Table of Contents
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MiscRes: FSMs
Factory Service Manual (FSM) for Sportsters
AKA Field Service Manual 1)
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.
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 2 EDMs.
These manuals are important for diagnosing all the electrical doo-dads on 200-up models.
On dissasembly / 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.
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.
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. 2)
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.
Aftermarket manuals tend to have more pictures and cheaper tool recommendations
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. 3)
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. 4) 5) 6) 7)
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. 8)
- Master service manuals were divided into seven different informational sections including: 9)
- 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.
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| 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 10) |
| 99480-60 | 1959-1960 | All Models | Yes | X | $18.00 11) |
| 99481-60 | 1960 | Supplement to 1959 FSM, all models | No | 99480-59 | $10.00 12) |
| 1961 service manuals were not published. See service bulletin #456 | |||||
| 99480-62 | 1959-1962 | All models | Yes | X | $21.00 13) |
| 99481-62 | 1962 | Supplement to 1960 FSM, all models | No | 99480-60 | $10.00 14) |
| 99480-63 | 1959-1963 | All models | Yes | X | $21.00 15) |
| 99481-63 | 1963 | Supplement to 1962 FSM, all models | No | 99480-62 | $6.00 16) |
| 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 17) |
| 99481-65 | 1965 | Supplement to 1964 FSM, all models | No | 99480-64 | $8.00 18) |
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 and could be updated with new model year supplements or a new full manual could be purchased.
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|---|---|---|---|---|---|
| Factory Individual Model Service Manuals for Sportsters | |||||
| Catalog # | Year Span | Dealer Price | List Price | Notes | Pics of Covers |
| 99484-59 | 1957-1959 | $4.00 | $5.00 | Complete loose leaf manual | Outside Cover Inside Cover |
| 99484-60 | 1959-1960 | $4.00 | $5.00 | Complete loose leaf manual | Outside Cover Inside Cover |
| 99485-60 | 1960 | $1.50 | $2.00 | Loose leaf supplement set Updates manual (99484-59) | |
| 1961 service manuals were not published. See service bulletin #456 | |||||
| 99484-62 | 1959-1962 | $4.00 | $5.00 | Complete loose leaf manual | Outside Cover Inside Cover |
| 99485-62 | 1962 | $1.00 | $1.50 | Loose leaf supplement set Updates manual (99484-60) | |
| 99484-63 | 1959-1963 | $4.00 | $5.00 | Complete loose leaf manual | Outside Cover Inside Cover |
| 99485-63 | 1963 | $0.75 | $1.00 | Loose leaf supplement set Updates manual (99484-62) | |
| 99480-64 | 1959-1964 | ? | ? | Complete loose leaf manual | Outside Cover Inside Cover |
| 99485-64 | 1964 | ? | ? | Loose leaf supplement set Updates manual (99484-63) | |
| 99484-65 | 1959-1965 | $4.00 | $5.00 | Complete loose leaf manual | Outside Cover inside cover needed |
| 99485-65 | 1965 | $1.70 | $2.25 | Loose leaf supplement set Updates manual (99484-64) | |
| 99484-66 | 1959-1966 | $4.00 | $5.00 | Complete loose leaf manual | Outside Cover Inside Cover |
| 99485-66 | 1966 | $1.90 | $2.50 | Loose leaf supplement set Updates manual (99484-64) | |
| Catalog # | Year Span | Notes | |||
| 99484-67 | 1959-1967 | Complete loose leaf manual | Outside Cover Inside Cover |
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| 99484-68 | 1959-1968 | Complete loose leaf manual | Outside Cover inside cover needed |
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| 99484-69 | 1959-1969 | Complete loose leaf manual | Outside Cover Inside Cover Latest Edition Cover |
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| 99484-70 | 1970 | Complete loose leaf manual | Outside Cover | ||
| 99484-71 | 1970-1971 | Complete manual | Outside Cover | ||
| 99484-72 | 1970-1972 | Complete manual | Outside Cover | ||
| 99484-73 | 1970-1973 | Complete manual | Outside Cover | ||
| 99484-74 | 1970-1974 | Complete manual | Outside Cover | ||
| 99484-75 | 1970-1975 | Complete manual | Outside Cover | ||
| 99484-76 | 1970-1976 | Complete manual | Outside Cover | ||
| 99484-77 | 1970-1977 | Complete manual | Outside Cover | ||
| 99484-78 | 1970-1978 | Complete manual | Outside Cover | ||
| 99484-79 | 1979 | Complete manual | Outside Cover | ||
| 99484-80 | 1979-1980 | Complete manual | Outside Cover | ||
| 99484-81 | 1979-1981 | Complete manual | Outside Cover | ||
| 99484-82 | 1979-1982 | Complete manual | Outside Cover | ||
| 99484-83 | 1979-1983 | Complete manual | Outside Cover | ||
| 99484-84 | 1979-1984 | Complete manual | Outside Cover | ||
| 99484-85 | 1979-1985 | Complete manual | Outside Cover | ||
| 99484-86 | 1986 | Complete manual | Outside Cover Dealer (only) Copy |
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| 99484-87 | 1986-1987 | Complete manual | Outside Cover | ||
| 99484-88 | 1986-1988 | Complete manual | Outside Cover | ||
| 99484-89 | 1986-1989 | Complete manual | Outside Cover | ||
| 99484-90 | 1986-1990 | Complete manual | Outside Cover | ||
| 99484-91 | 1991 | Complete manual | Outside Cover | ||
| 99484-92 | 1992 | Complete manual | Outside Cover | ||
| 99484-93 | 1993 | Complete manual | Outside Cover | ||
| 99484-94 | 1994 | Complete manual | Outside Cover | ||
| 99484-95 | 1995 | Complete manual | Outside Cover | ||
| 99484-96 | 1996 | Complete manual | Outside Cover | ||
| 99484-97 | 1997 | Complete manual | Outside Cover | ||
| 99484-98 | 1998 | Complete manual | Outside Cover | ||
| 99484-99 | 1999 | Complete manual | Outside Cover | ||
| 99484-00 | 2000 | Complete manual | Outside Cover | ||
| 99484-01 | 2001 | Complete manual | Outside Cover | ||
| 99484-02 | 2002 | Complete manual | Outside Cover | ||
| 99484-03 | 2003 | Complete manual | Outside Cover | ||
| 99484-04 | 2004 | Complete manual | Outside Cover | ||
| 99484-05 | 2005 | Complete manual | 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.
Known Errors in Service Manuals
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|---|---|---|
| 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” |
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| 1986 FSM | 3-10 | @ 3500 rpm, oil pressure will vary from 5-30 psi. |
| Correction | The rpm stated was corrected in future FSMs: @ 2500 rpm, oil pressure will vary from 5-30 psi. 19) | |
| 1986 FSM | 6-30 | Countershaft end play thrust washer chart, 2nd entry says; “if end play is 0.082”-0.086”, use 2 shims“ |
| Correction | This was corrected to 1 shim in TSB M-915 dated November 5, 1985 | |
| 1991 FSM | 2-1 | Shows 1.5 pints of oil for the primary / transmission. |
| Correction | This was corrected in the 1991-1992 FSM showing 40 oz for both years. 20) Read more on Transmission / Primary Oil in the Sportsterpedia |
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| 1991 FSM | 7-18 | Figure 7-14 shows the induction probe clamped around all three wires within the conduit connected to the voltage regulator. |
| Correction | 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. |
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| 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”. Diagnostic Note 1 in Chart 1 of Turn Signal Troubleshooting should be deleted 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. |
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| 2001 XL Electrical Diagnostic Manual | 4-51 and 4-54 | Has a connector wire location error. 21) |
| 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) |
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| 2004 FSM | 6.10 | (1) Greasing mainshaft / bearings before assembly left off the assm instructions. |
| 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” |
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| 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). 22) (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.” 23) |
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| 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. |
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| 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) 24) (2) See TSB M-1158 for corrections to Table 2-3 Capacities |
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