From 1959-1969, the different sections in the manuals were separated by card stock dividers. \\
Below are pics of the different dividers known to date. \\
{{:sportster_history:l001-fsm-divider00-dealer_page_needed.jpg?nolink&200|}} \\
{{:sportster_history:l001-fsm-divider01a-product.jpg?direct&200|}} {{:sportster_history:l001-fsm-divider01b-product.jpg?direct&200|}} {{sportster_history:l001-fsm-divider02a-chassis.jpg?direct&200|}} {{sportster_history:l001-fsm-divider02b-chassis.jpg?direct&200|}} \\
{{:sportster_history:l001-fsm-divider03a-engine.jpg?direct&200|}} {{:sportster_history:l001-fsm-divider03b-engine.jpg?direct&200|}} {{:sportster_history:l001-fsm-divider04a-transmission.jpg?direct&200|}} {{:sportster_history:l001-fsm-divider04b-transmission.jpg?direct&200|}} \\
{{:sportster_history:l001-fsm-divider05a-electrical.jpg?direct&200|}} {{:sportster_history:l001-fsm-divider05b-electrical.jpg?direct&200|}} {{:sportster_history:l001-fsm-divider06a-miscellaneous.jpg?direct&200|}} {{:sportster_history:l001-fsm-divider06b-miscellaneous.jpg?direct&200|}} \\
====== Known Errors in Service Manuals ======
Note: There are a lot more errors than listed below in service manuals over the years. More will be added when found. \\
^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&800|}}|||
|**Year Model FSM / Other**|**Page No.(s)**|**Error Noted**|
|1959-1985 FSMs|Various|Rocker arm acorn nut torque missing or incorrect \\ 1959-1969 FSM only says "securely tighten" \\ 1070-1978 FSM says "securely tighten to 60-65 ft/lbs \\ 1979-1985 FSM says "tighten to 8-16 ft/lbs" |
| **Correction**|In TSB M-813 dated January 30, 1981, is stated as follows; \\ "It has been brought to our attention that the torque value, given in the XL Service Manual, \\ for the rocker arm acorn nuts is incorrect. The correct torque value should be 15-20 ft-lbs"||
|1986 FSM|3-10|(1) @ 3500 rpm, oil pressure will vary from 5-30 psi.|
|:::|6-30|Countershaft end play thrust washer chart, 2nd entry says; \\ "if end play is 0.082"-0.086", use 2 shims"|
| **Correction**|(1) Stated rpm was corrected in future FSMs: @ 2500 rpm, oil pressure will vary from 5-30 psi. ((86-88 HD FSM pg 3-10)) \\ (2) This was corrected to 1 shim in TSB M-915 dated November 5, 1985||
|1991 FSM|2-1|(1) Shows 1.5 pints of oil for the primary / transmission.|
|:::|7-18|(2) Figure 7-14 shows the induction probe clamped around all three wires \\ within the conduit connected to the voltage regulator.|
|:::|3-47|Figure 3-56 shows either "T" or "C" cams. A sticker was included with the \\ manual to place over that text to read "D" cams instead.|
| **Correction**|(1) This was corrected in the 1991-1992 FSM showing 40 oz for both years. ((1991-1992 HD Sportster FSM pg 2-1)) \\ Read more on [[techtalk:ref:oil02#transmission_primary_oil_capacities|Transmission / Primary Oil]] in the Sportsterpedia \\ (2) TSB M-1000, dated October 5, 1990, correction: \\ Induction probe should be clamped around the output wire (dc current), main circuit breaker only. \\ The two wires to the alternator stator (a.c. current) are not a part of this test.||
|Some 1997 FSMs|7-61 \\ 7-63|Chart 1: Turn Signal Troubleshooting Section (Chart 1) has an incomplete box. \\ Turn Signal Troubleshooting Section Chart 3: Three boxes are missing.|
| **Correction**|Chart 1: The lower right hand box reading “See Chart 2” should read; \\ “See Chart 2 of Speedometer Troubleshooting”. \\ Delete diagnostic Note 1 in Chart 1 of Turn Signal Troubleshooting from the XL manual. \\ Chart 3: The boxes were filled in on the service bulletin. \\ See TSB M-1064 dated January 24, 1997 for corrections to the charts.||
|2001 XL \\ Electrical Diagnostic Manual|4-51, 4-54|Has a connector wire location error. ((HD Tech Tip #54 dated June 2001))|
| **Correction**|In connector 10, pin #4 should be Pink and pin #5 should be LtGn/Gy. \\ Please make note of these changes. \\ (on the wiring diagram on page 4-51 and to the three diagnostic boxes on page 4-54)||
|2004 FSM|6.10|(1) Greasing mainshaft / bearings before assembly left off the assm insts.|
|:::|2-66, 2-67|(2) Fork Stem Lower Bearing–Procedural Change|
|:::|1-51|(3) Under BRAKE COMPONENT GREASE reads: \\ "use G40M to lubricate brake system components"|
|:::|brake \\ section|Several more corrections for lube and installation (see TSB M-1178)|
| **Correction**|(1) See TSB M-1158 dated July 20, 2004 and Tech Tip #58 portion dated 5-24-2004 \\ (2) Step 4a under CLEANING, INSPECTION AND REPAIR should read: The lower bearing cone \\ is no longer a press fit on the fork stem. Remove lower bearing cone by sliding it up and off fork \\ stem. If necessary, gently pry bearing cone off fork stem with a pair of flat blade screw drivers. \\ Remove lower dust shield. \\ Correct step 7 page 2-66 under ASSEMBLY to read: Pour 11.6 fl oz. (342 ml) of type “E” \\ hydraulic fork oil into top end of slider tube. Install slider tube cap with O-ring. \\ Tighten to 22-58 ft-lbs (29.9-78.7Nm). ((TSB M-1158 dated July 20, 2004)) \\ (3) Use only CCI #20 BRAKE GREASE to lubricate master cylinder bores, \\ pistons, and primary and secondary cups. Use only G40M BRAKE GREASE \\ to lubricate all other brake system components.” ((TSB M-1178 dated October 19, 2005))||
|2004 \\ Electrical Diagnostic Manual|4-1|(1) The spark timing advance is wrong on the first table on the page \\ (under SPECIFICATIONS)|
|:::|1-19|(2) Wrong info in step 3 under Current and Voltage Output Test|
| **Correction**| (1) The data entry should read “0°-58° BTDC (range), 10° BTDC @ 1000 RPM”. \\ (2) Current output should be 19-23 amps. \\ Make note of measurement for Total Current Draw Test.||
|2005 FSM|brake \\ section|Several corrections for lube and installation|
| **Correction**|See TSB M-1178 for specific information.||
|2006 FSM|brake \\ section|(1) Several corrections for lube and installation. \\ (2) Wrong steering stem bolt, rear fender ICM lock nut, oil tank ICM \\ lock nut, engine sprocket nut torque specs. Main drive gear needle \\ bearing spec needs changing, plus minor turns and handlebar switch wordings. \\ Errors in transmission gear ratio chart.|
| **Correction**|(1) See TSB M-1178 for specific information. \\ (2) See TSB M-1181 for corrections.||
|2006 \\ Electrical Diagnostic Manual|Various|TSSM Key Fob Assignment, TSSM Alarm Sensitivity and function wording|
| **Corrections**|See TSB M-1181 for corrections||
|2007 \\ Electrical Diagnostic Manual|Varios|Updates and corrections needed.|
| **Corrections**|See TSB M-1206 for corrections.||
|2008 FSM|Various|Rear sprocket mounting screw torque procedure.|
| **Correction**|Under 2.3 WHEELS in the ASSEMBLY instructions, correct step 3, item b to read: \\ “Initially tighten screws to 60 ft-lbs (81.3 Nm). Back off screws and retighten to 80 ft-lbs (108.5 Nm).” \\ In Table 1-19, correct Final drive / Rear sprocket mounting screws torque to read: \\ “60 ft-lbs, loosen, 80 ftlbs / 81.3 Nm, loosen, 108.5 Nm”. ((TSB M-1219 dated April 15, 2008))||
|2008-2014|Various|Primary cover screws torque spec is incorrect. \\ These threads have stripped at 90 in/lbs for some. \\ 2008 manual gave two values (40-60 in/lbs) and (84-120 in/lbs), \\ whereas the 2013 manual has (90-120 in-lbs) and (100-120 in-lbs). ((Folkie of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/166131-primary-chain-inspection-cover-threads-broke/page2?t=1784304&page=2))|
| **Correction**|Torque should be 40-60 in/lbs (4.6-6.8 Nm) as in the Owners Manuals ((Screw Loose Dan of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/82072-2008-2014-owners-please-read-mistake-in-fsm-primary-chain-inspection-cover-screws?t=607355))||
|2014 FSM|4-1, 4-26|(1) Exhaust Flange Nut Torque **96-120 ft.-lbs.** (10.8-13.6 Nm)|
|:::|2-1|(2) Fork Oil Change–Specs and Procedural Changes|
| **Correction** |(1) Torque should be **96-120 in-lbs.** (10.8-13.6 Nm) ((jzink0883 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/193865-wrong-torque-spec-%C2%9114-fsm#post5680197)) \\ (2) See TSB M-1158 for corrections to Table 2-3 Capacities||
|2016 FSM version -16A|Approx 2-76|Section titled Front Forks is missing Fork Draining Procedure|
| **Correction** |See -16 & -17 FSM. Follow removal procedure carefully, then turn upside down over pan & pump fork to expel oil ((IXL2Relax https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/204611-2017-roadster-fork-oil-change?t=2082019))||
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[[:techtalk:menu|{{:techtalk:gototechnicalmenu.jpg?direct&}}]]
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