Service Manual - Indian Motorcycle Full-Size (2014-2016)

2014-16 Indian Motorcycle (Full-Size)
Service Manual
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most
recent version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Indian Motorcycle Master Service Dealer®
technicians in a properly equipped shop and should be kept available for reference. All references to left and
right side of the vehicle are from the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar
with the service procedures before starting any repair. Certain procedures require the use of special tools. Use
only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures
outlined in this Service Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more
useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit
feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature
Question'.
Publication Printed April 2016 (PN 9925933 R10)

© Copyright 2016 All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information
presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or
inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
SAFETY WARNINGS
The following signal words and symbols appear throughout this manual and on the vehicle. Your safety is involved
when these words and symbols are used. Become familiar with their meanings before reading the manual.
DANGER
DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.
WARNING
SAFETY ALERT WARNING indicates a hazardous situation which, if not avoided, COULD result in death or serious
injury.
CAUTION
SAFETY ALERT CAUTION indicates a hazardous situation which, if not avoided, COULD result in minor to
moderate injury.
NOTICE
NOTICE provides key information by clarifying instructions.
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.
TRADEMARKS
INDIAN MOTORCYCLE ACKNOWLEDGES THE FOLLOWING PRODUCTS THAT MAY BE MENTIONED IN THIS
MANUAL:
LOCTITE®, is a registered trademark of the Henkel Corporation.
DUNLOP®, is a registered trademark of the Dunlop Tire Corporation.
STA-BIL®, is a registered trademark of Gold Eagle.
NYOGEL™, is a trademark of Gold Eagle.
FLUKE ®, is registered trademark of the Fluke Corporation.
XM®, is a registered trademark of XM® Satellite Radio, Inc.
Torx®, is a registered Trademark of Textron.
Garmin®, is a registered trademark of Garmin, Ltd.
Some Indian Motorcycle factory publications can be downloaded from www. polarisindustries. com, purchased
from www.purepolaris.com or by contacting the nearest Indian Motorcycle dealer.
REVISION INDEX
REV DATE CHANGES
R01 7/22/2015 Initial release
R02 — —
R03 — —
R04 3/10/2016 Add Springfield content
R05 4/18/2016 Add Chieftain Darkhorse model info.
R06 06/08/2016 Add Engine Misfire Detection
• Added maintenance interval for gear position switch inspection /

cleaning
• Added gear position switch cleaning and replacement procedure topic
in the Electrical Chapter
Updated Fuel Line connection instructions in:

• Fuel System Depressurization
R07 9/10/2019 • Fuel Tank Removal and Installation
• Fuel Pump Removal and Installation
• Priming the Fuel System
Updated Oil Level Check and Oil Change procedures in:
• Engine Oil Level
• Engine Oil & Filter Change
• Update torque value of exhaust clamps

R08 1/9/2020
• Update torque value of cylinder head nuts
Connecting Rod Torque value from bulletin I-18-06

R09 12/18/2020 Connecting Rod Installation Topic Updated
R10 6/16/2022 Updated gear position switch testing values from bulletin I-20-03
FEEDBACK FORM
A feedback form has been created for the technician or consumer to provide
Indian Motorcycle with an overall satisfaction rating for this service manual,
provide comments on your experience or upload pictures/video. This feedback
form is viewable on a mobile device by scanning the QR code or by clicking
HERE if viewing this document electronically.
2014-16 Indian Motorcycle (Full-Size)
Service Manual
Chapter Summary
CHAPTER 1 : GENERAL / SPECIFICATIONS

CHAPTER 2 : MAINTENANCE
CHAPTER 3 : FRAME / BODY
CHAPTER 4 : LUBRICATION / COOLING
CHAPTER 5 : FUEL SYSTEM / EXHAUST
CHAPTER 6 : ENGINE REMOVAL / INSTALL
CHAPTER 7 : CYLINDER HEAD / VALVES
CHAPTER 8 : CYLINDER / PISTON
CHAPTER 9 : CLUTCH / PRIMARY / SHIFT
CHAPTER 10 : TRANSMISSION / CRANKSHAFT
CHAPTER 11 : FRONT WHEEL / SUSPENSION
CHAPTER 12 : REAR WHEEL / SUSPENSION
CHAPTER 13 : TIRES
CHAPTER 14 : BRAKES
CHAPTER 15 : STARTING / CHARGING
CHAPTER 16 : IGNITION SYSTEM
CHAPTER 17 : CHASSIS ELECTRICAL
GENERAL / SPECIFICATIONS
1
CHAPTER 1
VEHICLE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN/PIN LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MANUFACTURER LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
TIRE INFORMATION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2016 INDIAN SPRINGFIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2016 INDIAN DARK HORSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
2014 - 2016 INDIAN CHIEF CLASSIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12
2014 - 2016 INDIAN CHIEF VINTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.16
2014 - 2016 CHIEFTAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20
2015 - 2016 INDIAN ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24
VEHICLE LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.28
GROSS VEHICLE WEIGHT RATING (GVWR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.28
PUBLICATIONS & TECHNICAL LITERATURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.29
PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.29
REFINISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.30
PAINT COLORS BY MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.30
EMISSIONS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.35
EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.35
EMISSION SOURCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.35
EXHAUST EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.35
NOISE EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.35
CRANKCASE EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.35
EVAPORATIVE EMISSION CONTROL (CALIFORNIA AND INTERNATIONAL MODELS) . . . . . . . . . . . . . . .1.35
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.36
USING SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.36
TOOL ORDERING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.36
SPECIAL TOOLS INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.37
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.41
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.41
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.41
DECIMAL EQUIVALENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.42
FAHRENHEIT TO CELSIUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.43
MEASUREMENT CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.43
9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

© Copyright 1.1
V E H I C L E I N F O R M AT I O N
M O D E L N U M B E R D E S I G N AT I O N
Example: N16CCDAAAH
GRP MY TYPE MODEL LINE DISP NET BRAKE HP MARKET CONFIG COLOR
1st digit 2nd/ 4th digit* 5th digit* 6th digit* 7th digit* 8th digit 9th digit** 10th digit
3rd
digit
N= 14 = C= Cruiser C = Chief A = Standard A = 1811cc A = Full-size, A = 49 State A = Thunder Black

Indian 2014 M = Midsize C= Chieftain ABS (111ci) V-Twin Chief / Chieftain B = 50 State B = Springfield Blue
Motor- 15 = T = Touring H = Springfield B = Standard O = 1133cc O = Mid-size, C = Canadian C = Ivory Cream
cycle 2015 R = Roadmaster Non-ABS (69ci) V-Twin Scout E = EU (WVTA) D = Indian Red /
16 = S = Scout C = Classic ABS J = Japan (SVA) Thunder Black
2016 D = Dark Horse E = Indian Red /
ABS Cream
V = Vintage F = Springfield Blue
ABS / Cream
G = Willow Green /
Cream
H = Black Smoke
R = Indian Red
S = Black Hills
Silver
T = Vogue Silver w/
Blk Graphic
V = Matte Sunset
Red / Matte Black
* = digits that would transfer to 17 digit VIN and are used in digits 4–8 respectively.
** = 9th digit will be used on color / featured versions of models (not including base).
First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN.
E N G I N E N U M B E R L O C AT I O N V E H I C L E I D E N T I F I C AT I O N N U M B E R ( V I N )
The engine number q is stamped into the bottom of D E S I G N AT I O N
the RH engine case.. The stamping identifies the Example: 56KTCAAA0E3000024
engine model and serial number.
Vehicle Descriptors Vehicle Identifiers

World Mfg. ID
Chas- Check
Type Disp HP Series MY* Mfg Individual Serial No.
sis Digit
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
5 6 K C C A A A 0 E 3 0 0 0 0 0 0
* Model Year: E = 2014; F = 2015; G = 2016

1.2 © Copyright
V I N / P I N L O C AT I O N
The VIN/PIN number q is stamped on the right side of
the steering head.
1
M A N U FA C T U R E R L A B E L
The manufacturer label q located on the left side of
the steering head contains the following information:
Vehicle Identification Number / Product Identification
Number (VIN/PIN)
Gross Vehicle Weight Rating (GVWR)
Gross Axle Weight Rating (GAWR)
Tire Type and Load Information.
T I R E I N F O R M AT I O N L A B E L
See Manufacturer Label page 1.3 for tire information.

© Copyright 1.3
G E N E R A L S P E C I F I C AT I O N S
2016 INDIAN SPRINGFIELD
MODEL NUMBERS
2016
N16THAAAAA
N16THAAAAR
N16THAAAAT
N16THAAAAV
N16THAAABA
N16THAAABR
N16THAAABT
N16THAAABV
N16THAAACA
N16THAAACR
N16THAAACT
N16THAAACV
N16THAAAEA
N16THAAAER
N16THAAAET
N16THAAAEV
CHASSIS
CATEGORY SPECIFICATION
Dry Weight 818 lbs (371 kg)
Wet Weight 852 lbs (387 kg)
Gross Vehicle Weight Rating 1385 lbs (628 kg)
Gross Axle Weight Rating, Front 500 lbs (227 kg)
Gross Axle Weight Rating, Rear 885 lbs (402 kg)
Maximum Load 533 lbs (242 kg)
Overall Length 101.7 in (2583 mm)
Overall Width 39.4 in (1000 mm)
Overall Height 56.8 in (1443 mm)
Seat Height 26.0 in (660 mm)
Ground Clearance 5.6 in (142 mm)
Total Storage Capacity 22 lbs (10.0 kg)
Passenger Capacity 1

1.4 © Copyright
Wheelbase 67 in (1702 mm) 1
Rake / Trail 25° / 5.2 in (132.0 mm)
ENGINE
Engine Number 1205102
Engine Type Thunder Stroke 111 V-Twin
Engine Configuration 49° OHV Pushrod V-Twin
Engine Wet Weight 297 lbs (134.7 kg)
Engine Displacement 111 cid (1811 cc)
Engine Cooling System Air / Oil
Compression Ratio 9.5:1
Compression Pressure 90–110 psi (620–758 kPa)
Valve Train 2 Valves per cylinder / Hydraulic Lifters
Bore x Stroke 101 mm x 113 mm
Idle Speed / Fast Idle Spd 800 RPM ± 50 RPM (warm)
Oil Capacity 5.5 qts (5.2 L)
Oil Type SAE 20W40 (recommended)
Lubrication System Semi-Dry Sump
Spark Plug Type / Gap DCPR8E / 0.034 in (0.9 mm)
Exhaust System Two O2 Sensors (one in each pipe) / Single three-way catalyst
FUEL SYSTEM
Fuel System Type Electronic Fuel Injection (ME17)
Fuel Delivery Electronic Fuel Pump (in tank)
Fuel Pressure 58 psi (400 kPa)
Throttle Body Bore Size 2.125 in (54 mm)
Fuel Capacity 5.5 gal (20.8 L)
Fuel Reserve Capacity 1.0 gal (3.8 L)
Fuel Type 91 Octane (recommended)

© Copyright 1.5
ELECTRICAL
Stator Rated Output 710W @ 2000 RPM
Battery 12V / 18 AH / 310 CCA, Sealed Glass Mat
Headlights H4 12V 60/55W Long Life
Auxiliary Lights H8 35W
Tail / Brake LED (non-serviceable)
Turn Signals LED (non-serviceable)
Starting System Electric Start
Ignition System Bosch ME-17 (ECM Controlled)
Instrument Type Multifunction Instrument Cluster
DC Outlet Standard 12V
DRIVETRAIN
Transmission Type 6 Speed Overdrive, Constant Mesh
Clutch Type Wet, Multi-Plate, Coil Spring
Primary Drive Type Wet, Gear Drive w/Torque Compensator
Primary Reduction Ratio 1.56:1
Final Drive Type / Ratio Belt / 2.2:1
Belt Type / Belt Width 24 mm Carbon Fiber Reinforced Belt
Gear Shift Pattern 1 Down, 5 Up
Transmission Gear Ratios:
1st 2.73:1
2nd 1.86:1
3rd 1.38:1
4th 1.10:1
5th .94:1
6th .81:1

1.6 © Copyright
SUSPENSION
CATEGORY SPECIFICATION 1
Front Suspension Type Conventional Telescopic Fork
Front Travel 4.7 in (11.9 cm)
Front Tube Diameter 46 mm
Rear Shock Type Single, Monotube Air Adjustable Shock
Rear Swingarm Type Cast Aluminum
Rear Travel 4.5 in (11.4 cm)
WHEELS / BRAKES
Front Tire Type / Size Dunlop Elite 3– 130/90B16
Front Wheel Type / Size Cast / 16 in X 3.5 in
Front Tire Air Pressure 46 PSI (317 kPa)
Front Brake, Type Dual Floating Disc / 4 Piston Calipers
Rear Tire Dunlop Elite 3 – 180/60R16
Rear Wheel Cast / 16 in X 5 in
Rear Tire Air Pressure 41 PSI (282 kPa)
Rear Brake, Type Single Floating Disc / 2 Piston Caliper
Brake Fluid Type DOT 4
All specifications are for standard Indian Springfield models. Specifications may change with the addition of
custom order options and / or accessories. Indian Motorcycle Company reserves the right without prior notice to
discontinue at any time at its discretion any of the items herein or change specifications or designs without
incurring any obligation to the customer.

© Copyright 1.7
2016 INDIAN DARK HORSE

MODEL NUMBERS
2016
N16CCDAAAH
N16CCDAABH
N16CCDAACH
N16CCDAAEH
CHASSIS
Gross Axle Weight Rating, Front 485 lbs (220kg)
Total Storage Volume NA
Wheelbase 68.1 in (1730 mm)
Rake / Trail 29° / 6.1 in (155.0 mm)

1.8 © Copyright
ENGINE
Engine Type Thunder Stroke 111
Exhaust System Two O2 Sensors (one in each pipe) / Single three-way
catalyst
FUEL SYSTEM

© Copyright 1.9
ELECTRICAL
DC Outlet Standard 12V (Accessory)
DRIVETRAIN
1st 2.73:1
2nd 1.86:1
3rd 1.38:1
4th 1.10:1
5th .94:1
6th .81:1

1.10 © Copyright
SUSPENSION
Rear Shock Type Single, Monotube Gas with Adjustable Preload
WHEELS / BRAKES
Rear Tire Dunlop American Elite – 180/65B16
All specifications are for standard Indian Dark Horse models. Specifications may change with the addition of

© Copyright 1.11
2014 - 2016 INDIAN CHIEF CLASSIC

MODEL NUMBERS
2014 2015 2016
N14CCCAAAA N15CCCAAAD N16CCCAAAK
N14CCCAAAB N15CCCAAAR N16CCCAABK
N14CCCAAAC N15CCCAABD N16CCCAACK
N14CCCAAAE N15CCCAABR N16CCCAAEK
N14CCCAABA N15CCCAACD
N14CCCAABB N15CCCAACR
N14CCCAABC N15CCCAAED
N14CCCAABE
N14CCCAARA
N14CCCAARB
N14CCCAARC
N14CCCAARE
CHASSIS
Rake / Trail 29° / 6.1 in (155.0 mm)

1.12 © Copyright
ENGINE
catalyst
FUEL SYSTEM

© Copyright 1.13
ELECTRICAL
DRIVETRAIN
1st 2.73:1
2nd 1.86:1
3rd 1.38:1
4th 1.10:1
5th .94:1
6th .81:1

1.14 © Copyright
SUSPENSION
WHEELS / BRAKES
Front Tire Type / Size Dunlop Elite 3 – 130/90B16
Front Wheel Type / Size Cast - 16 in X 3.5 in
Rear Wheel Cast - 16 in X 5 in
All specifications are for standard Indian Chief Classic models. Specifications may change with the addition of

© Copyright 1.15
2 0 1 4 - 2 0 1 6 I N D I A N C H I E F V I N TA G E
MODEL NUMBERS
2014 2015 2016
N14CCVAAAA N15CCVAAAA N16CCVAAAA
N14CCVAAAB N15CCVAAAD N16CCVAABA
N14CCVAAAC N15CCVAAAE N16CCVAACA
N14CCVAAAE N15CCVAAAG N16CCVAAEA
N14CCVAABA N15CCVAAAR N16CCVAAAR
N14CCVAABB N15CCVAABD N16CCVAABR
N14CCVAABC N15CCVAABE N16CCVAACR
N14CCVAABE N15CCVAABG N16CCVAAER
N14CCVAARA N15CCVAABR N16CCVAAAT
N14CCVAARB N15CCVAACA N16CCVAABT
N14CCVAARC N15CCVAACD N16CCVAACT
N14CCVAARE N15CCVAACE N16CCVAAET
N15CCVAACG N16CCVAAAG
N15CCVAACR N16CCVAABG
N15CCVAAEE N16CCVAACG
N15CCVAAEG N16CCVAAEG
CHASSIS
Rake / Trail 29° / 6.1 in (155.0 mm)

1.16 © Copyright
ENGINE
FUEL SYSTEM

© Copyright 1.17
ELECTRICAL
DRIVETRAIN
1st 2.73:1
2nd 1.86:1
3rd 1.38:1
4th 1.10:1
5th .94:1
6th .81:1

1.18 © Copyright
SUSPENSION
WHEELS / BRAKES
Front Tire Type / Size Dunlop American Elite – 130/90B16
Front Wheel Type / Size Spoked / 16 in X 3.5 in
Rear Wheel Spoked / 16 in X 5 in
All specifications are for standard Indian Chief Vintage models. Specifications may change with the addition of

© Copyright 1.19
2 0 1 4 - 2 0 1 6 C H I E F TA I N
MODEL NUMBERS
2014 2015 2016
N14TCAAAAA N15TCAAAAA N16TCAAAAA
N14TCAAAAB N15TCAAAAD N16TCAAABA
N14TCAAAAC N15TCAAAAE N16TCAAACA
N14TCAAAAE N15TCAAAAF N16TCAAAEA
N14TCAAABA N15TCAAAAR N16TCAAAAR
N14TCAAABC N15TCAAABA N16TCAAABR
N14TCAAABB N15TCAAABD N16TCAAACR
N14TCAAABE N15TCAAABE N16TCAAAER
N14TCAAARA N15TCAAABF N16TCAAAAT
N14TCAAARC N15TCAAABR N16TCAAABT
N14TCAAARB N15TCAAACA N16TCAAACT
N14TCAAARE N15TCAAACD N16TCAAAET
N15TCAAACE N16TCDAAAH
N15TCAAACF N16TCDAABH
N15TCAAACR N16TCDAACH
N15TCAAAEA N16TCAAAEH
N15TCAAAEF
CHASSIS
Rake / Trail 25° / 5.9 in (150.0 mm)

1.20 © Copyright
ENGINE
Engine Type Thunder Stroke 111 V-Twin
FUEL SYSTEM

© Copyright 1.21
ELECTRICAL
DRIVETRAIN
1st 2.73:1
2nd 1.86:1
3rd 1.38:1
4th 1.10:1
5th .94:1
6th .81:1

1.22 © Copyright
SUSPENSION
Rear Shock Type Single, Monotube Air Adjustable Shock
WHEELS / BRAKES
Rear Tire Dunlop Elite 3– 180/60R16
All specifications are for standard Indian Chieftain models. Specifications may change with the addition of custom
order options and / or accessories. Indian Motorcycle Company reserves the right without prior notice to

© Copyright 1.23
2015 - 2016 INDIAN ROADMASTER

MODEL NUMBERS
2015 2016
N15TRAAAAA N16TRAAAAA
N15TRAAAAB N16TRAAABA
N15TRAAAAD N16TRAAACA
N15TRAAAAE N16TRAAAEA
N15TRAAAAF N16TRAAAAC
N15TRAAAAR N16TRAAABC
N15TRAAABA N16TRAAACC
N15TRAAABB N16TRAAAEC
N15TRAAABD N16TRAAAAE
N15TRAAABE N16TRAAABE
N15TRAAABF N16TRAAACE
N15TRAAABR N16TRAAAEE
N15TRAAACA N16TRAAAAX
N15TRAAACE N16TRAAABX
N15TRAAACR N16TRAAACX
N15TRAAAEA N16TRAAAEX
N15TRAAAEE N16TRAAAAF
N15TRAAAER N16TRAAABF
N16TRAAACF
N16TRAAAEF
CHASSIS
Seat Height 26.5 in (673.1 mm)
Rake / Trail 29° / 5.9 in (150.0 mm)

1.24 © Copyright
ENGINE
catalyst
FUEL SYSTEM

© Copyright 1.25
ELECTRICAL
DRIVETRAIN
1st 2.73:1
2nd 1.86:1
3rd 1.38:1
4th 1.10:1
5th .94:1
6th .81:1

1.26 © Copyright
SUSPENSION
WHEELS / BRAKES
Rear Tire Dunlop Elite 3– 180/60R16
All specifications are for standard Indian Roadmaster models. Specifications may change with the addition of

© Copyright 1.27
VEHICLE LOADING
G R O S S V E H I C L E W E I G H T R AT I N G ( G V W R )
WARNING
Exceeding the gross vehicle weight rating of your
motorcycle can reduce stability and handling and
could cause loss of control. NEVER exceed the gross
vehicle weight rating of your motorcycle.
The maximum load capacity of your motorcycle is the

maximum weight you may add to your motorcycle
without exceeding the GVWR. This capacity is
determined by calculating the difference between
your motorcycle’s GVWR and wet weight.
Refer to the specification section of this manual or the
Manufacturing Information / VIN/PIN label on the
motorcycle frame for model-specific information.
Refer to Information label section in this manual for
location on the motorcycle.
When determining the weight you will be adding to
your motorcycle, to ensure you do not exceed the
maximum load capacity, include the following:
• operator body weight

• passenger body weight
• weight of all riders’ apparel and items in or on
apparel
• weight of any accessories and their contents
• weight of any additional cargo on the motorcycle

1.28 © Copyright
P U B L I C AT I O N S & T E C H N I C A L L I T E R AT U R E
P U B L I C AT I O N PA R T N U M B E R S 1
Some Indian Motorcycle publications, such as Owner’s Manuals and Parts Books may be available on-line at the
Indian Motorcycle website; http://www.indianmotorcycle.com/
Service Manuals and Owner’s Manuals can be purchased through any authorized Indian motorcycle dealer. The
part numbers are listed in the following table.
MODEL YEAR / SERVICE MANUAL OWNER’S MANUAL PARTS BOOK

MODEL
MARKET PART NUMBERS PART NUMBERS PART NUMBERS
Classic
9925351 (2015)
Vintage
2016 Indian Motorcycle Dark Horse 9925931

9925933 (2014-2016) 9926221
(U.S.) Chieftain
9925690 (2015)
Roadmaster
Springfield 9926224
Classic
9925351 (2015)
Vintage

9925933 (2014-2016) 9926222
(CAN) Chieftain
9925690 (2015)
Roadmaster
Springfield 9926224
Classic
9925351 (2015)
Vintage

9925933 (2014-2016) 9926223
(INT’L) Chieftain
9925690 (2015)
Roadmaster
Springfield 9926224

© Copyright 1.29
REFINISHING
PA I N T C O L O R S B Y M O D E L
2014 CLASSIC 2015 CLASSIC
MODEL PAINT MODEL PAINT
PAINT COLOR PAINT COLOR
NUMBER CODE NUMBER CODE
N14CCCAAAA N15CCCAAAR
N15CCCAABR Indian Red P-639
N14CCCAAAB N15CCCAACR
Thunder Black P-266
N14CCCAAAC N15CCCAAAD
N14CCCAAAE N15CCCAABD Indian Red / P-639 /
N15CCCAACD Thunder Black P-266
N14CCCAABA N15CCCAAED
N14CCCAABB
Springfield Blue P-640
N14CCCAABC 2016 CLASSIC
N14CCCAABE MODEL PAINT

PAINT COLOR
NUMBER CODE
N14CCCAARA
N16CCCAAAK
N14CCCAARB
Indian Red P-639 N16CCCAABK
N14CCCAARC Pearl White P-566
N16CCCAACK
N14CCCAARE
N16CCCAAEK

1.30 © Copyright
2014 VINTAGE 2016 VINTAGE

MODEL
PAINT COLOR
PAINT MODEL
PAINT COLOR
PAINT 1
N14CCVAAAA N16CCVAAAA
N14CCVAAAB N16CCVAABA
Thunder Black P-266
Thunder Black P-266 N16CCVAACA
N14CCVAAAC N16CCVAAEA
N14CCVAAAE N16CCVAAAR
N14CCVAABA N16CCVAABR
Indian Red P-639
N16CCVAACR
N14CCVAABB
Springfield Blue P-640 N16CCVAAER
N14CCVAABC
N16CCVAAAG
N14CCVAABE N16CCVAABG Willow Green / P-670 /
N14CCVAARA N16CCVAACG Ivory Cream P-646
N16CCVAAEG
N14CCVAARB
Indian Red P-639 N16CCVAAAT
N14CCVAARC N16CCVAABT Star Silver P-354 /
N14CCVAARE N16CCVAACT / Thunder Black P-266
N16CCVAAET
2015 VINTAGE
MODEL PAINT
PAINT COLOR
NUMBER CODE
N15CCVAAAA
Thunder Black P-266
N15CCVAACA
N15CCVAAAR
N15CCVAABR Indian Red P-639
N15CCVAACR
N15CCVAAAD
Indian Red / P-639 /
N15CCVAABD
Thunder Black P-266
N15CCVAACD
N15CCVAAAE
N15CCVAABE Indian Red / P-639 /
N15CCVAACE Ivory Cream P-646
N15CCVAAEE
N15CCVAAAG
N15CCVAABG Willow Green / P-670 /
N15CCVAACG Ivory Cream P-646
N15CCVAAEG

© Copyright 1.31
2014 CHIEFTAIN 2016 CHIEFTAIN

N14TCAAAAA N16TCAAAAA
N16TCAAABA
N14TCAAAAB Thunder Black P-266
Thunder Black P-266 N16TCAAACA
N14TCAAAAC N16TCAAAEA
N14TCAAAAE N16TCAAAAR
N16TCAAABR
N14TCAAABA Indian Red P-639
N16TCAAACR
N14TCAAABC N16TCAAAER
Springfield Blue P-640
N14TCAAABB N16TCAAAAS
N16TCAAABS
N14TCAAABE Silver Smoke P-581
N16TCAAACS
N14TCAAARA N16TCAAAES
N14TCAAARC N16TCAAAAT
Indian Red P-639 N16TCAAABT Star Silver P-354 /
N14TCAAARB N16TCAAACT / Thunder Black P-266
N14TCAAARE N16TCAAAET
N16TCAAAEH
2015 CHIEFTAIN N16TCDAAAH
Thunder Black Smoke P-463
N16TCDAABH
MODEL PAINT N16TCDAACH
PAINT COLOR
NUMBER CODE
N15TCAAAAA
N15TCAAABA
Thunder Black P-266
N15TCAAACA
N15TCAAAEA
N15TCAAAAR
N15TCAAABR Indian Red P-639
N15TCAAACR
N15TCAAAAD
Indian Red / P-639 /
N15TCAAABD
Thunder Black P-266
N15TCAAACD
N15TCAAAAE Indian Red / P-639 /
N15TCAAABE Ivory Cream P-646
N15TCAAACE
N15TCAAAAF
N15TCAAABF Springfield Blue / P-640 /
N15TCAAACF Ivory Cream P-646
N15TCAAAEF

1.32 © Copyright
2015 ROADMASTER 2016 ROADMASTER

MODEL
PAINT COLOR
PAINT MODEL
PAINT COLOR
PAINT 1
N15TRAAAAA N16TRAAAAA
N15TRAAABA N16TRAAABA
Thunder Black P-266 Thunder Black P-266
N15TRAAACA N16TRAAACA
N15TRAAAEA N16TRAAAEA
N15TRAAAAR N16TRAAAAC
N15TRAAABR N16TRAAABC
Indian Red P-639 Diamond Blue P-447
N15TRAAACR N16TRAAACC
N15TRAAAER N16TRAAAEC
N15TRAAAAB Springfield Blue N16TRAAAAE
P-640 Indian Red /
N15TRAAABB N16TRAAABE P-639 /
N16TRAAACE Ivory Cream P-646
N15TRAAAAE
N16TRAAAEE
N15TRAAABE Indian Red / P-639 /
N15TRAAACE Ivory Cream N16TRAAAAF
P-646 Springfield Blue /
N15TRAAAEE N16TRAAABF P-640 /
N15TRAAABF N16TRAAACF Ivory Cream P-646
N16TRAAAEF
N16TRAAAAX
N16TRAAABX Steel Gray / P-692 /
N16TRAAACX Thunder Black P-666
N16TRAAAEX

© Copyright 1.33
2016 DARK HORSE 2016 SPRINGFIELD

N16CCDAAAH N16THAAAAA
N16CCDAABH N16THAAABA
Thunder Black Smoke P-463 Thunder Black P-266
N16CCDAACH N16THAAACA
N16CCDAAEH N16THAAAEA
N16THAAAAR
N16THAAABR
Indian Red P-639
N16THAAACR
N16THAAAER
N16THAAAAV
N16THAAABV Sunset Red Smoke &
P-669
N16THAAACV Thunder Black Smoke
N16THAAAEV
N16THAAAAT
N16THAAABT Star Silver & Thunder
P-354
N16THAAACT Black Two Tone
N16THAAAET

1.34 © Copyright
E M I S S I O N S I N F O R M AT I O N
EMISSION CONTROL SYSTEMS 6. Replacing any moving part of the motorcycle or 1
The U.S. Environmental Protection Agency and parts of the exhaust / intake system with parts
California Air Resources Board (CARB) require other than those specified by the manufacturer.
manufacturers to certify that their motorcycles comply
with applicable exhaust emissions standards during
their useful life, and that motorcycles built after CRANKCASE EMISSION CONTROL
January 1, 1983 comply with applicable noise emission The crankcase emission control system is comprised
standards for one year or 6,000 km (3,730 mi) after the of a closed system that routes crankcase emissions
time of sale to the ultimate purchaser, when operated through the air cleaner into the combustion chamber.
and maintained according to the instructions
provided.
E VA P O R AT I V E E M I S S I O N C O N T R O L
( C A L I F O R N I A A N D I N T E R N AT I O N A L
EMISSION SOURCES MODELS)
An internal combustion engine produces carbon California and International models are equipped with
monoxide and hydrocarbons during operation. an Evaporative Emissions Canister q. Activated
Hydrocarbons must be controlled because under charcoal inside the canister temporarily stores fuel
some conditions hydrocarbons react with sunlight to system vapors until the engine is started and the
produce photochemical smog. Carbon monoxide must motorcycle is driven. The Electronic Control Module
be controlled because it is toxic. (ECM) automatically opens a Purge Control Valve
under certain conditions, and engine intake vacuum
draws vapors out of the canister.
EXHAUST EMISSION CONTROL
Indian Motorcycles have an electronic engine
management system which controls fuel delivery and
ignition timing to control hydrocarbon and carbon
monoxide emissions. If components are replaced that
affect idle speed, no adjustments should be made to
the system. The Electronic Fuel Injection (EFI) and
Electronic Throttle Control (ETC) systems control idle
speed.
NOISE EMISSION CONTROL

Tampering with Noise Control Systems is Prohibited.
Federal law prohibits the following acts or causing
thereof:
1. The removal or rendering inoperative by any
person other than for purposes of maintenance,
repair or replacement, any device or element of
design incorporated into the motorcycle for the
purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in
use, or
2. The use of the motorcycle after such device or
element of design has been removed or rendered
inoperative.
Among those acts presumed to constitute
tampering are the acts listed below:
3. Removal of, or puncturing the muffler, baffles,
header pipes or any other component which
conducts exhaust gases.
4. Removal or puncturing of any part of the intake
system.
5. Lack of proper maintenance.

© Copyright 1.35
SPECIAL TOOLS
USING SPECIAL TOOLS How To Use This Book
Special tools have been designed exclusively for The Special Tools Index located in this chapter
servicing the specialized components found on Indian provides a comprehensive list and pictorial
Motorcycles. By using these tools, service technicians representation of the special tools used throughout
can maximize efficiency and minimize the likelihood this service manual. The Special Tools section at the
of causing damage to the motorcycle during service. beginning of each chapter provides a short list of the
tools required to perform procedures specific to that
chapter.
T O O L O R D E R I N G I N F O R M AT I O N
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory,
while other tools may be substituted with a similar tool, if available. Indian Motorcycle recommends use of the
Special Tools referenced in the chapters of this service manual when servicing any Indian Motorcycle product.
Dealers may order special tools through Indian Motorcycle’s official tool supplier, Bosch Automotive Service
Solutions, by phone at 1-800-328-6657 or on-line via your dealer website.

1.36 © Copyright
SPECIAL TOOLS INDEX

ABS Tool (Brake Lever Reserve) Battery Tester Bearing Removal Kit 1
PV-50104 PU-50296 PF-51324
Belt Tension Meter Body Panel Tool Kit Cartridge Shaft Tool
PV-43532 PV-49955 PV-49452
Crankcase Tool Clutch Shaft Holding Tool Crankshaft Locking Pin

PF-51234 PF-51232 PF-52135

© Copyright 1.37
Crankshaft Rotation Tool Damper Rod Holder Electrical Tester Kit

PF-51239 PV-49453 PV-43526
Engine Stand Adapter Fork Spring Compressor Adapter Fork Oil Level Tool
PF-51240 PV-49464 PV-59000A
Fork Seal Tool Fork Spring Compressor Fuel Pressure Adapter

PV-49494 PV-49463 PV-48656
Fuel Pressure Gauge Oil Filter Wrench Oil Pressure Gauge

PU-43506A PU-50105 PV-43531

1.38 © Copyright
Output Shaft Seal Tool Relay Bypass Tool Shock Air Pump 1
PF-51243 PU-49466 PV-48909
Shock Spanner Wrench Smartlink Module Kit Spanner Socket (Stem)

PV-46993 PU-47471 PV-43508
Swingarm Bushing Tool TPMS Activation Tool USB to Serial Adapter

PF-51237 PF-51288 PU-50621

© Copyright 1.39
Cam Installation Tool

PF-51455

1.40 © Copyright
REFERENCE
S A E TA P D R I L L S I Z E S M E T R I C TA P D R I L L S I Z E S 1
THREAD SIZE / DRILL THREAD SIZE / DRILL DECIMAL NEAREST
DRILL
SIZE SIZE TAP SIZE EQUIVA- FRAC-
SIZE
LENT TION
#0-80 3/64 1/2-13 27/64
3x.50 #39 0.0995 3/32
#1-64 #53 1/2-20 29/64
3x.60 3/32 0.0937 3/32
#1-72 #53 9/16-12 31/64
4x.70 #30 0.1285 1/8
#2-56 #51 9/16-18 33/64
4x.75 1/8 0.125 1/8
#2-64 #50 5/8-11 17/32
5x.80 #19 0.166 11/64
#3-48 5/64 5/8-18 37/64
5x.90 #20 0.161 5/32
#3-56 #45 3/4-10 21/32
6x1.00 #9 0.196 13/64
#4-40 #43 3/4-16 11/16
7x1.00 16/64 0.234 15/64
#4-48 #42 7/8-9 49/64
8x1.00 J 0.277 9/32
#5-40 #38 7/8-14 13/16
#5-44 #37 1-8 7/8 8x1.25 17/64 0.265 17/64
#6-32 #36 1-12 59/64 9x1.00 5/16 0.3125 5/16
#6-40 #33 1 1/8-7 63/64 9x1.25 5/16 0.3125 5/16
#8-32 #29 1 1/8-12 1 3/64 10x1.25 11/32 0.3437 11/32
#8-36 #29 1 1/4-7 1 7/64 10x1.50 R 0.339 11/32
#10-24 #24 1 1/4-12 1 11/64 11x1.50 3/8 0.375 3/8
#10-32 #21 1 1/2-6 1 11/32 12x1.50 13/32 0.406 13/32
#12-24 #17 1 1/2-12 1 27/64 12x1.75 13/32 0.406 13/32
#12-28 #15 1 3/4-5 1 9/16

1/4-20 7 1 3/4-12 1 43/64
1/4-28 3 2-4 1/2 1 25/32
5/16-18 F 2-12 1 59/64
5/16-24 I 2 1/4-4 1/2 2 1/32
3/8-16 O 2 1/2-4 2 1/4
3/8-24 Q 2 3/4-4 2 1/2
7/16-14 U 3-4 2 3/4
7/16-20 25/64

© Copyright 1.41
D E C I M A L E Q U I VA L E N T S
1/64 in = .0156 in 39/64 in = .6094 in
1/32 in = .0312 in [1 mm = .0394 in] 5/8 in = .625 in [16mm=. 6299 in]
3/64 in = .0469 in 41/64 in = .6406 in
1/16 in = .0625 in 21/32 in = .6563 in [17 mm = .6693 in]
5/64 in = .0781 in [2 mm = .0787 in] 43/64 in = .6719 in
3/32 in = .0938 in 11/16 in = .6875 in
7/64 in = .1094 in [3 mm = .1181 in] 45/64 in = .7031 in [18 mm = .7087 in]
1/8 in = .1250 in 23/32 in = .7188 in
9/64 in = .1406 in 47/64 in = .7344 in [19 mm = .7480 in]
5/32 in = .1563 in [4 mm = .1575 in] 3/4 in = .75 in
11/64 in = .1719 in 49/64 in = .7656 in
13/64 in = .2031 in 51/64 in = .7969 in
7/32 in = .2188 in 13/16 in = .8125 in [21 mm =. 8268 in]
15/64 in = .2344 in [6 mm = .2362 in] 53/64 in = .8281 in
1/4 in = .25 in 27/32 in = .8438 in
9/32 in = .2813 in 7/8 in = .875 in
19/64 in = .2969 in 57/64 in = .8906 in [23 mm = .9055 in]
5/16 in = .3125 in [8mm= .3150 in] 29/32 in = .9063 in
21/64 in = .3281 in 59/64 in = .9219 in
23/64 in = .3594 in 61/64 in = .9531 in
3/8 in = .375 in 31/32 in = .9688 in [25 mm = .9843 in]
25/64 in = .3906 in [10 mm = .3937 in] 63/64 in = .9844 in
13/32 in = .4063 in 1 in = 1.0 in
27/64 in = .4219 in [11 mm =.4331 in]
7/16 in = .4375 in
29/64 in = .4531 in
15/32 in = .4688 in [12 mm = .4724 in]
31/64 in = .4844 in
1/2 in = .5 in [13mm = .5118 in]
33/64 in = .5156 in
17/32 in = .5313 in
35/64 in = .5469 in [14 mm = .5512 in]
9/16 in = .5625 in
37/64 in = .5781 in [15 mm = .5906 in]
19/32 in = .5938 in

1.42 © Copyright
FA H R E N H E I T T O C E L S I U S UNIT OF MULTIPLIED
COVERTS TO
oC to oF: 9 (o C + 40) ¸ 5 - 40 = oF
MEASURE BY 1
in x 25.4 = mm
oF to oC: 5 (oF + 40) ¸ 9 - 40=oC
mm x.03937 = in
DEGREES F DEGREES C in x 2.54 = cm
32 0 mile x 1.6 = km
41 5 km x.6214 = mile
50 10 Ounces (oz) x 28.35 = grams (g)
59 15
Fluid Ounce x 29.57 = CCs
68 20
grams (g) x.035 = Ounces (oz)
77 25
= Fluid Ounces
86 30 cc’s x.03381 (oz)
95 35 lbs x.454 = kg
104 40
kg x 2.2046 = lbs
113 45
= Cubic
122 50 Cubic Inches x 16.387
Centimeters
131 55 Cubic
x.061 = Cubic Inches
140 60 Centimeters
149 65 Imperial pints x.568 = liters (l)
158 70 liters (l) x 1.76 = Imperial pints

167 75 Imperial quarts x 1.137 = liters (l)
176 80 = Imperial
liters (l) x.88
185 85 quarts
194 90 Imperial quarts x 1.201 = US quarts

203 95 = Imperial
US quarts x.833 quarts
212 100
US quarts x.946 = liters
liters x 1.057 = US quarts
MEASUREMENT CONVERSION CHART
US gallon x 3.785 = liter
UNIT OF MULTIPLIED
COVERTS TO
MEASURE BY liter x .264 = US gallon
ft-lbs x 12 = in-lbs Pounds force
= Kilo pascals
in-lbs x.0833 = ft-lbs per square inch x 6.895 (kPa)
(psi)
ft-lbs x 1.356 = Nm
= Pounds force
in-lbs x.0115 = kg-m Kilo pascals
x .145 per square inch
(kPa)
Nm x.7376 = ft-lbs (psi)
kg-m x 7.233 = ft-lbs Kilo pascals = Kilograms

(kPa) x .01 force per cm2
kg-m x 86.796 = in-lbs
kg-m x 10 = Nm

© Copyright 1.43
UNIT OF MULTIPLIED
COVERTS TO
MEASURE BY
Kilograms force = Kilo pascals
per cm2 x 98.1 (kPa)
p (3.14159) x R2 x H (height) = Cylinder

Volume

1.44 © Copyright
MAINTENANCE
CHAPTER 2
MAINTENANCE
2
MAINTENANCE QUICK REFERENCE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
SPECIFICATIONS - MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
MAINTENANCE INTERVAL CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
BREAK-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
AIR FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
ENGINE OIL & FILTER CHANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
IDLE SPEED / FAST IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21
TIRE PRESSURE / SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21
CLUTCH CABLE INSPECTION / LUBRICATION (2017-2020) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23
CLUTCH LEVER LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
CLUTCH LEVER FREE PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
FRONT BRAKE LEVER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
FRONT BRAKE LEVER LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
FRONT BRAKE LEVER REACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
BRAKE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
BRAKE PEDAL LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
SHIFT PEDAL INSPECTION / LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
SHIFT PEDAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
BRAKE FLUID LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29
FRONT BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
REAR BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
CRANKCASE VENTILATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
FUEL TANK VENT INSPECTION (49 STATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA AND INTERNATIONAL MODELS) . . . . . .2.32
FUEL HOSE (FUEL RAIL) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33
SPARK PLUG REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34
SPARK PLUG INSPECTION / GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34
SPARK PLUG INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35
ENGINE COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35
ENGINE COMPRESSION TEST (WET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
BATTERY STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
BATTERY, REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37

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DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38

DRIVE BELT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39
DRIVE BELT TENSION MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.40
DRIVE BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.42
SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.43
FUSE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.44
HEADLIGHT AIM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.45
HEADLIGHT AIM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.47
SIDESTAND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.48
SIDESTAND REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.48
STEERING HEAD / FRONT WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.48
SWINGARM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.49
REAR SHOCK PRELOAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.49
REAR SHOCK PRELOAD ADJUSTMENT - CHIEF MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.51
REAR SHOCK PRELOAD ADJUSTMENT - SPRINGFIELD / CHIEFTAIN / ROADMASTER . . . . . . . . . . . . . . . . . . . . .2.51
MAINTENANCE - CHECK WHEEL SPOKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.52

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MAINTENANCE QUICK REFERENCE GUIDE

S P E C I F I C AT I O N S - M A I N T E N A N C E
GENERAL SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Battery Type / CCA 12 Volt / 18 AH / 310 CCA — 2
Brake Pad Thickness, Front .16 in (4.0 mm) .04 in (1.0 mm)
Brake Disc Thickness, Front .20 in (5.0 mm) .18 in (4.5 mm)
Brake Pad Thickness, Rear .25 in (6.5 mm) .04 in (1.0 mm) Minimum
Brake Disc Thickness, Rear .28 in (7 mm) .26 in (6.5 mm)
Clutch Lever Freeplay .019–.059” (0.5–1.5 mm) —
Compression Pressure 90-110 psi (620-758 kPa) Below 80 psi (552 kPa)
(Cylinder)
Drive Belt Deflection (with 10 Classic / Vintage / Dark Horse: 1.1“ (28 mm) —
lbs force) or 8 notches up on belt guard.
Chieftain / Roadmaster / Springfield: 1.3“ (34
mm) or 11 notches up on belt guard.
Fuel Pressure (KOEO) 58 psi (400 kPa) 51 psi (350 kPa)
Idle Speed / Fast Idle Speed 800 RPM ±50 RPM
Oil Pressure, Lubrication @ 60 PSI (414 kPa) ± 15% 30 PSI (207 kPa)
3000 rpm Engine at operating temperature.
Ride Height (Rear Spring Pre- See adjustment procedure outlined in this —
Load) chapter
Spark Plug Type / Gap NGK DCPR8E / GAP — .034 in (0.9 mm) —
FRONT:
All Models (EXCEPT Springfield): 36 PSI (248
—
kPa)
Springfield: 46 PSI (317 kPa)
Tire Pressure REAR: —
Chief Classic / Chief Vintage / Chief Dark Horse:
40 PSI (276 kPa)
Springfield / Chieftain Dark Horse / Chieftain /
Roadmaster / : 41 PSI (282 kPa)
Tire Tread Depth (Minimum) — .063 in (1.6 mm)
Valve Lash (Int. / Ex.) NOT ADJUSTABLE (Lash is self-adjusting via —
hydraulic lifters)

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TORQUE SPECIFICATIONS
DESCRIPTION TORQUE SPECIFICATIONS

Air Filter Cover Fastener — M6 x 1.0 x 10
(QTY.3)
Battery Terminal Nuts
Battery Cable to Starter Motor
Brake Bleeder Fasteners (Caliper) 48 in-lbs (5.4 Nm)
Drive Sprocket Nut 180 ft-lbs (244.0 Nm)
Drive Sprocket Nut Retainer Plate 88 in-lbs (10.0 Nm)
Fuel Tank Mounting Fasteners 18 ft-lbs (24.5 Nm)
Master Cylinder Cover Fasteners (Front) 13 in-lbs (1.5 Nm)
Oil Drain Plugs (2) 15 ft-lbs (20.0 Nm)
Oil Filter Approximately 3/4 turn after sealing ring has contacted the
filter adapter.
Seat Fasteners 18 ft-lbs (24.4 Nm)
Spark Plugs 12.7 ft-lbs (17.2 Nm)
FLUID SPECIFICATIONS
DESCRIPTION FLUID TYPE CAPACITY
Brake Hydraulic Fluid DOT 4 —
Engine / Transmission Oil Semi-Synthetic 20W40 Engine Oil 5.5 Qts (5.2 L)
Fork Oil (Classic / Vintage / Indian Motorcycle Fork Oil 20.3 oz (599 cc) per leg
Dark Horse)
Fork Oil (Chieftain / Indian Motorcycle Fork Oil 18.8 oz (557 cc) per leg
Roadmaster / Springfield)
Fuel 91 Octane (Recommended) 5.5 gal (20.8 L) / Reserve 1.0 gal (3.8 L)

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MAINTENANCE
M A I N T E N A N C E I N T E R VA L C H A R T
The maintenance interval charts outline required maintenance and inspection based on vehicle miles. Each table
states the number of miles that service is required on the vehicle. Some items or components may need to be
serviced more often due to severe use. When the vehicle goes beyond 50,000 miles, return to the 500 mile chart
and start the interval process over.
500 MILES (800 KM) SERVICE 2

CODE ITEM ACTION
D Crankcase Ventilation System Inspect; tighten, clean, adjust
D Drive Belt Inspect; tighten, clean, adjust
Visual inspection for cracks or deformation is required whenever the rear
Damper, Cushion Drive
wheel is removed. Replace if damage is found.
D Engine Mount Fasteners Inspect; tighten, adjust
XU Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants
E Evaporative Emission Control System Inspect; clean
E Exhaust System Inspect; tighten, adjust
D Fuel System Inspect; clean
Key Fob Battery Replace at specified interval or every 2 years
D Oil Lines / Oil System Inspection Inspect; clean, adjust if necessary
Battery Check terminals; clean; test
D Brake Fluid Change every two years (DOT 4)
XU / D Brake Pads Inspect pad wear; replace if worn beyond service limit
D Clutch Lever Lubricate with proper lubricant as directed
D Clutch Cable Freeplay Inspect; adjust if necessary
D Control Cable Ends Inspect; lubricate with proper lubricant as directed
D Fasteners Inspect; tighten if necessary
D Front Brake Lever Adjust if necessary, lubricate with proper lubricant as directed
D Front Fork Oil Inspect
D Front Forks and Front Axle Inspect; adjust if necessary
D Gear Shift Pedal Inspect; adjust if necessary
D Head Light Inspect; adjust if necessary
D Pinion Shaft Clevis Inspect; clean and lubricate
D Rear Brake Pedal Inspect; adjust if necessary
D Rear Shock Absorber Inspect; adjust if necessary
D Rear Wheel Alignment Inspect; adjust if necessary
Road Test Perform Road Test
D Sidestand Lubricate with proper lubricant as directed
D Steering Bearings Inspect
D Suspension Linkage, Rear Inspect
D Swing Arm and Rear Axle Inspect
D Tires / Wheels Inspect tread depth, sidewall cracking, wear patterns
XU - Perform these procedures more often for vehicles subjected to severe use.
D - Have an authorized Indian Motorcycle dealer perform these services.
E - Emission Control System Service (California / International)

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2,500 MILES (4,000 KM) SERVICE
CODE ITEM ACTION

XU Air Filter Inspect; clean
D Front Brake Lever Inspect; adjust if necessary, lubricate with proper lubricant as directed
D Sidestand Inspect; adjust if necessary, lubricate with proper lubricant as directed

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CODE ITEM ACTION


2
D Clutch Lever Inspect; adjust if necessary
D Front Fork Oil Replace at specified interval or every 2 years

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CODE ITEM ACTION

XU Air Filter Replace
D Engine Compression Inspect; correct if necessary
D/E Spark Plugs Inspect; torque to specification
D Brake Fluid Replace (DOT 4)
D Control Cable Ends Lubricate with proper lubricant as directed
D Front Fork Oil Replace at specified interval or every 2 years
D Gear Position Switch Inspect; clean. See “GEAR POSITION SWITCH REPLACEMENT”

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CODE ITEM ACTION


2
D Control Cable Ends Inspect; adjust if necessary
D Front Fork Oil Replace

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CODE ITEM ACTION

Key Fob Battery Replace

2.10 © Copyright
MAINTENANCE
CODE ITEM ACTION


2

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CODE ITEM ACTION

D Drive Belt Replace
D/E Spark Plugs Replace
D Front Brake Lever Lubricate with proper lubricant as directed

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CODE ITEM ACTION


2

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CODE ITEM ACTION

Key Fob Battery Replace

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CODE ITEM ACTION


2
D Front Brake Lever Lubricate with proper lubricant as directed

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CODE ITEM ACTION

D Engine Mount Fasteners Inspect; tighten, adjust
Applies only to fuel pumps built before 11/10/2015 and all 2018+ units.
D Fuel Filter Replacement Fuel pumps built after 11/11/2015 and all 2017 units do not have a
replaceable fuel filter.
D Rear Shock Absorber Replace

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When the vehicle goes beyond 50,000 miles, return to the 500 mile chart and start the interval process over.

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G E N E R A L I N F O R M AT I O N
SERVICE NOTES BREAK-IN PROCEDURE
Periodic Maintenance Overview Engine break-in for Indian Motorcycles occurs in the
first 500 miles (800 km) of operation. Indian
Inspection, adjustment and lubrication of important
Motorcycles are manufactured using the best possible
components are explained in the periodic
materials and manufacturing techniques, but the final
maintenance chart.
machining process is the break-in. During this break-
Inspect, clean, lubricate, adjust and replace parts as in period, critical engine parts wear and polish to
necessary. When inspection reveals the need for correct operating clearances. Read, understand and
replacement parts, use genuine Indian Motorcycle follow all break-in procedures to ensure the long-term
parts available from your Indian Motorcycle dealer. performance and durability of the engine.
IMPORTANT CAUTION
Service and adjustments are critical. If you’re not Failure to properly follow the engine break-in
familiar with safe service and adjustment procedures outlined in this manual can result in
procedures, have a qualified dealer perform these serious damage to the engine. Follow all break-in
operations. procedures carefully. Avoid full throttle operation and
other condition that may place an excessive load on
the engine during the break-in period.
SPECIAL TOOLS
Observe the following precautions during the break-in
TOOL DESCRIPTION PART NUMBER period:
Brake Lever Reserve PV-50104 • Upon initial start-up, do not allow the engine to idle
Tool for long periods as overheating can occur.
Battery Tester PU-50296 • Avoid fast starts with wide open throttle. Drive
Belt Tension Meter PV-43532 slowly until the engine warms up.
Oil Filter Wrench PU-50105 • Avoid running the engine at extremely low RPM in
higher gears (lugging the engine).
Shock Air Pump PV-48909
Shock Spanner Wrench PV-46993
Break-In Guidelines
ODOMETER BREAK-IN PROCEDURE
Bosch Automotive Service Solutions: 1-800-328-
6657 or https://polaris.service-solutions.com/ 0–90 Miles Do not operate for extended
(0–145 km) periods above 1/3 throttle or at any
one throttle position. Vary engine
speed frequently.
91–300 Miles Do not operate for extended
(146–483 km) periods above 1/2 throttle or at any
one throttle position. Vary engine
speed frequently.
301–500 Miles Do not operate for extended
(484–805 km) periods above 3/4 throttle.
500 Miles Perform the break-in maintenance
(805 km) procedure outlined in the Periodic
Maintenance Interval Table located
in this chapter.

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MAINTENANCE PROCEDURES
A I R F I LT E R R E P L A C E M E N T E N G I N E O I L & F I LT E R C H A N G E
Change the engine oil at the intervals specified in the
NOTICE
Periodic Maintenance Table beginning on
If the motorcycle is operated in wet or dusty Maintenance Interval Chart page 2.5. Change the oil
conditions, more frequent servicing is required. more frequently if the motorcycle is subjected to
The air filter element cannot be cleaned. Replace the severe use, especially operation in cold weather. 2
filter when necessary.
NOTICE
Failure to perform frequent oil changes during cold
1. Remove air box cover fasteners q and air box weather operation can result in condensation
cover w. forming. Freezing condensation can result in
plugged oil lines and serious engine damage.
NOTICE
After an oil change, the low oil pressure indicator
may illuminate when the engine is started. If this
occurs, do not increase RPM above idle speed until
the indicator turns off. Operating above idle speed
could result in damage to the engine.
IMPORTANT
Engine MUST BE WARM while performing the
following procedure.
WARNING
HOT COMPONENTS Wear insulated gloves and/
2. Remove three fasteners e securing air filter or allow engine and exhaust to cool before
element r to air box backing plate and remove handling these parts.
filter.
1. Change the oil and filter when the engine is warm.

If the engine is cold, start the engine and allow it to
run at idle for at least 5 minutes.
2. Park the motorcycle with the sidestand down on a
firm, level surface. If using a service lift, the
motorcycle should be centered.
3. Clean the area around the scavenge area drain
plug q and the storage area drain plug w. Place a
drain pan under both drain plugs.
3. Installation of new filter is performed by

reversing the removal procedure.
TORQUE
Air Filter Fasteners e : 62 in-lbs (7 N·m)
Air Box Cover Fasteners q : 88 in-lbs (10 N·m)

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4. Remove the drain plugs. Allow the oil to drain 17. Check for leaks around drain plug and oil filter.
completely.
NOTICE
5. Install new sealing washers on the drain plugs. The
sealing surfaces on drain plugs and engine should Recycle used oil and oil filter in accordance with
be clean and free of burrs, nicks or scratches. local regulations.
6. Reinstall the drain plugs. Torque to specifications.

18. CHIEFTAIN MODELS / ROADMASTER: Reset the oil
TORQUE change life in the instrument gauge.
Drain Plugs:
ENGINE OIL LEVEL
7. Place oil pan beneath the oil filter. Using an oil With the semi-dry sump lubrication system, the
filter wrench, turn the filter counter-clockwise to engine oil level on the dipstick will fluctuate,
remove it. depending on the motorcycle’s position and engine
temperature when checked. To ensure a proper
8. Using a clean dry cloth, clean the filter sealing reading of the engine oil level, follow all inspection
surface on the engine. procedures closely.
9. Lubricate the o-ring on the new filter with a film of
fresh engine oil. Check to make sure the o-ring is WARNING
in good condition. Operating with insufficient, deteriorated or
10. Install the new filter and rotate it clockwise by hand contaminated engine oil will cause accelerated wear
until the filter gasket contacts the sealing surface, and may result in engine or transmission seizure,
then turn it an additional 3/4 to one full turn. which could result in loss of control and serious
injury or death. Check the oil level frequently.
11. Remove the dipstick. Add only 4.5 qts. (4.25 l) of
the recommended oil at this step. Do not overfill.
Always check the oil after running a cold engine at
12. Reinstall the dipstick securely. idle for 30 seconds. The oil fill/dipstick is located on
13. With the motorcycle in an upright, centered the left side of the motorcycle. Always use the
position, start the engine and idle for 30 seconds. recommended oil.
14. Stop the engine and add the additional 1 - 1.5 qts. 1. Position the motorcycle on level ground in the fully
(0.95 - 1.42 L) of engine oil. Do not add oil if oil upright and centered position.
level is between the ADD and FULL marks. 2. Start the engine (from cold) and allow it to idle for
Overfilling can result in loss of engine performance 30 seconds. Stop the engine.
and an oil-saturated air filter. Use suction device to
remove excess oil if overfilled. 3. Remove the dipstick q and wipe it clean.
IMPORTANT
Total fill with oil filter change will be approximately
5.5 - 6.0 US quarts.
15. To ensure the oil level is within the safe operating

range, re-check the oil level as outlined in Engine
Oil Level page 2.20.
CAUTION
4. Thread the dipstick until fully seated.
16. Dispose of used filter and oil properly.

2.20 © Copyright
MAINTENANCE
5. Remove the dipstick and view the oil level. T I R E P R E S S U R E / S P E C I F I C AT I O N S

NOTICE WARNING
Do not overfill. Overfilling can result in loss of engine
Indian motorcycles are produced using the
performance and an oil-saturated air filter. Use a
designated tires listed below as original equipment.
suction device to remove excess oil if overfilled.
This includes field testing to ensure stability and
superior handling. The use of tires other than original 2
6. Add the recommended oil as needed to bring the equipment may cause instability. See Steering /
level between the ADD and FULL marks. Do not Suspension chapter for a review of all tire related
add oil if between the ADD and FULL marks. Warnings.
NOTICE
The approximate volume between the FULL w and 1. Inspect tires for weather checking, cuts, imbedded
ADD e marks on the dipstick is 32 oz. (.94 L). foreign objects, etc.
2. Inspect front and rear wheels for damage.
3. Measure tread depth at center of tread.
4. Measure in 3-4 places equally spaced around the
tire and record the smallest measurement.
WARNING
It is dangerous to ride with a worn tire. When a
tire reaches the minimum tread depth listed
below, replace the tire immediately.
MINIMUM TREAD DEPTH (ALL MODELS)

Front Tire Minimum Tread Depth .063 in (1.6 mm)
Rear Tire Minimum Tread Depth .063 in (1.6 mm)
7. Reinstall the dipstick securely.
T I R E P R E S S U R E TA B L E ( C O L D )
CAUTION NOTICE
Oil level will NOT be accurate if checked on a cold Also refer to Manufacturing Information label.
engine. DO NOT ADD oil to bring to FULL mark on a
cold engine, as this can result in overfilling.
CHIEF CLASSIC
FRONT: Dunlop American Elite
36 PSI(248 kPa)
(130/90 B16)
I D L E S P E E D / FA S T I D L E S P E E D REAR: Dunlop American Elite
40 PSI (276 kPa)
NOTICE (180/65 B16)
Idle speed is continuously monitored and adjusted
by the ECM. CHIEF VINTAGE
FRONT: Dunlop American Elite
36 PSI (248 kPa)
(130/90 B16)
REAR: Dunlop American Elite
40 PSI (276 kPa)
(180/65 B16)
CHIEF DARK HORSE

FRONT: Dunlop Elite 3 (130/90
36 PSI (248 kPa)
B16)
REAR: Dunlop American Elite
40 PSI (276 kPa)
(180/65 B16)

© Copyright 2.21
MAINTENANCE
SPRINGFIELD
46 PSI (317 kPa)
B16)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)
SPRINGFIELD DARK HORSE

36 PSI (248 kPa)
B19)
CHIEFTAIN DARK HORSE

36 PSI (248 kPa)
B19)
CHIEFTAIN
36 PSI (248 kPa)
B16)
CHIEFTAIN LIMITED / ELITE

FRONT: Dunlop American Elite - 36 PSI (248 kPa)
130/60B19
REAR: Dunlop Elite 3 - 180/60R16 41 PSI (282 kPa)
ROADMASTER
36 PSI (248 kPa)
B16)
ROADMASTER CLASSIC
36 PSI (248 kPa)
B16)

2.22 © Copyright
MAINTENANCE
CLUTCH CABLE INSPECTION / 3. Remove lower cable guide fastener w and E-clip
L U B R I C AT I O N ( 2 0 1 7 - 2 0 2 0 ) e. Using an adjustable wrench, rotate the clutch
shaft arm r to release the cable housing from the
NOTICE mounting boss.
Control cable casings are lined with a low friction
sleeve and are factory lubricated for reliable
operation. Periodic lubrication of cables is not 2
required and could be detrimental to cable
performance. Only cable ends must be periodically
inspected and lubricated in accordance with the
Periodic Maintenance Schedule.
See Maintenance Interval Chart page 2.5.
CAUTION
Inspect inner cable for fraying. Do not kink, bend or
twist inner cable or cable casing during removal or
installation.
1. Inspect the clutch cable for proper routing, smooth

movement, and damage to the external casing. IMPORTANT
Protect finish of clutch shaft arm with a shop towel or
tape.
4. Apply a thin coating of all purpose grease to both

cable ends.
5. Reverse steps 3–4 to reinstall clutch cable.
6. Tighten the lower cable guide fastener to
specification..
TORQUE
Cable Guide Fastener:
84 in-lbs (9 N·m)
7. Adjust cable free play.

2. Push the rubber boot q up to expose the lower
cable end and inspect for damage or frayed wires.

© Copyright 2.23
MAINTENANCE
C L U T C H L E V E R L U B R I C AT I O N C L U T C H L E V E R F R E E P L AY
1. With handlebars pointing straight ahead, measure
1. Disconnect clutch cable at primary cover.
the clutch lever free play at point shown q.
See Clutch Cable Inspection / Lubrication page
2.23.
2. Pull cable housing out of lever perch and remove
barrel from clutch lever. Do not kink cable.
3. Remove snap ring q and push pivot pin w upward
to remove.
Clutch Lever Free Play:

.019–.059” (0.5–1.5 mm)
2. Compare measurement to specification. If

adjustment is required, proceed to Step 3.
3. Locate the clutch cable adjuster boot w and pull it
4. Inspect both ends of inner cable for frayed strands. back to expose the jam nut and barrel adjuster.
Clean parts and apply moly paste to pivot fastener
and both cable ends.
5. Assemble lever.
6. Install cable to lever. Rotate cable back through
slot in perch, and push outer casing back into
perch recess.
7. Lubricate and attach lower end of cable to clutch
arm on primary cover.
8. Adjust clutch lever free play
See Clutch Lever Free Play page 2.24.
4. Hold cable and loosen the adjuster jam nut.

5. Turn cable adjuster in or out until clutch free play
is correct.
6. Tighten adjuster jam nut to specification.
TORQUE
Clutch Cable Adjuster Jam Nut:
48 in-lbs (5 N·m)
7. Slide adjuster boot back over adjuster assembly.

2.24 © Copyright
MAINTENANCE
FRONT BRAKE LEVER INSPECTION F R O N T B R A K E L E V E R L U B R I C AT I O N

1. Remove snap ring q and pivot pin w.
1. Pull and release the front brake lever. It should
move freely and smoothly and return to its rest
position quickly when released. Lubricate brake
lever if binding, or if it does not return quickly and
completely when released.
See Front Brake Lever Lubrication page 2.25.
2
2. Measure brake lever free play q. You should feel a
firm resistance in the lever within the specified
length of lever travel. If brake lever travels too far
before beginning to apply the brake, inspect for
brake fluid leaks and bleed air from the system.
See Brake Fluid Replacement & Bleeding
Precautions page 14.21.
2. Clean pivot pin, lever and lever perch.

3. Remove brake lever and apply grease to pivot pin
w, lever bushing, and contact surface of pushrod
as shown.
Brake Lever Free Play:

.75–1.0” (19.1–25.4 mm)
3. Safely elevate the front wheel. Verify wheel rotates

freely without drag or binding when lever is
released. 4. Assemble brake lever.

© Copyright 2.25
MAINTENANCE
FRONT BRAKE LEVER REACH B R A K E P E D A L L U B R I C AT I O N

1. Lever reach (distance to hand grip) is adjustable: Lubricate brake pedal at intervals listed on periodic
maintenance table. See Maintenance Interval Chart
• Pull lever forward (away from hand grip) and hold. page 2.5.
• TO ADJUST reach distance, turn dial q on the lever. 1. Place the motorcycle in an upright position with the
front wheel clamped in a wheel vise.
2. Working on the RH side of the motorcycle, remove
floorboard support fasteners q and move
floorboard / master cylinder assembly so the brake
pedal pivot pin can be accessed.
2. The adjustment pin will seat at different depths in

the dial at each setting. Stop once the proper
brake lever reach is achieved.
IMPORTANT
Make sure the adjustment pin is not resting between
pockets on the dial. Once the reach is set, pull the NOTICE
brake lever 2–3 times to verify proper operation. It is not necessary to disconnect the brake line from
the master cylinder to perform this procedure.
BRAKE PEDAL INSPECTION IMPORTANT

1. Press and release brake pedal. It should move Keep the floorboard / master cylinder assembly in an
freely and smoothly and return to the rest position upright position at all times to ensure air does not
quickly when released. enter the brake system.
2. Press brake pedal and check for firm resistance. If

pedal feels spongy or travels too far without 3. Remove cotter pin and flat washer w and pushrod
resistance, inspect system for leaks and bleed pivot pin e. Release the pushrod from the brake
brakes. pedal.
See Brake Fluid Replacement & Bleeding 4. Remove snap ring r and washer t. Remove pedal
Precautions page 14.21. and inner wave washer from post.

2.26 © Copyright
MAINTENANCE
5. Clean off old lubricant and dirt from all parts. S H I F T P E D A L I N S P E C T I O N / L U B R I C AT I O N

6. Apply all-purpose grease to post and pedal 1. Check all shift pedal and linkage fasteners to be
bushing as shown. sure they are tight. Torque fasteners to
specification. See Shift Pedal Adjustment page
2.28.
2. Lubricate shift pedal pivot bushing and all pivots q
with all-purpose lubricant.
2
7. Install wave washer, pedal, flat washer t and snap

ring r. Be sure snap ring is fully seated in the
groove.
8. Install pushrod pivot pin e and flat washer and
cotter pin w.
9. Assemble floorboard support to frame. Torque
mounting fasteners q to specification.
See Floorboard (Driver), Installation page 3.17.
10. Depress brake pedal to verify proper operation
and pedal feel. Bleed brakes if necessary. See
Brake Fluid Replacement & Bleeding
Precautions page 14.21.

© Copyright 2.27
MAINTENANCE
SHIFT PEDAL ADJUSTMENT 3. Torque jam nuts q to specification.

1. Loosen jam nuts q.
TORQUE
2. Rotate linkage rod w until pedal angle is correct.
Shift Rod Jam Nuts:
88 in-lbs (10 N·m)
CAUTION
Do not remove and reposition the shift arm on the
shift shaft to adjust gear shift pedal height. Dots on
shift shaft and shift arm must be aligned for gears to
shift correctly.

2.28 © Copyright
MAINTENANCE
BRAKE FLUID LEVEL INSPECTION 7. Reinstall reservoir diaphragm and cover and
torque fasteners to specification.
IMPORTANT
The brake fluid level in the reservoir will go down as TORQUE
brake pads wear. If you notice a constant or sudden Front Master Cylinder Cover Fasteners:
lowering of the brake fluid level, inspect brake pads 14 in-lbs (2 N·m)
for wear and brake system for leaks. 2
Front Brake Fluid Inspection Rear Brake Fluid Inspection
8. Fluid level is checked at the rear brake master
1. Turn handlebars or adjust the motorcycle until top cylinder reservoir.
of reservoir is level.
9. View fluid level through reservoir sight glass t.
2. View front brake fluid level through sight glass. The fluid should be clear and at a level between
The fluid should be clear and at or above the LOW UPPER and LOWER level marks.
level mark q.
10. Wipe area around reservoir cover with a clean

3. Wipe area around reservoir cover with a clean cloth.
cloth.
11. Wipe brake fluid container with a clean cloth.
4. Wipe brake fluid container with a clean cloth.
12. Remove fasteners y, reservoir cover u, and
5. Remove fasteners w, reservoir cover e and diaphragm i. If diaphragm is extended, return it
diaphragm r. If diaphragm is extended, return it to the neutral position.
to the neutral position.
13. Carefully add enough DOT 4 brake fluid to bring

6. Carefully add enough DOT 4 brake fluid to bring level to the upper edge of the sight glass.
level to the upper edge of the sight glass.

© Copyright 2.29
MAINTENANCE
14. Install diaphragm and cover. Tighten cover 3. Wear indicator grooves should be visible on both
fasteners to specification. inboard and outboard brake pads of both calipers.
TORQUE CAUTION
Rear Master Cylinder Cover Fasteners: Front brake pads should always be replaced as a
7 in-lbs (1 N·m) complete set. If it is determined that an individual
brake pad has worn past the wear indicator groove,
both front calipers should receive new pad sets.
Failure to replace both sets of front brake pads
F R O N T B R A K E PA D I N S P E C T I O N together may cause reduced braking performance or
NOTICE brake failure, resulting in a vehicle crash.
Wear indicator grooves are provided on each front

brake pad to allow for a visual inspection without pad 4. Install caliper cover. Torque to specification.
removal. Inspect pads by viewing from rear of
caliper. TORQUE
Replace pads if worn to bottom of grooves. Caliper Cover Acorn Nuts:
See Front Brake Pad Replacement page 14.25 18 in-lbs (2 N·m)
1. Remove two acorn nuts q and fastener w from

each side of the motorcycle and remove the caliper
covers e.
2. Viewing the front brake pads from the rear of the

calipers, locate the wear indicator grooves q.

2.30 © Copyright
MAINTENANCE
R E A R B R A K E PA D I N S P E C T I O N C R A N K C A S E V E N T I L AT I O N S Y S T E M
1. Inspect condition of ventilation hose q along its
NOTICE
length and at both ends.
Wear indicator grooves are provided on each rear
brake pad to allow for a visual inspection without pad
removal. Inspect pads by viewing from the rear of the
motorcycle, directly behind the LH tailpipe.
Replace pads if worn to bottom of grooves.
2
See Rear Brake Pad Replacement page 14.26.
1. Place the motorcycle in an upright position with the

2. Viewing the rear brake pads from behind the
motorcycle and below the lip of the rear fender,
locate the wear indicator grooves q.
2. Inspect condition of ventilation hose w along its

length and at both ends.
3. Wear indicator grooves should be visible on both

inboard and outboard brake pads.
3. Be sure hoses are not restricted, kinked, or

cracked.
4. Replace hose if worn or damaged.

© Copyright 2.31
MAINTENANCE
F U E L TA N K V E N T I N S P E C T I O N ( 4 9 S TAT E ) E VA P O R AT I V E E M I S S I O N C O N T R O L S Y S T E M
1. Inspect fuel tank vent hose q in accordance with ( C A L I F O R N I A A N D I N T E R N AT I O N A L
periodic maintenance schedule and any time fuel
tank has been removed and installed. Be sure the
MODELS)
hose is clear and not pinched or kinked, and that NOTICE
all connections are tight.
The fuel tank vent line is routed to a carbon canister
where the fuel vapor is stored until specific operating
parameters are met and the ECM opens the purge
valve. Fuel vapor is then routed out of the carbon
canister, through the purge valve and into the throttle
body for combustion. Inspect all EVAP lines for
abrasion or wear. Check that all connections for both
vent and canister purge systems are securely
attached.
NUMBER PART DESCRIPTION

q Fuel Tank Vent Line
w Evaporative Emissions Carbon

Canister
e Purge Line (Canister to Purge
Valve)
r Purge Valve
t Purge Line (Purge Valve to

Throttle Body)

2.32 © Copyright
MAINTENANCE
FUEL HOSE (FUEL RAIL) INSPECTION

1. The fuel hose (fuel rail) can be found behind the
horn cover on the RH side of the motorcycle.
2. Inspect fuel supply line q and fuel rail w for
deterioration, damage, leakage, or kinked areas.
Inspect fuel supply line-to-fuel rail connection e
for signs of leakage. 2
3. Replace any components that fail inspection with

genuine Indian Motorcycle replacement parts.
WARNING
The fuel lines exiting fuel pump are subjected to high
pressure. Replace with genuine Indian Motorcycle
replacement parts to reduce the possibility of fuel
line failure. Be sure fuel lines are routed properly and
do not come in contact with sharp or hot objects, or
anything that may cause wear or damage.

© Copyright 2.33
MAINTENANCE
S PA R K P L U G R E M O VA L S PA R K P L U G I N S P E C T I O N / G A P
CAUTION CAUTION
HOT COMPONENTS A hot engine can cause serious burns. Allow engine
Wear insulated gloves and/or allow engine and to cool or wear protective gloves when removing the
exhaust to cool before handling these parts. spark plugs.
NOTICE 1. Remove spark plugs. See Spark Plug Removal

The front spark plug can be removed without having page 2.34.
to remove the fuel tank by using a 3” extension and 2. Inspect electrodes for wear and carbon buildup.
standard 5/8” spark plug socket. Look for a sharp outer edge with no rounding or
erosion of the electrodes.
1. With the engine at room temperature, grasp the
3. Clean with electrical contact cleaner or a glass
spark plug boot q and rotate back and forth bead spark plug cleaner only.
slightly to release from the spark plug. DO NOT
pull on the wire or spark plug wire may be
damaged. CAUTION
A wire brush or coated abrasive (sandpaper) should
not be used to clean electrodes.
4. Measure electrode gap with a wire gauge q.

Adjust gap if necessary by carefully bending the
grounding electrode until the specified gap is
achieved.
2. Grabbing only the base of the spark plug boot,

pull straight out of spark plug well.
Spark Plug Type: DCPR8E
Spark Plug Gap: .034 in (0.9 mm)
3. Clean out spark plug wells with compressed air to

remove any loose dirt or debris.
4. Using a 3” extension and a 5/8” spark plug socket,
remove spark plugs.

2.34 © Copyright
MAINTENANCE
S PA R K P L U G I N S TA L L AT I O N ENGINE COMPRESSION TEST

1. Inspect spark plug gap with a wire gauge. If gap 1. Warm engine to operating temperature.
adjustment is necessary, bend ground electrode
2. Shift transmission into neutral and stop engine.
carefully using a spark plug gap tool.
3. Remove the LH upper side cover to access the fuse
Spark Plug Type: DCPR8E box q. See Side Cover (Upper), Removal /
Installation page 3.15. 2
Spark Plug Gap: .034 in (0.9 mm)
2. Apply anti-seize compound sparingly to spark

plug threads, avoiding the bottom 2 - 3 threads.
3. Torque spark plugs to specification.
TORQUE
Spark Plug:
13 ft-lbs (17 N·m)
CAUTION
Do not over tighten spark plugs. Damage to the
cylinder head or spark plug may result.
4. Remove the Fuel Pump Relay w to disable fuel
4. Install spark plug wire boots securely over the pump.
plugs.
5. Disconnect the ignition coil e to disable ignition

system.

© Copyright 2.35
MAINTENANCE
6. Disconnect ignition cables from both spark plugs. 3. If compression does not increase, inspect valves
and valve seats.
7. Remove spark plug from cylinder to be tested. See
Spark Plug Removal page 2.34.
8. Install compression tester in the spark plug hole B AT T E R Y
following manufacturers instructions. This motorcycle is equipped with a maintenance free
9. Open throttle and crank engine until needle on battery which is located under the seat. DO NOT
compression gauge stops rising (about 5 remove cell caps or add distilled water to the battery.
seconds). If the battery discharges, refer to Electrical chapter for
diagnostic information.
10. Repeat procedure for other cylinder.
Specification - Thunder Stroke 111: All Models WARNING
STD: 90-110 psi (620-758 kPa) Battery electrolyte is poisonous. It contains sulfuric
SERVICE LIMIT: Below 80 psi (552 kPa) acid. Serious burns can result from contact with skin,
eyes or clothing. Antidote:
High engine compression may indicate: External: Flush with water.
Internal: Drink large quantities of water or milk.
• Carbon deposits in combustion chamber Follow with milk of magnesia, beaten egg, or
• Engine modification vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt
• Faulty Gauge medical attention.
Batteries produce explosive gases. Keep sparks,
Low engine compression may indicate: flame, cigarettes, etc. away. Ventilate when charging
or using in an enclosed space. Always shield eyes
• Slow starter motor cranking speed
when working near batteries. KEEP CHILDREN
• Carbon or foreign material on valve seat AWAY FROM BATTERY.
• Worn or damaged piston and/or piston rings
• Leaking exhaust or intake valves CAUTION
• Leaking head gasket Whenever removing the battery, disconnect the
negative (black) cable first. When reinstalling the
• Valve timing incorrect battery, connect the negative (black) cable last.
• Non-OEM camshafts or faulty gauge Do not remove the battery cables while the engine is
running. Doing so may damage the Electronic
If cylinder compression is below specification, Control Module (ECM).
perform a cylinder leakage test to determine Take great care NOT to reverse the battery leads
where the leak is occurring. Follow the instructions when installing the battery.
provided with the leakdown tester.
ENGINE COMPRESSION TEST (WET) B AT T E R Y I N S P E C T I O N

Battery terminals and connections should be kept free
IMPORTANT of corrosion. If cleaning is necessary, remove the
The 111ci engine is equipped with a decompression corrosion with a stiff wire brush. Wash with a solution
system. Due to this system, cranking speed can of one tablespoon baking soda to one cup water. Rinse
greatly affect compression readings. Indian well with tap water and dry off with clean rags. Coat
Motorcycle strongly recommends using the cylinder terminals with dielectric grease.
leakdown method to determine how well the 1. Visually inspect the exterior of the battery.
combustion chamber is sealing. Replace battery if housing is damaged, case is
deformed, or if electrolyte is leaking.
1. Pour 3-5 cc of clean engine oil into each cylinder 2. To remove corrosion, remove battery from
through spark plug hole. Repeat cylinder motorcycle and wash terminals with water and
compression test. See ENGINE COMPRESSION baking soda solution. Clean terminals, fasteners,
TEST. and cable ends with a brass wire brush and apply
a thin film of dielectric grease.
2. If compression increases substantially, inspect
cylinder, piston, and rings.

2.36 © Copyright
MAINTENANCE
3. Measure battery voltage.
Specification: 12.5V DC minimum

4. If battery voltage is below 12.5V DC, charge it
thoroughly. See Battery Charging - In Service
page 15.14.
5. Replace battery if it will not accept a charge.
B AT T E R Y C H A R G I N G
See Battery Charging - New Battery page 15.14 or
Battery Charging - In Service page 15.14.
B AT T E R Y S T O R A G E
When the motorcycle is not used for periods of one
month or longer the battery should be fully charged
prior to operation. Store battery in a cool, dry place.
Battery should be charged monthly using a 12 volt
battery charger with a maximum charge rate of 1.8
amp-hr.
WARNING
Battery charging can create explosive gasses;
keep sparks, flames, cigarettes or anything that
could ignite the gasses away. Provide adequate
ventilation when charging in an enclosed space.
Batteries contain acid that is caustic. Wear
protective clothing and a face shield or protective
eyewear when working with the battery. KEEP
OUT OF REACH OF CHILDREN.
B AT T E R Y , R E M O VA L
1. See Battery Removal page 15.10.
B AT T E R Y I N S TA L L AT I O N
1. See Battery Installation page 15.11.

© Copyright 2.37
MAINTENANCE
D R I V E B E LT I N S P E C T I O N
NOTICE
Inspect drive belt in accordance with Periodic Maintenance Interval Chart and replace at specified intervals
regardless of belt condition. See Maintenance Interval Chart page 2.5.
DRIVE BELT WEAR EXAMPLES CONDITION SERVICE RECOMMENDATION

External Tooth Cracks Replace Belt
Internal Tooth Cracks OK to run, but monitor condition
Fuzzy Edge Cord OK to run, but monitor condition
Hook Wear Replace Belt
Missing Teeth Replace Belt
Bevel Wear (Outer Edge Only) OK to run, but monitor condition
Chipping (Not Serious) OK to run, but monitor condition
Stone Damage Belt should be replaced if damage

is on the edge of the belt
1. Periodically inspect drive belt for cuts, excessive wear, foreign substance (oil, grit), missing teeth, or any
other damage.
2. If any damage is found, belt should be replaced.
NOTICE
Adjust drive belt tension at intervals in accordance with the Periodic Maintenance Interval Chart.
See Maintenance Interval Chart page 2.5.
3. If the drive belt or sprocket is being replaced due to damage, replace belt and both sprockets as a set if drive
system has more than 5000 miles (8000 Km) of use.

2.38 © Copyright
MAINTENANCE
D R I V E B E LT S P E C I F I C AT I O N S
D R I V E B E LT D E F L E C T I O N D ATA
MODEL DEFLECTION AT 10 LBS FORCE
Chief Classic
Chief Vintage 1.1” (28 mm) or 8 notches up on belt guard. See Drive Belt Tension page 2.40. 2
Chief Dark Horse
Springfield
Chieftain Dark Horse
Chieftain 1.3“ (34 mm) or 11 notches up on belt guard. See Drive Belt Tension page 2.40.
Roadmaster
Roadmaster Classic
D R I V E B E LT F R E Q U E N C Y T E N S I O N D ATA
NOTICE
Due to the low frequency levels produced by Indian Motorcycle drive belts, it is recommended to use a
commercially available CLAVIS optical sensor or equivalent to achieve the most accurate tension measurement.

© Copyright 2.39
MAINTENANCE
D R I V E B E LT T E N S I O N M E A S U R E M E N T • Continue to rotate the wheel in normal drive

Special Tool: Belt Tension Gauge PV-43532 direction (CLOCKWISE) 1-2 revolutions until
your reference mark (the tightest point) is lined
IMPORTANT up with the tension setting window in the lower
Do not adjust the belt when wet, or immediately after belt guard q.
riding. Belt must be dry and the drive system must be
at ambient temperature (60-80° F). This is extremely
important for accuracy.
IMPORTANT
Perform this procedure to achieve proper belt
tension and alignment. Belt tension should be set
before performing the alignment procedure.
WARNING
A drive belt that is not properly tensioned can cause
drive line noise and damage the drive belt, causing
possible belt failure and loss of control of the
motorcycle.
• Adjust belt deflection with wheel in this position.
WARNING 5. Place tape measure or ruler next to drive belt or

use the graduations on lower belt guard for
Care should be taken to be sure the motorcycle will reference.
not tip or fall while elevated. Severe personal injury
or death may occur if the motorcycle tips or falls. 6. Slide O-ring on belt tension gauge to the 10 lb.
mark.
• Place belt tension gauge squarely against belt at
1. Secure motorcycle in an upright position with the center and keep it at a 90° angle to the belt
front wheel clamped in a wheel vise. surface.
2. Shift transmission into NEUTRAL. •
3. ELEVATE rear wheel off the ground when checking
deflection or adjusting the belt. Belt Belt
Find Tight Spot In Belt

4. Use the tire valve stem as a reference and perform
the following Steps:
• Check / record belt deflection at 4 different
points, 90 degrees apart. Rotate wheel in a 90o
CLOCKWISE rotation as viewed from belt side of
motorcycle.
• Place a mark on rear wheel at the tightest point
(least deflection) to use as a reference. OK OK
7. Push up on gauge until O-ring just touches tool

body. See Drive Belt Specifications page 2.39 for
drive belt deflection specifications.

2.40 © Copyright
MAINTENANCE
8. If belt deflects more than the specified distance

with 10 lbs. of force, tighten the belt. If deflection is
less than specified loosen the belt.
See Drive Belt Adjustment page 2.42.
NOTICE
New drive systems (new vehicle or when belt and 2
sprockets are replaced) should be set to the tight
side of the specification and inspected after the first
500 miles (800 km).

© Copyright 2.41
MAINTENANCE
D R I V E B E LT A D J U S T M E N T 4. Loosen axle nut e and retighten to the

ADJUSTMENT SPECIFICATION during the
IMPORTANT
adjustment procedure.
Perform this procedure to achieve proper belt
tension and alignment. Belt tension should be set
before performing the alignment procedure.
Belt Tension
WARNING
A drive belt that is not properly tensioned can
cause drive line noise and damage the drive belt,
causing possible belt failure and loss of control of
the motorcycle.
NOTICE
Marks q and w are used as a reference for initial
wheel alignment. Marks should be in roughly the
same position on both left and right sides of wheel.
TORQUE
Axle Nut Torque (ADJUSTMENT SPECIFICATION):
15 ft-lbs (20 Nm)
5. Turn the RIGHT SIDE adjuster nut r to achieve

proper belt tension
See Drive Belt Tension Measurement page 2.40.

2. Make note of adjuster locations q and w.
3. Raise the rear of the motorcycle so the rear tire can
be freely rotated.

2.42 © Copyright
MAINTENANCE
6. When belt tension is correct, check and adjust final 9. If necessary, loosen the axle nut and LEFT SIDE
wheel alignment as follows: adjuster until belt just moves off the right flange
and begins to track down the center of the driven
Belt Alignment
sprocket flange during forward wheel rotation.
WARNING NOTICE
A drive belt that is not properly aligned can cause
drive line noise and damage the drive belt,
It may be necessary to loosen the axle nut and tap 2
the left end of the axle to ensure it moves forward
causing possible belt failure and loss of control of when the adjuster is loosened. The axle nut must be
the motorcycle. retightened to the ADJUSTMENT SPECIFICATION
before proceeding.
NOTICE
To minimize change in belt tension, use LEFT SIDE 10. Rear wheel alignment is satisfactory when the
adjuster only to make final adjustments to belt drive belt remains centered on driven sprocket
alignment. during forward and backward wheel rotation.
Sprocket teeth should be visible from both sides
of the drive belt.
7. Rotate the wheel BACKWARD. Tighten LEFT SIDE 11. Verify that drive belt tension is still within
adjuster until belt comes off inside sprocket flange specification.
during backward wheel rotation.
See Drive Belt Tension Measurement page 2.40.
IMPORTANT
12. Tighten rear axle nut to FINAL specification.
The belt should track to the center of the sprocket
tooth surface when properly aligned t. Sprocket TORQUE
teeth should be visible on both sides of the drive
belt. Axle Nut Torque (FINAL TIGHTENING):
1. Torque to 15 ft-lbs (20 N·m)2. Torque to 65 ft-lbs
(88 N·m)
8. Rotate the wheel in the FORWARD direction and
verify that sprocket teeth are still visible on both
sides of the drive belt t. 13. Pump rear brake pedal several times to reset brake
pad distance.
14. Verify wheel rotates smoothly and freely without
drag when brake pedal is released.
SPROCKET INSPECTION
NOTICE
Drive belt and sprocket service life are maximized
and drive line noise minimized by proper cleaning.
Cleaning interval is approximately every tire change,
or more often if operated in dirty, dusty, or high
debris environments.
Inspection
1. Clean the drive belt and front and rear sprockets
with a mild mixture of dish soap and warm water.
Rinse and dry thoroughly.
2. Inspect front and rear sprocket teeth for wear or
damage from foreign material.
3. Closely inspect drive belt condition.

© Copyright 2.43
MAINTENANCE
FUSE REPLACEMENT
Fuses and relays are located in the fuse box under the
LH upper side cover.
1. Remove LH upper side cover. See Side Cover
(Upper), Removal / Installation page 3.15.
2. Squeeze fuse box tabs together as shown and lift
cover off of fuse box.
3. If any fuse is blown, turn off main switch. Install

new fuse of specified amperage. Turn on switches
and see if system operates correctly. Repeat fuse
failure indicates an electrical problem.
CAUTION
Do not use fuses of a higher amperage rating than
what is specified.
If the correctly rated fuse continues to blow,
something is wrong and needs to be corrected.
Substituting a higher amperage fuse can lead to
extensive electrical system and vehicle damage.

2.44 © Copyright
MAINTENANCE
HEADLIGHT AIM INSPECTION 1. Check and adjust the tire pressure to specification.
Adjust headlight aim when there is a change in load See Tire Pressure / Specifications page 2.21.
(rider, cargo, accessories, etc.) or after suspension 2. Verify suspension ride height (preload) is set to
adjustment. specification. See Rear Shock Preload Inspection
To determine what headlight your model uses, refer to page 2.49.
GENERAL SPECIFICATIONS 3. Move the motorcycle to a clear area with a level
floor and dim lighting, and place it so the top front
2
• Models equipped with INCANDESCENT edge of the headlight housing is 25 ft. (7.6 m) from
headlights: the wall.
With the headlight switched to HIGH beam, the 4. With the rider and passenger ( if applicable) on
center of highest intensity (appears as a diamond board, bring the motorcycle to a fully upright
shape) should be 7.5 in (19 cm) below the height of position. Center the handlebars in a straight ahead
the headlight bulb when centered straight ahead at position.
25 feet (7.62 m).
5. Start the engine and switch the headlight on to the
• Models equipped with LED headlights: specified mode:
These models use LED bulbs. • INCANDESCENT = HIGH
With the headlight switched to LOW beam, the top • LED = LOW
of the highest intensity (appears as a diamond
shape) should be 3.0 in (7.6 cm) below the height of 6. Compare the position of headlight beam on the
the headlight bulb when centered straight ahead at wall to the illustration below and adjust if
25 feet (7.62 m). necessary. See Headlight Aim Adjustment page
2.47
Follow all steps below to ensure accurate aim
inspection.
INCANDESCENT HEADLIGHTS
HIGH
BEAM

© Copyright 2.45
MAINTENANCE
LED HEADLIGHTS
LOW
BEAM

2.46 © Copyright
MAINTENANCE
HEADLIGHT AIM ADJUSTMENT

NOTICE
Chieftain / Roadmaster models:
Access headlight adjustment fasteners by removing
the headlight bezel. See Headlight Bulb
Replacement - All Models page 17.14. 2
Classic / Vintage / Dark Horse / Springfield
models:
Headlight adjustment fasteners can be accessed
directly through the headlight nacelle. It is not
necessary to remove the nacelle for adjustment.
1. To adjust the headlight vertically, both adjustment

fasteners q must be turned in or out equally. Turn
fasteners in (clockwise) to lower the beam. Turn
fasteners out (counter-clockwise) to raise the
beam.
2. To adjust the headlight horizontally, turn the left

adjustment fastener out (counter-clockwise) to
adjust the beam to the left. Turn the right
adjustment fastener out (counter-clockwise) to
adjust the beam to the right.

© Copyright 2.47
MAINTENANCE
S I D E S TA N D I N S P E C T I O N 4. Pull sidestand rearward against spring tension

1. Support the motorcycle in an upright position with until mounting flange on sidestand is clear of the
the front wheel clamped in a wheel vise. mounting boss on the frame.
2. Inspect sidestand spring for damage or loss of 5. Relax tension and remove spring.
tension. Be sure stand returns to fully retracted
position. 6. Installation: Attach spring to sidestand.
3. Inspect sidestand for smooth movement. 7. Lightly grease sidestand mounting boss on frame
and the shouldered portion of the pivot fastener.
4. Inspect sidestand pivot fastener nut for proper
torque. 8. Place loose end of spring through hole in frame
rail.
TORQUE 9. With sidestand in the retracted position (up), pull
Sidestand Pivot Fastener: stand rearward against spring tension until the
37 ft-lbs (50.2 Nm) mounting flange on the sidestand drops onto the
mounting boss on the frame.
5. Replace sidestand if it is bent. Do not attempt to 10. Swing sidestand to the extended position to align
straighten sidestand. fastener hole and install NEW fastener and nut.
11. Torque to specification and wipe off any excess
S I D E S TA N D R E M O VA L / I N S TA L L AT I O N grease.
TORQUE
WARNING
Sidestand Pivot Fastener: 37 ft-lbs (50.2 Nm)
The sidestand spring is under tension. Wear eye and
face protection when removing and installing the
spring and sidestand. Be sure the vehicle is properly 12. Cycle the sidestand to be sure it moves freely, and
secured before you begin. returns to the fully retracted position.
IMPORTANT STEERING HEAD / FRONT WHEEL

Sidestand fasteners must be replaced any time the INSPECTION
sidestand is removed. The nut is a crushed lock and
therefor it can not be reused. WARNING
Care should be taken to be sure the motorcycle will
1. Sidestand will be moved between the UP not tip or fall while elevated. Severe personal injury
(retracted) and DOWN (extended) position during or death may occur if the motorcycle tips or falls.
removal and installation. Be sure vehicle is
properly secured.
NOTICE
2. Remove sidestand pivot fastener q using a 6mm
hex wrench while holding the nut with a 15 mm Be sure control cables, hoses and wiring are not
wrench. interfering with handle bar rotation.
1. Secure motorcycle with front wheel off the floor.

2. Turn handlebars from full left to full right and
inspect for smooth, free movement. Point front
wheel straight ahead, grasp fork tubes and pull/
push fork tubes back and forth. If steering binds,
feels rough or uneven, or if movement is detected
at steering stem, adjust or replace steering head
bearings as necessary.
3. Rotate front wheel and inspect for smooth rotation
of front wheel bearings. If roughness or unusual
sounds are present, replace front wheel bearings.
See Steering / Suspension chapter.
3. Grasp sidestand firmly and move it to the UP

position.

2.48 © Copyright
MAINTENANCE
4. Turn handle bars full right or left and hold against 5. Rotate rear wheel and inspect for smooth rotation
the fork stop. Attempt to move front wheel side-to- of rear wheel bearings. If roughness or unusual
side. If movement is observed, inspect front axle, sounds are detected, inspect rear wheel bearings,
wheel, and bearings. See Steering / Suspension belt tension and alignment, and brake pads.
chapter.
6. Inspect rear shock for leakage and all rear
suspension components for damage or loose
SWINGARM INSPECTION fasteners. 2
7. Inspect suspension pivots and shock mounts for
WARNING radial movement in all pivot joints. If a joint has
Care should be taken to be sure the motorcycle will radial movement, remove rear shock absorber and
not tip or fall while elevated. Severe personal injury inspect suspension pivot linkage. See Steering /
or death may occur if the motorcycle tips or falls. Suspension chapter.
8. Verify axle nut is tight.
1. Sit astride the motorcycle. Compress the rear
suspension several times and check for smooth 9. Replace any worn or damaged parts.
and quiet operation w.
2. Secure motorcycle with rear wheel elevated. REAR SHOCK PRELOAD INSPECTION
3. Inspect for worn swing arm bearings by grasping Periodically inspect rear shock preload. For the most
the rear wheel and attempting to move wheel side- comfortable ride and proper ground clearance, adjust
to-side q. preload if ride height is out of specification.
1. Verify that tire pressure is at specification.
See Tire Pressure / Specifications page 2.21.
3. Remove saddlebags, if equipped.
4. Apply a strip of removable tape q to the rear
fender directly over the center of the rear axle.
4. If movement is detected, determine if movement is

at axle area e or swingarm pivot area r. Refer to
Steering / Suspension chapter for wheel bearing
and swingarm bearing replacement.

© Copyright 2.49
MAINTENANCE
5. RECOMMENDED SUSPENSION SAG

CAUTION Chief Classic / Chief 35 mm
Vintage / Chief Dark
For CALIFORNIA and INTERNATIONAL motorcycles, Horse
the Evaporative Canister must be removed prior to
raising the motorcycle. If the canister is not removed Springfield / Chieftain 45 mm
and the motorcycle is raised, the fittings will contact Dark Horse / Chieftain /
the swingarm and become damaged. Roadmaster
Using a scissor jack or similar tool, raise the

motorcycle until the rear shock is completely
extended.
6. Measure the distance (in millimeters) from the
center of the rear axle w to the bottom of the tape
e. Record the results as measurement M1.
7. Lower the motorcycle and remove the scissor jack.

8. Load the motorcycle with all intended cargo.
Wearing riding gear, sit on the motorcycle in the
normal riding position.
IMPORTANT
Have an assistant stabilize the motorcycle in a
vertical position so rider can sit in a normal riding
position with feet on floorboards.
9. Have an assistant measure the same location.

Record the results as measurement M2.
10. Subtract measurement M2 from M1. The result is
the measured rider sag. (M1–M2=Sag)
11. Adjust preload as needed to achieve suspension
sag indicated in the table below.
See
• Rear Shock Preload Adjustment - Chief
Models page 2.51 or
• Rear Shock Preload Adjustment - Springfield /
Chieftain / Roadmaster page 2.51
for adjustment procedure.

2.50 © Copyright
MAINTENANCE
REAR SHOCK PRELOAD ADJUSTMENT - 7. Tighten the lock nut securely against the adjuster
CHIEF MODELS nut.
1. Place the motorcycle in an upright position with the 8. Install the seat as outlined in Frame / Body chapter.
2. Remove the seat as outlined in Frame / Body
chapter. 2
3. Using shock spanner wrench (PV-46993) loosen the
lock nut by turning it counter-clockwise (as viewed
from the top of the shock).
4. Spray a light lubricant on the adjuster nut where it
contacts the spring.
5. Adjust shock preload by rotating the adjuster nut
clockwise (as viewed from the top of the shock) to
INCREASE preload (firm) or counter-clockwise to
DECREASE preload (softer).
6. Recheck the preload measurement after adjusting.
R E A R S H O C K P R E L O A D A D J U S T M E N T - S P R I N G F I E L D / C H I E F TA I N / R O A D M A S T E R
Refer to the label located on the inside of the left side
cover. The label shows recommended pressures
based on potential load weights. Always inspect and
adjust shock preload (ride height) based on your
actual load weight.
AIR SUSPENSION ADJUSTMENT
AIR PRESSURE (PSI)

TOTAL CARGO & OCCUPANT LEATHER PAINTED
WEIGHT (LB) NO TRUNK TRUNK TRUNK MAX PRESSURE: 150 PSI
0 0 0 0
150 0 0 0
175 0 0 10
200 0 10 23
225 10 23 30
250 23 30 38
SELECT PRESSURE
275 30 38 48 CORRESPONDING TO TOTAL
CARGO AND OCCUPANT WEIGHT.
300 38 48 60 REMOVE ALL PASSENGERS AND
325 48 60 71 CARGO BEFORE SETTING /
CHECKING SHOCK PRESSURE. SET
350 60 71 85 PRESSURE WITH BIKE ON SIDE
STAND.
375 71 85 100
400 85 100 122
425 100 122 134
450 122 134 145
475 134 145 NA
500 145 NA NA

© Copyright 2.51
MAINTENANCE
IMPORTANT MAINTENANCE - CHECK WHEEL SPOKES

If your motorcycle is equipped with spoked wheels,
Follow these guidelines when adjusting: inspect both wheels for loose, bent, broken or missing
• Park motorcycle with the sidestand down on a firm, spokes. To identify loose spokes, grasp each spoke
level surface. and try to move it side to side or up and down. All
spokes should be equally tight and have the same
• Remove all riders and cargo. amount of flex. Tighten loose spokes or replace bent,
• DO NOT exceed 150 psi (1034 kPa) in the shock. broken or missing spokes.
• Use shock air pump (PV-48909) to complete Inspect spokes after first 500 miles, then again every
adjustment procedure. 5,000 miles.
1. Remove the LH upper side cover.

See Side Cover (Upper), Removal / Installation
page 3.15.
2. Remove the cap from the air fitting q.
3. Refer to the label on the inside of the LH side cover

to determine the recommended shock air pressure.
4. Install the hose fitting the shock air pump onto the
fitting and read the gauge.
5. To reduce air pressure, push the bleed button on
the gauge. Release air until the desired pressure
reading is obtained.
6. To increase pressure, pump the handle until
pressure increases to the desired level.
7. Remove the hose from the air fitting and reinstall
the cap.
8. Repeat the preload inspection to verify proper
preload. See Rear Shock Preload Inspection
page 2.49.

2.52 © Copyright
FRAME / BODY
CHAPTER 3
FRAME / BODY
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 3
ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
FENDERS / SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
FLOORBOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
FAIRING, CHIEFTAIN / ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
LOWER FAIRING, ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
SEAT - ALL (EXCEPT ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
SEAT - ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
SIDE PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11
TRUNK, ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12
SADDLEBAGS, CHIEFTAIN / ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13
NACELLE, VINTAGE / SPRINGFIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14
BODY / FRAME SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15
SIDE COVER (UPPER), REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15
SIDE COVER (LOWER), REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15
PASSENGER FOOT PEG BLANKS (DARK HORSE), REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .3.16
FLOORBOARD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16
FLOORBOARD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17
FOOT PEGS (PASSENGER), REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19
SEAT REMOVAL / INSTALLATION - ALL (EXCEPT ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19
SEAT REMOVAL / INSTALLATION - (ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
SEAT REMOVAL / INSTALLATION - (DARK HORSE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21
HIGHWAY BAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22
HIGHWAY BAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22
LOWER FAIRING REMOVAL - (ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23
LOWER FAIRING INSTALLATION - (ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23
FRONT FENDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24
FRONT FENDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26
TRUNK REMOVAL, ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26
TRUNK INSTALLATION, ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.27
TRUNK LOCK REPLACEMENT - ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28
REAR FENDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31
REAR FENDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.32
FRONT CASTING (MAIN FRAME), REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33
FRONT CASTING (MAIN FRAME), INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.36
INSTRUMENT PANEL REMOVAL / INSTALLATION - (CHIEFTAIN DARK HORSE) . . . . . . . . . . . . . . . . . . . . . .3.38
INSTRUMENT PANEL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.39
OUTER FAIRING REMOVAL, CHIEFTAIN / ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40

© Copyright 3.1
FRAME / BODY
INNER FAIRING REMOVAL, CHIEFTAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.42

INNER FAIRING INSTALLATION, CHIEFTAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.43
OUTER FAIRING INSTALLATION - CHIEFTAIN / ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.44
NACELLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.46
NACELLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.48

3.2 © Copyright
FRAME / BODY
SERVICE NOTES
This section covers the removal and installation of
frame and body components, assemblies and systems.
Pay close attention to assembly procedures and torque
specifications.
Cables, hoses and tie straps that have been removed
during disassembly must be replaced per factory
standards during assembly. Caution should be used
when tightening body panels. Any deformation on the
panel around the fastener is an indication that the 3
fastener is too tight. Do not over tighten body
components in order to avoid damage.
SPECIAL TOOLS
TOOL DESCRIPTION PART NUMBER
PV-49955 Body Panel Tool Kit

6657 or https://polaris.service-solutions.com/

© Copyright 3.3
FRAME / BODY
A S S E M B LY V I E W S
F E N D E R S / S E AT
NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)
q Passenger Seat Fastener 18 ft-lbs (24 N·m)
w Driver Seat Fastener 18 ft-lbs (24 N·m)
e Strut Cover Fastener 18 in-lbs (2 N·m)
r Rear Fender Upper Fastener 88 in-lbs (10 N·m)
t Rear Fender Lower Stud / Ball 88 in-lbs (10 N·m)
y Fender Fastener 18 ft-lbs (24 N·m)
u Caliper Cover Acorn Nut 18 in-lbs (2 N·m)
i Front Fender Fastener 18 ft-lbs (24 N·m)

3.4 © Copyright
FRAME / BODY
FRAME
q Fastener, Down Tube (Lower)— M10 x 1.5 x 60 (QTY.4) 45 ft-lbs (60 N·m)
w Fastener, Down Tube (Lower LH) — M10 x 1.5 x 25 45 ft-lbs (60 N·m)
(QTY.1)
e Fastener, Down Tube (Upper) — M10 x 1.5 x 100 (QTY.2) 45 ft-lbs (60 N·m)
r Fastener — M12 x 1.75 x 120 (QTY.3) 75 ft-lbs (102 N·m)
t Fastener, Midcast — M12 x 1.75 x 50 (QTY.3) 75 ft-lbs (102 N·m)
y Fastener, Rear Subframe — M10 x 1.5 x 35 (QTY.6) 35 ft-lbs (48 N·m)
u Fastener, Rear Lower Subframe — M8 x 1.25 x 20 (QTY.4) 18 ft-lbs (24 N·m)
i Fastener, Engine Bracket — M8 x 1.25 x 20 (QTY.2) 18 ft-lbs (24 N·m)

© Copyright 3.5
FRAME / BODY
FLOORBOARDS
q Fastener, Floorboard Pivot — M8 x 1.25 x 120 (QTY.2) 18 ft-lbs (24 N·m)
w Fastener, Floorboard Support — M10 x 1.5 x 30 (QTY.4) 35 ft-lbs (48 N·m)
e Fastener, Brake Pedal Pad — M6 x 1.0 x 15 (QTY.2) 18 ft-lbs (24 N·m)
r Shifter Toe Pedal 88 in-lbs (10 N·m)
t Floorboard Pan -
y Floorboard Pad -
u Brake Pedal Pad -
i External Snap Ring (Brake Pedal and Shifter) -
o Retaining Pin, Pushrod -
a Passenger Foot Peg Support Bracket -
s Passenger Foot Peg -

3.6 © Copyright
FRAME / BODY
FA I R I N G , C H I E F TA I N / R O A D M A S T E R
q Bolt, Bezel — M6 x 1.0 (QTY.2) 36 in-lbs (4.1 Nm)
w Headlight Bezel —
e Screw, Headlight Bracket — M6 x 1.0 x 40 (QTY.3) NA
r Screw, Fairing — NOTE: Screws differ in size See Fairing Installation (Frame / Body
chapter)
t Speaker Grill, RH —
y Speaker Grill, LH —

© Copyright 3.7
FRAME / BODY
L O W E R FA I R I N G , R O A D M A S T E R
q Fastener, Inner to Outer Fairing - (QTY.10) 12 ft-lbs (16 N·m)
w Fastener, Clamp - M6 x 1.0 x 16 - (QTY 6) 36 in-lbs (4 N·m)

3.8 © Copyright
FRAME / BODY
S E AT - A L L ( E X C E P T R O A D M A S T E R )
q Seat, Passenger (except Dark Horse) –
w Seat, Driver –
e Fastener, Seat - M8 x 1.25 x 20 (QTY.2) 18 ft-lbs (24 N·m)

Fastener, Seat - M8 x 1.25 x 16 (QTY.1) 88 in-lbs (10 N·m)
r (except Dark Horse)
Fastener, Passenger to Driver Seat - M x 88 in-lbs (10 N·m)
t 1.0 x 15 (QTY.4) (except Dark Horse)
y Washer (QTY.1) (except Dark Horse) –
u Washer (QTY.1) (except Dark Horse) –

© Copyright 3.9
FRAME / BODY
S E AT - R O A D M A S T E R
q Harness, Trunk –
w Strap - Passenger Seat –
e Heated Seat Assembly –
r Wire Cover –
t Cable Tie –
y Fastener - M8 x 1.25x16 (QTY.1) 88 in-lbs (10 N·m)
u Fastener, Seat - M8 x 1.25 x 20 (QTY.2) 18 ft-lbs (24 N·m)
i Fastener, Strap - M6 x 1.0 x 25 (QTY.2) 88 in-lbs (10 N·m)
o Fastener (QTY.4) 18 ft-lbs (24 N·m)
a Washer (QTY.1) –
s Washer (QTY.1) –

3.10 © Copyright
FRAME / BODY
S I D E PA N E L S
q Side Cover, Left Hand Upper —
w Rubber Grommet —
e Fastener, Left Hand Lower Side Cover — M6 x 1.0 x 15 88 in-lbs (10 N·m)
(QTY.3)
r Side Cover, Left Hand Lower —
t Rubber Isolator —
y Side Cover, Right Hand Lower —
u Fastener, Right Hand Sprocket Cover — M6 x 1.0 x 70 88 in-lbs (10 N·m)

(QTY.2)
i Fastener, Right Hand Sprocket Cover — M6 x 1.0 x 40 88 in-lbs (10 N·m)

(QTY.2)
o Side Cover, Right Hand Upper —

© Copyright 3.11
FRAME / BODY
TRUNK, ROADMASTER
q Fastener, Trunk Base - M8 x 1.25 x 20 (QTY.10) 13 ft-lbs (17.6 Nm)
w Fastener, Trunk Back - M6 x 1.0 x 20 (QTY.2) 12 in-lbs (1.4 Nm)
e Luggage Rack -
r Washer, Cup -
t Washer, Upper -
y Washer, Lower -
u Fastener, Luggage Rack - M6 x 1.0 x 20 (QTY.4) 12 in-lbs (1.4 Nm)

3.12 © Copyright
FRAME / BODY
S A D D L E B A G S , C H I E F TA I N / R O A D M A S T E R

q Pad, Saddle Bag Mount (QTY.4) -
w Bracket, Saddle Bag Mount (QTY.4) -
e Fastener - M6 x 1.0 x 16 (QTY.16) 88 in-lbs (10 N·m)

r Fastener, Latch Striker - M4 x 0.7 x 16 (QTY.4) 36 in-lbs (4 N·m)
t Washer, Rubber (QTY.4) -
y Spacer, Saddlebag Latch (QTY.4) -
u Bushing, Rubber (QTY.4) -
i Pin, Anchor (QTY.4) -
o Fastener, Spool - M8 x 1.25 x 25 (QTY.4) 25 ft-lbs (34 N·m)
a Spool (QTY.4) -
s Hinge, Lid (QTY.4) -
d Fastener, Hinge - M5 x 0.8 x 12 (QTY.4) 45 in-lbs (5 N·m)
f Fastener, Latch Asm. - M6 x 1.0 x 20 (QTY.4) 65 in-lbs (7 N·m)
g Actuator, Lock (QTY.2) -
h Seal, Saddlebag Lock (QTY.2) -
j Lock Cylinder (QTY.2) -
k Handle, Latch (QTY.2) -

© Copyright 3.13
FRAME / BODY
N A C E L L E , V I N TA G E / S P R I N G F I E L D

q Cover, Front Headlight(QTY.1) -
w Fastener - #8-18 x .50” (QTY.4) 36 in-lbs (4 N·m)
e Retaining Ring, Bulb (QTY.1) -
r Fastener, Headlight Adjuster (QTY.2) -
t Bushing, Headlight Flange (QTY.3) -
y Bracket, Headlight (QTY.1) -
u Isolator, Headlight (QTY.3) -
i Washer - 6.4 x 10 x 1.6 (QTY.3) -
o Fastener - M6 x 1.0 x 35 (QTY.3) -
a Fastener - 10-16 (QTY.1) 12 in-lbs (1 N·m)
s Grommet (QTY.1) -
d Spring, Headlight Adjuster (QTY.2) -
f Carrier, Headlight (QTY.1) -
g Cover, Front Nacelle (QTY.1) -
h Washer, Flat (QTY.4) -
j Fastener - M6 x 1.0 x 15 (QTY.4) 12 in-lbs (1 N·m)
k Fastener - M6 x 1.0 x 16 (QTY.2) 36 in-lbs (4 N·m)
l Clip, Speed Nut (QTY.2) -
1( Cover, Rear Nacelle (QTY.1) -
2) Spacer, Nacelle Bezel (QTY.1) -

3.14 © Copyright
FRAME / BODY
BODY / FRAME SERVICE

S I D E C O V E R ( U P P E R ) , R E M O VA L / S I D E C O V E R ( L O W E R ) , R E M O VA L /
I N S TA L L AT I O N I N S TA L L AT I O N
CAUTION CAUTION
Use care not to scratch or damage painted surfaces Use care not to scratch or damage painted surfaces
during side cover removal and / or installation. during side cover removal and /or installation.
1. Working from the right side of the motorcycle, pull

1. Remove the upper side covers page 3.15 from both
corners of the upper cover evenly straight outward
to disengage each tab from rubber grommet in sides of the motorcycle. 3
frame. 2. If applicable, remove the passenger foot pegs
page 3.19 from both sides of the motorcycle.
3. Remove theCross Over Pipe Removal page 5.15.
4. Pull the rear edge of the right-hand lower side
panel straight out to disengage the two rubber
grommets q.
2. Working from the left hand side of the motorcycle,

pull corners of the upper cover evenly straight
outward to disengage each tab from rubber
grommet in frame.
5. Pull back slightly on the right-hand lower side

panel to disengage from the front rubber grommet.
6. Working from the left-hand side of the motorcycle,
use a 6 mm hex wrench to remove the three
fasteners w securing the panel to the frame.
Remove panel.
INSTALLATION is performed by reversing the re-

moval procedure. Using a mild soapy water solu-
tion on the rubber grommets will make it easier to
press the side covers into position.

© Copyright 3.15
FRAME / BODY
7. INSTALLATION is performed by reversing the F L O O R B O A R D R E M O VA L

removal procedure. Using a mild soapy water Secure the motorcycle in an upright position.
solution on the rubber grommets will make it For detailed floorboard assembly / disassembly infor-
easier to press the side covers into position. mation, please see the FLOORBOARD ASSEMBLY
VIEW page 3.6 located in this chapter.
TORQUE
1. Remove cotter pin and washer q from brake
Left-Hand Side Cover Fasteners: master cylinder pushrod. Disengage pushrod from
88 in-lbs (10 N·m) the brake pedal assembly.
PA S S E N G E R F O O T P E G B L A N K S ( D A R K
H O R S E ) , R E M O VA L / I N S TA L L AT I O N
1. Remove fastener q and passenger foot peg blank
w.
2. Loosen the jam nut w and remove the brake

master cylinder from the RH floorboard assembly
and move out of the way.
2. Installation is performed by reversing the

removal procedure. Torque fasteners to
specification.
TORQUE
Foot Peg Blank Fastener:
35 ft-lbs (48 N·m)
CAUTION
Do not bend or kink flexible brake line during
floorboard removal. Master cylinder assembly
should be kept in an upright position and properly
supported at all times.

3.16 © Copyright
FRAME / BODY
3. Working on the RH side of the motorcycle, remove F L O O R B O A R D I N S TA L L AT I O N

the two fasteners e securing the floorboard Secure the motorcycle in an upright position.
support bracket to the frame. 1. Working from the left-hand side of the motorcycle,
lift the floorboard assembly into position and
torque the two fasteners q to specification.
4. Working from the left side of the motorcycle,

remove the rear shift rod fastener r and move
shift rod out of the way.
TORQUE
Floorboard Bracket Fasteners:
35 ft-lbs (48 N·m)
2. Lift the shift rod into position at the inside of the

shift arm and torque shift rod fastener w to
specification.
5. Remove the two fasteners t securing the LH

floorboard to the frame and remove floorboard
assembly.
TORQUE
Shift Rod Fastener:
88 in-lbs (10 N·m)

© Copyright 3.17
FRAME / BODY
3. Working on the right-hand side of the motorcycle, 5. Apply a thin coat of grease to the pushrod pivot
lift the floorboard assembly into position and pin t and connect the pushrod to the foot pedal
torque the two fasteners e to specification. linkage.
TORQUE 6. Test foot brake and verify that the pedal feels
good and no air has entered the hydraulic circuit.
Floorboard Bracket Fasteners: Bleed brakes if necessary.
35 ft-lbs (48 N·m)
4. Lower the master cylinder assembly onto the

floorboard bracket and torque the jam nut r to
specification.
TORQUE
Master Cylinder Jam Nut:
35 ft-lbs (48 N·m)

3.18 © Copyright
FRAME / BODY
F O O T P E G S ( PA S S E N G E R ) , R E M O VA L / S E AT R E M O VA L / I N S TA L L AT I O N - A L L
I N S TA L L AT I O N (EXCEPT ROADMASTER)
1. Remove fasteners q securing foot peg bracket to 1. Remove left and right side covers. page 3.15
frame.
2. Using a 6 mm hex wrench, remove the two
2. Remove foot peg / bracket as an assembly. fasteners q securing the driver’s seat to the frame.
NOTICE
It may be necessary to lift the seat skirt to access the
side fasteners on some models.
3. Remove the passenger seat fastener w.
3. INSTALLATION is performed by reversing the

removal procedure.
4. Torque passenger foot peg bracket fasteners q to
specification.
TORQUE
Passenger Foot Peg Fasteners:
35 ft-lbs (48 N·m)

© Copyright 3.19
FRAME / BODY
4. Lift the rear of the seat and pull rearward to S E AT R E M O VA L / I N S TA L L AT I O N -

disengage front retaining arms from the bracket (ROADMASTER)
behind the fuel tank. 1. Remove left and right side covers. page 3.15
2. Remove trunk assembly. See Trunk Removal,
Roadmaster page 3.26.
fasteners q securing the driver’s seat to the frame.

removal procedure.
6. Torque the seat fasteners to specification.
TORQUE
Seat Fasteners (All): NOTICE
18 ft-lbs (24 N·m)
4. Remove the passenger seat fastener w.

3.20 © Copyright
FRAME / BODY
5. Lift the rear of the seat and pull rearward to S E AT R E M O VA L / I N S TA L L AT I O N - ( D A R K

disengage front retaining arms from the bracket HORSE)
behind the fuel tank.
1. Remove left and right side covers. page 3.15
fasteners q securing the driver’s seat to the frame.
6. If applicable, disconnect the trunk harness q and

heated seat connector w.
NOTICE
3. Lift the rear of the seat and pull rearward to

disengage front retaining arms from the bracket
behind the fuel tank.
NOTICE
Mark the vehicle side connectors with tape for
reference during seat installation.
7. Remove the seat assembly.

removal procedure.
9. Torque the seat fasteners to specification.
TORQUE
Seat Fasteners (All):
18 ft-lbs (24 N·m) 4. INSTALLATION is performed by reversing the
removal procedure.
TORQUE
Seat Fasteners (All):
18 ft-lbs (24 N·m)

© Copyright 3.21
FRAME / BODY
H I G H WAY B A R R E M O VA L H I G H WAY B A R I N S TA L L AT I O N
Place the motorcycle on the side stand. Turn the han- Place the motorcycle on the side stand. Turn the han-
dlebar all the way to the left. dlebar all the way to the left.
CAUTION CAUTION
Protect chrome and painted surfaces prior to Protect chrome and painted surfaces prior to
removal, particularly the front fender. removal, particularly the front fender.
1. Using an 8 mm hex wrench, remove the lower two 1. Carefully maneuver the highway bar into position
fasteners q from the right and left side of the and thread the upper mounting fasteners q in
highway bar assembly. finger tight.
2. 2. Install the lower mounting fasteners w and torque

upper and lower fasteners to specification.
CAUTION
Hold the highway bar assembly in place while
removing the top fasteners so it doesn’t swing down
and damage the front fender.
Using a 6 mm hex wrench, remove the top two

fasteners w from the highway bar assembly.
TORQUE
Upper Highway Bar Fasteners: 18 ft-lbs (24 N·m)
Lower Highway Bar Fasteners: 35 ft-lbs (48 N·m)
3. Carefully maneuver the highway bar out from the

frame / fender area.

3.22 © Copyright
FRAME / BODY
L O W E R FA I R I N G R E M O VA L - ( R O A D M A S T E R ) L O W E R FA I R I N G I N S TA L L AT I O N -
(ROADMASTER)
CAUTION
1. Install the upper and lower fairing clamps onto the
Painted surfaces can be easily scratched or damaged highway bars as shown.
during removal and installation. Be sure you have a
safe location to store painted body components NOTICE
before they are removed.
• The upper fairing clamp is positioned against the
1. Remove fasteners q and carefully remove the locating dowel q.
outer fairing assembly. • The lower fairing clamp is positioned to the outside
of the locating mark w.
3
• The center (outer) fairing clamp is attached last
and does not have a locating mark.
2. Remove fasteners w from clamps securing the

inner fairing assembly to the highway bars.
3. Remove the inner fairing assembly and associated

clamps from the highway bars.
2. Position the inner fairing assembly over the
highway bar so the clamps line up with the fastener
holes.
3. Install the upper and lower clamp fasteners finger
tight.

© Copyright 3.23
FRAME / BODY
4. Position the center (outer) fairing clamp onto the 8. Alternately tighten outer fairing fasteners to
highway bar and line up with the fastener hole in specified torque.
the fairing.
TORQUE
5. Starting with the upper clamp, followed by the
lower and center clamps, torque all clamp Inner to Outer Fairing Fasteners:
fasteners e to specification. 36 in-lbs (4 N·m)
F R O N T F E N D E R R E M O VA L
NOTICE
Motorcycle should be parked on a level surface
resting on the side stand.
CAUTION
Use care not to scratch or damage painted surfaces
during fender removal and / or installation.

each side of the motorcycle and remove the
caliper covers e.
TORQUE
Lower Fairing Clamp Fasteners:
36 in-lbs (4 N·m)
6. Carefully position the outer fairing assembly over

the inner and align the fastener holes.
7. Install the five fasteners r securing the outer
fairing to the inner fairing finger tight.
2. Follow the fender light harness up into the fairing /

nacelle, locate the connector and disconnect.
3. Noting their position for reinstallation, cut the
cable ties that are securing the fender light wire
harness to the brake line.

3.24 © Copyright
FRAME / BODY
4. Remove the three fasteners r from each side of

the fender.
5. Stand in front of the motorcycle facing the front

fender and squeeze the sides together while
“rolling” the fender out from the fork legs.
IMPORTANT
Once fender has been removed from the
motorcycle, make sure the fender is stored safely
until it is reinstalled.

© Copyright 3.25
FRAME / BODY
F R O N T F E N D E R I N S TA L L AT I O N 4. Install cable ties to secure fender light harness

away from moving parts.
NOTICE
Motorcycle should be parked on a level surface 5. Install caliper cover. Torque to specification.
resting on the side stand. TORQUE
Caliper Cover Acorn Nuts:
CAUTION 18 in-lbs (2 N·m)
during fender removal and / or installation. 6. Turn the handlebar all the way to the left and right
to verify proper operation and freedom of
movement.
1. Gently squeeze the sides of the front fender and
“roll” the fender into position so the fastener holes
line up.
T R U N K R E M O VA L , R O A D M A S T E R
1. If applicable, remove the left and right saddlebags
and remove the trunk lock fastener q from each
trunk latch.
2. Install the three fasteners q on each side of the

fender and torque to specification.
2. Disconnect the trunk harness multi-plug w.
TORQUE
Front Fender Fasteners:
18 ft-lbs (24 N·m)
3. Route the fender light wire harness into the fairing

/ nacelle and reconnect.

3.26 © Copyright
FRAME / BODY
3. Lift the trunk latches e to unlock the trunk from the T R U N K I N S TA L L AT I O N , R O A D M A S T E R

mount.
CAUTION
Use care when installing the trunk assembly so that
no electrical wires / connectors get pinched.
1. Lift the flap at the rear of the passenger seat pad to

access the vehicle side of the trunk harness
connector and lay harness on fender.
3
4. Lift up on the rear of the trunk r and slide

rearward t to release the trunk from the
motorcycle.
2. Slide the trunk forward q onto the mounting

bracket and lower w the rear of the trunk until fully
seated.

© Copyright 3.27
FRAME / BODY
3. Push the trunk locking levers e down until fully TRUNK LOCK REPLACEMENT -
seated and the trunk is held securely in place. ROADMASTER
NOTICE
It is recommended that the trunk is removed from the
motorcycle prior to disassembly. See TRUNK
REMOVAL as outlined in this chapter.
R E M O VA L
1. Remove the trunk from the motorcycle and place
on flat work surface.
2. Open the trunk lid completely.
3. Lift the trunk liner q up to remove from trunk base.
4. Reconnect the trunk harness connector r.
5. If applicable, install the mounting fasteners t into

left and right locking levers.
6. Install saddlebags, if equipped.

3.28 © Copyright
FRAME / BODY
4. Insert body panel tool (PV-49955) or similar into 6. Remove the four fasteners r securing the lock
the relief holes w cut into the bezel and gently pry assembly to the trunk.
bezel off of the trunk base.
7. Remove the latch and lock actuator together as an

NOTICE assembly.
Bezel is held in place with pressure sensitive 8. If replacing individual components, disconnect the
adhesive. It will be necessary to replace the adhesive lock actuator cable from the latch assembly to
with a suitable alternative (e.g. double sided tape) separate the components.
when the bezel is reinstalled.
5. Remove the two fasteners e from the lock actuator

bracket and disconnect electrical connector.

© Copyright 3.29
FRAME / BODY
I N S TA L L AT I O N
1. Install the latch / lock actuator assembly and
tighten fasteners finger-tight.
2. Torque latch fasteners to specification following the
torque sequence.
TORQUE
Trunk Latch Fasteners:
65 in-lbs (7 N·m)
3. Torque lock actuator fasteners to specification.

TORQUE
Lock Actuator Fasteners:
12 in-lbs (1 N·m)
4. If installing a new latch bezel:

• Peel protective layer off of pressure sensitive
adhesive
• Press bezel into place on the trunk bin with constant
and even pressure and hold for 30 seconds.
5. Install trunk liner.

6. Operate lock and latch assembly to verify proper
operation.

3.30 © Copyright
FRAME / BODY
R E A R F E N D E R R E M O VA L 9. Locate the rear harness connector y and

disconnect.
1. Disconnect the antenna cable from the mast.
2. Remove seat. See Seat Removal / Installation - All
(except Roadmaster) page 3.19
3. Remove upper side panels. See Side Cover
4. Remove lower side panels. See Side Cover
(Lower), Removal / Installation page 3.15.
5. Remove saddlebags, if equipped. 3
6. Using a 6mm hex wrench, remove the saddlebag
mounting cylinders q from both sides of the
fender, if equipped.
7. Remove the strut cover fasteners w and the strut 10. Loosen the four fasteners u on the underside of the
covers e from both sides of fender. fender.
11. Remove the three plastic darts i on the upper,

forward lip of the fender.
8. Remove fasteners r and t from both sides of the
fender.
12. Lift the fender off of the motorcycle.

NOTICE
There is enough slack in the antenna wire to remove
fender, turn it over and clip the cable ties.
CAUTION
Be careful not to damage painted surfaces.

© Copyright 3.31
FRAME / BODY
R E A R F E N D E R I N S TA L L AT I O N 4. Install the four fasteners e on the inside of the

fender so they are finger tight.
CAUTION
during fender removal and / or installation.
1. Route the rear harness and antenna cable along

the rear fender and secure with cable ties.
2. Place the rear fender assembly onto the
motorcycle so the top fastener holes line up and
install fasteners q so they are finger tight.
5. Plug the rear harness connector r into the chassis

harness.
3. Line up the holes of the dust cover and install the

three plastic darts w as shown.
6. Install forward fender fasteners t on both sides of

the fender and torque to specification.
TORQUE
Forward Fender Fasteners t:
88 in-lbs (10 N·m)

3.32 © Copyright
FRAME / BODY
7. Torque top fender fasteners q to specification. F R O N T C A S T I N G ( M A I N F R A M E ) , R E M O VA L

TORQUE
WARNING
Top Fender Fastener q: Care should be taken to be sure the motorcycle will
88 in-lbs (10 N·m) not tip or fall while elevated. Severe personal injury
or death could occur if the motorcycle tips or falls.
8. Torque the lower inside fender fasteners e to
specification.
TORQUE front wheel clamped in a wheel vise.
Inside Fender Fasteners e: 2. Remove the fuel tank. See Fuel Tank Removal 3
88 in-lbs (10 N·m) page .
3. Disconnect the negative cable from the battery. See
9. Install strut covers i and strut cover fasteners u Battery Removal page 15.10.
and torque to specification.
4. Remove the lower side covers. See Side Cover
TORQUE (Lower), Removal / Installation page 3.15.
Strut Cover Fasteners: 5. Remove the front triple clamps. See Triple Clamp
88 in-lbs (10 N·m) Removal page .
6. Remove the driver floorboard assemblies. See
10. Install saddlebag mounting cylinders and Floorboard Removal page 3.16.
mounting cylinder fasteners y, if equipped, and
7. Remove the highway bar assembly. See Highway
torque to specification.
Bar Removal page 3.22.
8. Remove the head pipes. See Head Pipe Removal
page 5.17.
9. If applicable, disconnect the oil cooler from the
down tubes. See Oil Cooler Removal page 4.13.
10. Unclip the harness conduit from the front casting.
11. Remove the upper fasteners q from the left side
down tube.
TORQUE
Mounting Cylinder Fasteners:
25 in-lbs (3 N·m)
11. Install lower side panels. See Side Cover (Lower),

Removal / Installation page 3.15.
12. Install upper side panels. See Side Cover (Upper),
13. Install seat as outlined in this chapter.
14. Install saddlebags, if equipped.
15. Connect antenna cable to mast.

© Copyright 3.33
FRAME / BODY
12. Loosen lower fasteners w and e enough so the 14. Remove fastener t and loosen fasteners y and u
dowels can be released from the front casting. on the right side mid-casting.
NOTICE
Remove the upper spacer from between the mid-
casting and the engine.
13. Remove fasteners r from the mid casting.
15. Move the front casting toward the right hand side of
the motorcycle to release dowels i and o.

3.34 © Copyright
FRAME / BODY
16. Remove the front casting from the motorcycle.

© Copyright 3.35
FRAME / BODY
FRONT CASTING (MAIN FRAME), 3. Loosely install the upper down tube fasteners e
I N S TA L L AT I O N through the front casting.
1. Lower the front casting into position over the

engine.
4. DO NOT install the upper engine spacer r at

this time; Starting with the lower engine mount y
torque mid-cast fasteners t and y to specification.
2. Move the front casting to the left side of the
motorcycle and engage the dowels q and w on the
mid-casting and down tube.
TORQUE
Upper Mid-Cast Fasteners t:
IMPORTANT 35 ft-lbs (48 N·m)
The upper engine spacer will not be installed during
the initial torque and measurement stage of this TORQUE
procedure.
Lower Mid-Cast Fastener y:
75 ft-lbs (102 N·m)

3.36 © Copyright
FRAME / BODY
5. Torque front casting fasteners u to specification. 7. Torque lower right-hand down tube fasteners s to
specification.
TORQUE
TORQUE
Front Cast to Mid-Cast Fasteners u:
75 ft-lbs (102 N·m) Lower, Right-Hand Down Tube Fasteners s:
45 ft-lbs (60 N·m)
6. Torque left hand down tube fasteners i, o and a
to specification. 8. Measure the gap d between the engine and mid-
cast where the upper spacer should be.
Upper Engine Spacer Gap: 6.5 mm — 10.0 mm
TORQUE
Upper, Left-Hand Down Tube Fasteners i:
45 ft-lbs (60 N·m)
9. If the gap is correct, the upper spacer can be
installed and the upper fastener torqued to
TORQUE specification.
Lower, Left-Hand Down Tube Fasteners o & a: TORQUE
45 ft-lbs (60 N·m)
Upper Engine Mount Fastener:
75 ft-lbs (102 N·m)

© Copyright 3.37
FRAME / BODY
10. If the gap is incorrect, repeat STEPS 4-8 until gap I N S T R U M E N T PA N E L R E M O VA L /

measurement is correct. Torque upper engine I N S TA L L AT I O N - ( C H I E F TA I N D A R K H O R S E )
mount fastener to specification.
1. Position the motorcycle on it’s side stand on a flat
11. Reverse STEPS 2 - 10 from the removal procedure surface.
to complete installation.
2. Using Body Panel tool (PV-49955) or a similar tool,
alternately lift the LH side q and RH side w of the
instrument panel until the rubber retainer is free.
3. Lift instrument panel out of the fairing mount and

disconnect the single multi-plug.
removal procedure. Using a mild soapy water
solution on the rubber seal will make it easier
to press the instrument panel into position.
CAUTION
Do not use alcohol on seal for installation.

3.38 © Copyright
FRAME / BODY
I N S T R U M E N T PA N E L R E M O VA L / 5. Remove the rubber grommet e from the console

I N S TA L L AT I O N cover.
1. Position the motorcycle on it’s side stand on a flat
surface.
2. Remove the console cover. See STEPS 1– 5 of Fuel
Tank Removal page .
3. Remove fasteners q securing bracket to
speedometer head and remove fasteners w
securing the speedometer bracket to the console
cover. 3

removal procedure. Using a mild soapy water
solution on the rubber seal will make it easier
to press the instrument panel into position.
7. Torque speedometer bracket fasteners to
specification.
TORQUE
Speedometer to Bracket Fasteners:
4. Remove the bezel from the speedometer and lift 88 in-lbs (10 N·m)
the speedometer head out of the rubber grommet.
TORQUE
Bracket to Console Cover Fasteners:
88 in-lbs (10 N·m)

© Copyright 3.39
FRAME / BODY
O U T E R FA I R I N G R E M O VA L , C H I E F TA I N / 3. Remove the four LONG screws w from the top of

ROADMASTER the fairing assembly.
Place the power windshield in the FULL UP position
prior to fairing removal.
CAUTION
Screws removed in STEPS 3 & 5 are different lengths.
It is imperative that the screws are reinstalled in the
same positions they are removed from or damage to
outer fairing may occur. Reference the drawing
below for proper screw locations.
4. Using the Body Panel tool (PV-49955), gently pry

the LH e and RH r speaker grill out of the inner
fairing assembly.
1. Place the motorcycle on a flat surface resting on

it’s side stand.
2.
NOTE
When removing the five windshield screws be sure to 5. Remove six screws t from the inner fairing
capture the T-nuts as they are not captive. assembly.
Remove the five screws q from the windshield and

remove windshield.
NOTE
The top screw on each side will be LONG. The
bottom two screws on each side will be short.

3.40 © Copyright
FRAME / BODY
6. Remove two screws y and head light bezel.
7. Remove three screws u and withdraw the head

light assembly far enough to disconnect electrical
connector.
8. Remove fairing assembly.

© Copyright 3.41
FRAME / BODY
I N N E R FA I R I N G R E M O VA L , C H I E F TA I N 5. Using a side-cutter, carefully clip the outboard

cable ties e.
NOTE
The inner fairing assembly can be removed with the
radio module, power windshield actuator and
speakers intact.
CAUTION
During disassembly, pay close attention to harness
routing and connector orientation. Always route
electrical wiring the same way as it was removed to
avoid damaging wires and connectors.
1. Remove the outer fairing. See Outer Fairing

Removal, Chieftain / Roadmaster page 3.40.
2. Remove the instrument cluster. See Instrument
Cluster, Chieftain page .
3. Remove the four nuts and washers q as shown.
IMPORTANT
Use a marker or tape to index each multi-plug before
disconnecting. Some of the connectors are unmarked
and interchangeable.
6. Disconnect all multi-plugs between the fairing and

chassis harnesses.
7. Disconnect the 12V accessory socket connector
and fog lamp button.
8. Lift the inner fairing assembly off of the triple
clamp studs and route wire through the access
hole.
4. Using a side-cutter, carefully clip the four cable

ties w securing the wiring harness to the inner
fairing.

3.42 © Copyright
FRAME / BODY
I N N E R FA I R I N G I N S TA L L AT I O N , C H I E F TA I N 5. Route the fog lamp button and 12V accessory

socket harnesses so they can be secured by their
CAUTION respective cable ties e, and reconnect.
During installation of the inner fairing, pay close
attention to harness routing and connector
orientation. Always route electrical wiring the same
way as it was removed to avoid damaging wires and
connectors.
1. Rest the inner fairing assembly on the lower

mounting studs q and tilt forward. 3
6. Paying attention to the natural form of the wiring

harness, reconnect all of the multi-plugs between
the chassis and inner faring.
IMPORTANT
Pay attention to index marks placed on connectors
during disassembly when reconnecting as some of
them are interchangeable.
2. Carefully route all loose wires through the access
hole in the inner fairing mount. 7. Connect the radio antenna and radio multi-plugs.
3. Install the inner fairing assembly on the four triple 8. Remove the cut cable ties from the four fir tree
clamp studs w and install washers and nuts finger clips and install new cable ties.
tight. 9. Position the wiring harness so it can be secured by
the four cable ties.
10. Replace the cable ties securing the fog lamp
button and 12V accessory socket to the inner
fairing.
11. Install the outer fairing assembly. See Outer
Fairing Installation, Chieftain / Roadmaster page
3.44.
12. Install the instrument cluster. See Instrument
Cluster, Chieftain page
4. Verify that no wires or connectors have been

pinched between the inner fairing and the triple
clamp and torque mounting nuts to specifications.
TORQUE
Inner Fairing Mounting Nuts: 12 ft-lbs (16.3 Nm)

© Copyright 3.43
FRAME / BODY
O U T E R FA I R I N G I N S TA L L AT I O N - C H I E F TA I N 2. Install the head light assembly w and torque

/ ROADMASTER screws to specification.
CAUTION
Screws installed in STEPS 4 & 6 are different lengths.
It is imperative that the screws are installed in the
correct location or damage to outer fairing may
occur. Reference the drawing below for proper screw
locations.
TORQUE
Head Light Bracket Screws: 7 ft-lbs (9.5 Nm)
3. Install head light bezel and torque screws e to

specification.
1. Install outer fairing assembly q onto fairing

subframe as shown.
TORQUE
Head Light Bezel: 36 in-lbs (4.1 Nm)

3.44 © Copyright
FRAME / BODY
4. 7. Install the windshield and torque screws y to

specification.
NOTE
Screws r and t used to secure outer fairing to inner
fairing are different sizes. The four screws along the
top and the top screw on each side are LONG. The
bottom two screws on each side are SHORT.
Install the six screws r into the inner fairing

assembly and torque to specification.
3
TORQUE
Windshield Screws: 36 in-lbs (4.1 Nm)
TORQUE
Inner Fairing Screws: 36 in-lbs (4.1 Nm)
5. Install the LH and RH speaker grills.

6. Install the four screws t into the top of the fairing
assembly and torque to specification.
TORQUE
Upper Fairing Screws: 36 in-lbs (4.1 Nm)

© Copyright 3.45
FRAME / BODY
N A C E L L E R E M O VA L 4. Remove two fasteners per side e securing the

windshield mounting bracket assembly.
CAUTION
Protect painted surfaces on the front fender and fuel
tank prior to beginning the following procedure. Use
care when removing the nacelle so the chrome does
not get scratched.
CAUTION
During disassembly, pay close attention to harness
routing and connector orientation. Always route
electrical wiring the same way as it was removed to
avoid damaging wires and connectors.
1. Remove windshield assembly, if equipped.

2. Remove two fasteners q at the top of the nacelle
assembly.
5. Rotate the auxiliary lamp assembly forward and
lower out of the way.
6. Pull the rear portion of the nacelle assembly back
toward the fuel tank to expose the handlebar
risers.
7. Loosen the front handlebar clamp fasteners r and
rotate the handlebar up so the rear portion of the
nacelle can be removed.
3. Remove two fasteners w securing the console

cover to the fuel tank and lift console back and set
on protected fuel tank.

3.46 © Copyright
FRAME / BODY
8. Disconnect the auxiliary light switch (if equipped) 10. Pull the headlamp bucket out far enough to
and remove the rear portion of the nacelle t. disconnect the headlamp connector and remove
the bucket assembly u.
9. Pull the front portion of the nacelle out far enough

to access the four fasteners y securing the 11. Using a side cutter, carefully clip the six cable ties
headlamp bucket and remove. securing the harness to the front portion of the
nacelle assembly.
IMPORTANT
Use a marker or tape to index each multi-plug before
disconnecting. Some of the connectors are unmarked
and interchangeable.
12. Disconnect all multi-plugs between the switch

cube and chassis harness and route through the
front portion of the nacelle.
13. Remove nacelle.

© Copyright 3.47
FRAME / BODY
N A C E L L E I N S TA L L AT I O N 6. Install the four headlamp bucket fasteners q and

CAUTION
During installation of the nacelle assembly, pay close
attention to harness routing and connector
orientation. Always route electrical wiring the same
way as it was removed to avoid damaging wires and
connectors.
1. Move the front portion of the nacelle into position

and feed the wire harness through the center hole
as shown.
TORQUE
Headlamp Bucket Fasteners:
12 in-lbs (1 N·m)
7. Lower the rear portion of the nacelle w into

position and reconnect the auxiliary light switch (if
equipped).
2. Install new cable ties into all six fir tree clips.
3. Paying attention to the natural form of the wiring
harness, reconnect all of the multi-plugs between
the chassis and switch cubes.
IMPORTANT
Pay attention to index marks placed on connectors
during disassembly when reconnecting as some of
them are interchangeable.
4. Secure harness to the front portion of the nacelle

using the newly installed cable ties.
5. Position the headlamp bucket in front of the
nacelle and reconnect the headlamp bulb.

3.48 © Copyright
FRAME / BODY
8. Rotate the handlebar into the desired position and 11. Install the two fasteners t located at the top of the
torque the riser clamp fasteners e to nacelle and torque to specification.
specification.
TORQUE
TORQUE
Upper Nacelle Fasteners:
Riser Clamp Fasteners: 36 in-lbs (4 N·m)
18 ft-lbs (24 N·m) Tighten front fastener then rear.
12. Torque the auxiliary light bar bracket fasteners r
9. Push the front and rear portions of the nacelle to specification.
together into position around the triple clamp.
TORQUE
10. Move the light bar / turn signal assembly into
position and install the four fasteners r finger Auxiliary Light Bar Bracket Fasteners:
tight. 88 in-lbs (10 N·m)
13. Move the console cover into position and torque

fasteners to specification.
TORQUE
Console Cover Fasteners:
88 in-lbs (10 N·m)
14. Install windshield assembly, if equipped.

15. Verify that all controls are operating correctly and
the handlebar turns freely from lock to lock.
NOTICE
Verify that the rubber grommets securing the
auxiliary light / turn signal harness have been slid
into place.

© Copyright 3.49
LUBRICATION / COOLING
CHAPTER 4
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 4
FILTER ADAPTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
OIL FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
OIL PRESSURE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
OIL PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10
OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10
OIL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.11
OIL COOLER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13
OIL COOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13
OIL COOLER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.14
OIL COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.15

© Copyright 4.1
SERVICE NOTES If the engine is making irregular noises that appear to
The Thunderstroke 111 uses a semi-dry sump be coming from rotating parts, check the lubrication
lubrication system. The engine oil is housed in a side oil pressure. Check the oil pressure before
separate chamber within the engine cases q as shown engine disassembly, and recheck the oil pressure after
in the image below. a repair.
TROUBLESHOOTING
LOW OIL PRESSURE HIGH OIL PRESSURE
Incorrect oil being used Incorrect oil being used
or low oil level
Engine temp above test Additives added to oil to
temperature range increase viscosity
Damaged O-rings or Engine temp below test
leaks at pipes or fittings temperature range
Damaged or worn oil Restricted oil passages
pump or oil pump drive
Pressure relief valve Incorrect oil filter
stuck open
Damaged engine Pressure relief valve stuck
bearings/excessive closed
engine wear.
Restricted oil filter, oil
The oil pump has two sets of internal gerotors. One set filter screen or
provides lubrication pressure and the second set passages
provides the scavenge. The oiling system pressure
relief valve is also located inside the oil pump.
To access the oil pump, the engine must be removed
from the frame and disassembled. Before disassembly, SPECIAL TOOLS
review the troubleshooting charts located in this TOOL DESCRIPTION PART NUMBER
chapter.
Oil Pressure Gauge PV-43531

S E R V I C E S P E C I F I C AT I O N S
ITEM STANDARD LIMIT
Engine Oil Capacity (After Disassembly) 5.8 U.S. qts (5.5 Liters) Not Applicable
Engine Oil Capacity (At Change with Filter) Follow 5.5 U.S. qts (5.2 Liters) Not Applicable
the oil change procedure outlined in the
Maintenance chapter.
Engine Oil Capacity (At Change without Filter) 5.4 U.S. qts (5.1 Liters) Not Applicable
Follow the oil change procedure outlined in the
Maintenance chapter.
Recommended Engine Oil if Indian Motorcycle Indian Motorcycle Semi-Synthetic Not Applicable
20W/40 is not available, use motorcycle oil with 20W/40
same specifications.
Oil Pressure @ 3000 rpm (supply side) Engine at 60 psi (513.7 kPa) Readings should MINIMUM
operating temperature and specified Indian be within 20% of the specification. PRESSURE: 30 psi
Motorcycle Engine Oil (206.8 kPa)

4.2 © Copyright
ITEM STANDARD LIMIT

OIL PUMP CLEARANCES
Scavenge Gerotor OD to Oil Pump Body .006"-.010" (.15 mm-.25 mm) .015" (.381 mm)
Feed Gerotor OD to Oil Pump Body .006"-.010" (.15 mm-.25 mm) .015" (.381 mm)
Oil Pump End Clearance .0014"-.0032" (.036 mm-.081 mm) .008" (.203 mm)
Gerotor Tip Clearance .003"-.005" (.076 mm-.127 mm) .007" (.178 mm)

© Copyright 4.3
OIL COOLER
NOTE
This system only applies to certain models. See Oil Flow Diagram page 4.6 for list of affected models.
q Oil Filter (Apply oil to filter seal) Approximately 3/4 turn after sealing ring has
contacted the filter adapter.
w Screw, Oil Cooler Pipes - M6 x 1.0 x 12 (QTY.2) 1 in-lbs (8.0 Nm)
e Oil Cooler Assembly –
r Backing Ring, O-ring –
t O-ring, Oil Cooler –
y Fitting, Oil Filter 22 ft-lbs (30.0 Nm)
u Screw, Oil Filter Adapter - M6 x 1.0 x 40 (QTY.3) 88 in-lbs (10.0 Nm)
i Oil Filter Adapter Assembly –

4.4 © Copyright
F I LT E R A D A P T E R
q Fastener, Oil Filter Adapter - M6 x 1.0 x 40 88 in-lbs (10 N·m)

(QTY.3)
w Oil Filter Adapter Assembly –
e O-ring, Oil Cooler –

© Copyright 4.5
OIL FLOW DIAGRAM
OIL COOLER FILTER ADAPTER INTERNAL BYPASS
• 2014–15 Chief Vintage / Chief Classic • 2016 Chief Classic / Chief Vintage
• Chieftain Dark Horse • Chief Dark Horse
• Chieftain • Springfield
• Roadmaster

4.6 © Copyright

© Copyright 4.7
L U B R I C AT I O N S Y S T E M
q Fastener, Oil Feed Pipe - M6 x 1.0 x 15 (QTY.3) 88 in-lbs (10.0 Nm)
w Oil Feed Pipe –
e Engine Case (RH) –
r Oil Jet, Piston Cooling –
t Fastener, Oil Jet - M5 x 0.8 x 10 (QTY.2) 62 in-lbs (7.0 Nm)
y Fastener - M6 x 1.0 x 12 (QTY.3) 88 in-lbs (10.0 Nm)
u Fastener, Oil Pump - M6 x 1.0 x 115 (QTY.3) 88 in-lbs (10.0 Nm)
i Pickup Screen, Oil Pump –
o Oil Drain Plugs, Scavenge and Oil Tank - M12 x 1.5 15 ft-lbs (20.0 Nm)
(QTY.2)
a Oil Pressure Sensor 88 in-lbs (10.0 Nm)
s Adapter, Oil Pressure Sensor 15 ft-lbs (20.0 Nm)
d Dipstick, Oil –

4.8 © Copyright
OIL PRESSURE INSPECTION

OIL PRESSURE
CAUTION
Use caution when working around hot engine oil.
NOTICE
Oil pressure switch activates at 3 psi ± 1 psi.
1. Start the engine and run until operating

temperature is reached.
2. Turn the engine OFF.
3. Remove oil pressure sensor q.
4
4. Install oil pressure gauge.

5. Use the dipstick to check the engine oil level and
add recommended oil, if necessary.
6. Start engine and check oil pressure at 3000 rpm.
7. Compare reading to oil system specifications.
8. If oil pressure is outside of specification, refer to
the troubleshooting section page 4.2.
9. Once testing is completed, clean threads with
Loctite® Primer N, and apply thread sealant to the
oil pressure switch threads and torque to
specification.
TORQUE
Oil Pressure Switch: 88 in-lbs (10 Nm)

© Copyright 4.9
OIL PUMP SERVICE

O I L P U M P R E M O VA L 5. Remove the three fasteners y from the oil pump
1. Remove engine from frame. See Removing Engine assembly.
From Frame page 6.6.
2. Separate engine cases. See Crankcase Separation
page 10.22.
3. Remove external snap-ring q, flat washer w, oil
pump drive gear e, and drive pin r from oil
pump input shaft.
6. Remove the oil pump / snorkel tube assembly

from the LH crankcase.
4. Remove the oil pump snorkel tube fasteners t.

4.10 © Copyright
O I L P U M P I N S TA L L AT I O N 4. Align fastener holes and install oil pump fasteners

1. Clean oil pipe and dry with compressed air. e and torque to specification.
2. Loosely install the snorkel tube and fastener q to
the pump body.
4
TORQUE
3. Install the oil pump / snorkel tube assembly into Oil Pump Fasteners:
the crankcase and loosely install fastener w 88 in-lbs (10 N·m)
securing the snorkel tube to the left-hand
crankcase. 5. Torque snorkel tube fasteners to specification.
TORQUE
Snorkel Tube Fasteners:
88 in-lbs (10 N·m)
6. Rotate the oil pump drive shaft by hand a few

revolutions to verify smooth operation.
NOTICE
Pump should rotate by hand with little resistance. If it
is difficult to rotate, loosen then re-torque oil pump
fasteners and check again.
7. Install oil pump drive pin r, sprocket t, washer

y and external snap-ring u.
8. Assemble engine crankcase. See Crankcase

Assembly page 10.39.

© Copyright 4.11
9. Install engine in frame. See Engine Installation

page 6.11.
10. Verify engine oil pressure after assembly. See Oil
Pressure page 4.9.

4.12 © Copyright
OIL COOLER SERVICE

O I L C O O L E R R E M O VA L
1. Place an oil pan beneath the oil filter adapter to
catch any oil that drains out of the cooler assembly
upon removal.
2. Remove the two fasteners q securing the oil
cooler lines to the oil filter adapter.
3. Pull the oil cooler lines out of the filter adapter.

NOTICE
It may be necessary to gently pry between the oil
cooler line flange and filter adapter using a plastic
body tool to assist with removal.
4. Remove the upper oil cooler fastener w and lift the

lower cooler mounts off of the rubber isolators.
5. Remove the oil cooler assembly from the vehicle.

© Copyright 4.13
OIL COOLER INSPECTION

1. Inspect cooler, lines and all connection for leaks.
2. Inspect lines for proper routing. Replace if there is
any sign of abrasion or damage.
3. Inspect cooler surface for obstructions or debris.
4. Rinse from back side to front with low pressure
water.
5. Inspect oil cooler fins for deformation. Fins can be
straightened if not severely deformed and no oil
leaks are present.
6. Inspect cooler mounting fastener for proper
torque.
7. Inspect mounting bracket and rubber grommets
for cracks or damage.
8. Replace any damaged components.

4.14 © Copyright
O I L C O O L E R I N S TA L L AT I O N
Inspect the o-rings and backup washers on both oil
cooler lines for damage and replace if necessary.
1. Fit the lower oil cooler mounts into the rubber
isolators located on the frame down tubes.
2. Install the upper oil cooler mounting fastener q
TORQUE
Oil Cooler Mounting Fastener:
88 in-lbs (10 N·m)
3. Install the oil cooler lines into the oil filter adapter
and torque flange fasteners w to specification.
TORQUE
Oil Cooler Line Fasteners:
88 in-lbs (10 N·m)
4. Run the engine to cycle oil through the oil cooler

and check oil level. Top off if necessary.

© Copyright 4.15
NOTES

4.16 © Copyright
FUEL SYSTEM / EXHAUST
CHAPTER 5
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
SERVICE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
EFI SYSTEM PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
FUEL LINE ROUTING (49 STATE MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
FUEL LINE ROUTING (CA & INTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
5
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.11
SENSORS — POWERTRAIN MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.12
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.13
EXHAUST SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.14
MUFFLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.14
CROSS OVER PIPE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.15
HEAD PIPE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.17
HEAD PIPE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
CROSS OVER PIPE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.19
MUFFLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22
AIR BOX REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22
AIR BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23
FUEL DELIVERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.26
INTAKE MANIFOLD, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.26
FUEL PUMP PRESSURE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.26
FUEL SYSTEM DEPRESSURIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.27
FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.29
FUEL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.30
FUEL FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.32
FUEL TANK VENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.34
FUEL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.34
FUEL TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.36
FUEL LEVEL SENSOR RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.37
FUEL PUMP SUPPLY VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.38
FUEL PUMP CURRENT DRAW TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.39
PRIMING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.39
EFI SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.40
FUEL INJECTION SYSTEM - OVERVIEW OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.40

© Copyright 5.1
ECM CONNECTOR MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.41

TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.42
SENSOR DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.50
ECM PINOUT TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.51
ECM CONNECTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.52
ECM REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.52
TEMPERATURE & MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) REPLACEMENT . . . . . . . . . . . . . . . . . . . .5.53
CYLINDER HEAD TEMPERATURE SENSOR, TEST / REPLACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.54
FUEL INJECTOR, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.55
FUEL INJECTOR RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.55
CRANKSHAFT POSITION SENSOR, TEST / REPLACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.56
DETONATION SENSOR TEST / REPLACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.57
THROTTLE BODY (ETC) REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.58
CYLINDER MISFIRE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.59
CAN DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.61
CAN (CONTROLLER AREA NETWORK) DIAGNOSTIC OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.61
DIGITAL WRENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.62
DIGITAL WRENCH DIAGNOSTIC SOFTWARE OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.62
DIAGNOSTIC SOFTWARE VERSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.62
ECM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.62
GUIDED DIAGNOSTIC AVAILABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.62
DIGITAL WRENCH COMMUNICATION ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.62
DIGITAL WRENCH DIAGNOSTIC CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.62
DIGITAL WRENCH SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.63
DIGITAL WRENCH VERSION AND UPDATE ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.63
DIGITAL WRENCH UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.63
DIGITAL WRENCH FEATURE MAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.65
ENGINE CONTROLLER REPROGRAMMING (REFLASH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.66
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.68
FUEL SYSTEM TROUBLESHOOTING, PART 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.68

5.2 © Copyright
SERVICE NOTES WARNING
Many hazards are present when working on or around
the fuel injection system. Read and pay close attention The battery should always be disconnected before
to the following warnings and cautions when working working on the fuel system.
on any component in this section.
When replacing fuel lines, always use genuine Indian
WARNING Motorcycle replacement parts. This will ensure top
performance, function and durability.
Gasoline is extremely flammable and is explosive
under certain conditions. Work in a well ventilated Fuel lines remain under pressure at all times. Use
area. Open flames, sparks and cigarettes must be caution when disconnecting lines for service.
kept away from gasoline. Always depressurize the fuel system prior to service.
Cover the fuel hose connections with a clean,
WARNING absorbent towel to minimize spillage while
disconnecting.
Careless handing of the control cables can result in
twisting or bending of the cables. This can cause the Don’t overlook the basics while troubleshooting
cables to stick or bind, resulting in loss of vehicle the fuel system:
control.
• Except where noted, views of connectors are from 5
WIRE side of the connector.
WARNING • A battery in a low state of charge can cause
The engine exhaust from this product contains problems. Be sure battery is in good condition and
chemicals known to cause cancer, birth defects or fully charged.
other reproductive harm. • Air leaks in intake tract / air box - check for air leaks
and repair to avoid misdiagnosing the EFI system.
• Contaminated or improper fuel.
WARNING
The engine and exhaust system become very hot • Restricted fuel flow / filters (low fuel pressure).
during operation and remains hot for a period of time • Fuel tank vent line pinched or obstructed.
after the engine is shut off. Wear insulated protection
for hands and arms or wait until the engine and • Faulty spark plug(s).
exhaust system have cooled before performing • Corroded, disconnected, or incorrectly connected
service work. wiring.
• Poor ground connections - be sure all grounds are
WARNING clean and tight.
Always stop the engine and refuel outdoors or in a • Exhaust system restriction or improper exhaust.
well ventilated area.
• Engine mechanical condition.
WARNING
If you get gasoline in your eyes or if you swallow
gasoline, see your doctor immediately. Never try to
syphon gasoline using mouth suction.
WARNING
Never start the engine or let it run in an enclosed
area. Engine exhaust fumes are poisonous and can
cause loss of consciousness and death in a short time.

© Copyright 5.3
SPECIAL TOOLS T O R Q U E S P E C I F I C AT I O N S
TOOL DESCRIPTION PART NUMBER DESCRIPTION TORQUE
Electrical Tester Kit PV-43536 SPECIFICATION
Fuel Line Plug Tool 2521832 Air Box Cover 84 in-lbs (9.5 Nm)
Fuel Rail Fastener 2564374 Air Filter Element 62 in-lbs (7.0 Nm)
Torquing Tool Air Filter Retainer Plate 31 in-lbs (3.5 Nm)
Fuel Pressure Adapter PV-48656 CHT 70 in-lbs (8.0 Nm)
Fuel Pressure Gauge PU-43506–A Console Panel Screws 84 in-lbs (9.5 Nm)
Relay Bypass PU-49466 CPS 88.5 in-lbs (10.0 Nm)
Smartlink Module Kit PU-47471 Evaporative Emissions 84 in-lbs (9.5 Nm)
USB to Serial Adapter PU-50621 Canister
Exhaust Clamp 31 ft-lbs (42.0 Nm)
6657 or https://polaris.service-solutions.com/ Fuel Filter Screws 12 in-lbs (1.4 Nm)
Fuel Pump Nut 24 in-lbs (2.7 Nm)
S E R V I C E S P E C I F I C AT I O N S Fuel Tank Screw 12 ft-lbs (16.3 Nm)
ITEM SPECIFICATIONS Gear position Switch 43 in-lbs (4.9 Nm)
Fuel Pump Pressure Head Pipe Flange Nuts 15 ft-lbs (20.0 Nm)
4.0 BAR (400 kPa) (58 psi)
(Normal Operation)
Head Pipe Trim Covers 84 in-lbs (9.5 Nm)
Idle Speed 800 rpm ± 50 rpm
Ignition Coil 84 in-lbs (9.5 Nm)
Fuel Pump Amp Draw
3–5 Amps
(Normal Operation) Knock Sensor 15 ft-lbs (20.0 Nm)
Recommended Muffler Hanger Bolts 18 ft-lbs (24.4 Nm)
91 Octane Minimum
Octane
Oil Pressure Switch 88 in-lbs (10.0 Nm)
Injector Resistance 11.4 - 12.6 Ohms
Oxygen Sensor 14 ft-lbs (19.0 Nm)
Rear Head Pipe Hanger 18 ft-lbs (24.4 Nm)
Side Stand Switch 43 in-lbs (4.9 Nm)
TMAP 62 in-lbs (7.0 Nm)
TPMS Sensor Bolt 44 in-lbs (5.0 Nm)
Wheel Speed Sensor 96 in-lbs (10.8 Nm)
Worm Drive Exhaust 31 in-lbs (3.5 Nm)
Clamps

5.4 © Copyright
SERVICE PRECAUTIONS
EFI SYSTEM PRECAUTIONS The ECM, VCM and sensors are sensitive pieces of
electronic equipment. Dropping or hitting them may
NOTICE
cause irreparable damage.
While electronic fuel injection is durable and
reliable, the components can be damaged or
problems may occur if the following precautions are
not taken.
It is not advisable to “jump start” the machine with

another battery. Although problems are unlikely to
occur if everything is done carefully, the electrical
component could be damaged.
Never disconnect the battery while the engine is
running.
When connecting and disconnecting the battery
cables refer to Electrical chapter for complete battery
connection and charging information. See Battery
Installation page 15.11. Static electricity can damage the electronic controllers
Make sure that the ignition is powered down before
beyond repair. The human body can easily store 5
enough static electricity to damage sensitive
connecting and disconnecting connections. Best electronic components. Before working with any
practice is to disconnect the battery before connecting components of the Fuel Injection system, ground
or disconnecting the electrical connections. yourself to dissipate any static charge. Also take care
Fuses and circuit breakers protect critical electrical not to touch any of terminal pins on the ECM.
components and circuits. Never replace the fuse with a Anti-static wrist strap PV-43541
larger value fuse or “jumper” the fuse with wire,
aluminum foil or any other means. Always investigate NOTICE
the cause of the problem and repair before replacing
the fuse. Some tests require probing of the ECM wiring
harness connector. Do not touch or probe the
exposed pins on the ECM. Static electricity from your
body or the meter can easily damage the ECM.
Always use the proper adapter from the Connector

Test Adapter Kit when probing the terminals. Most of
the connectors are sealed and cannot be back probed.
Be extremely careful not damage the connectors by
forcing meter probes into the connectors.
Connector test adapter kit PV-43526
Poor connections are the most common cause of
Electronic Fuel Injection malfunctions. Inspect
connector and wiring connections carefully during
troubleshooting.
Carefully inspect the connections of the failed circuit
before doing any other troubleshooting steps. Wire
terminals should be corrosion free and fully seated
into the connectors. Connector should snap together
and lock.

© Copyright 5.5
F U E L L I N E R O U T I N G ( 4 9 S TAT E M O D E L S )

q Fuel Line (Pump to Fuel Rail)
w Fuel Vent Line, Upper (from tank)
e Fuel Vent Line, Lower (to atmosphere)

5.6 © Copyright
FUEL LINE ROUTING (CA & INTL)

q Carbon Canister
w Fuel Vent Line, Lower (from canister)
e Purge Valve
r Fuel Vent Line, Lower (to canister)
t Fuel Vent Line, Upper (to engine)
y Fuel Vent Line, Upper (from tank)
u Fuel Line (Pump to Fuel Rail)
FUEL SYSTEM
2017–2020

© Copyright 5.7

5.8 © Copyright
2021+
q Fastener,Carbon Canister — M6 x 1.0 x 12 (QTY.2) 84 in-lbs (9.5 Nm)
w Carbon Canister (CA & INTL Models ONLY) —
e Purge Line (CA & INTL Models ONLY) —
r Purge Valve (CA & INTL Models ONLY) —
t Fastener, Fuel Tank — M8 x 1.25 x 35 (QTY.2) 18 ft-lbs (24.4 Nm)
y Nut, Fuel Pump — M5 x 0.8 (QTY.10) 24 in-lbs (2.7 Nm)
u Fuel Pump Access Panel —

© Copyright 5.9
F U E L TA N K
q Screw, Console Panel — M6 x 1.0 x 12 (QTY.2) 84 in-lbs (9.5 Nm)
w Plastic Dart –
e Console Cover –
r Nut, Fuel Pump — M5 x 0.8 (QTY.10) 24 in-lbs (2.7 Nm)
t Fuel Pump Access Panel –
y Gasket, Fuel Pump –
u Fuel Pump –
i Screw, Fuel Tank — M8 x 1.25 x 35 (QTY.2) 18 ft-lbs (24.5 Nm)

5.10 © Copyright
AIR BOX
q Fastener, Air Box Cover — M6 x 1.0 x 10 (QTY.3) 88 in-lbs (10 N·m)
w Cover, Air Box –
e Fastener, Air Filter Element — M5 x 0.8 x 10 62 in-lbs (7 N·m)

(QTY.3)
r Gasket, Air Box Cover –
t Air Filter Element –
y Fastener, Air Filter Retainer Plate — 10 x 5/8 84 in-lbs (9 N·m)

(QTY.3)
u Retainer Plate, Air Filter –

© Copyright 5.11
SENSORS — POWERTRAIN MANAGEMENT
TORQUE (IF
NUMBER SENSOR / LOCATION APPLICABLE)
q TPMS (Tire Pressure Monitoring System) — Sensor located 180° from valve 44 in-lbs (5 N·m)
stem
w Wheel Speed Sensor, Rear — Located at the rear caliper carrier 96 in-lbs (11 N·m)
e ECM (Engine Control Module) — Located inside the lower RH side cover, —
behind the drive sprocket
r Fuse Box — Located inside the LH upper side cover. NOTE: High current J-Case —
Fuse Box located behind battery box
t ABS (Anti-Lock Brake) Module — Located in front of the rear tire —
y Purge Valve (CA models only) — Located inside the RH upper side cover —
u Oil Pressure Switch — Located at the rear of the LH engine case 2017–2019: 88 in-
lbs (10 N·m)
2020–2022: 11 ft-
lbs (15 N·m)
i Gear Position Switch — Located inside the drive sprocket cover, below the 43 in-lbs (5 N·m)
drive sprocket
o Oxygen Sensor, Rear — Located on the rear head pipe 14 ft-lbs (19 N·m)
a Side Stand Switch — Located behind the side stand hinge 43 in-lbs (5 N·m)
s CPS (Crank Position Sensor) — Located on the front of the engine by the oil 88 in-lbs (10 N·m)
filter
d Oxygen Sensor, Front — Located on the front head pipe 14 ft-lbs (19 N·m)
f Detonation “Knock” Sensor — Located on the rear face of the front cylinder 15 ft-lbs (20 N·m)
heat sink
g CHT (Cylinder Head Temperature) Sensor — Located on the rear face of the 71 in-lbs (8 N·m)
front cylinder head
h Fuel Injectors — Located at the cylinder head intake ports —

5.12 © Copyright
TORQUE (IF
NUMBER SENSOR / LOCATION APPLICABLE)
j Ignition coil — Located behind the horn assembly on the RH side of the engine 88 in-lbs (10 N·m)
k TMAP — (Temperature / Manifold Absolute Pressure) Sensor — Located on the 62 in-lbs (7 N·m)
back side of the intake manifold
EXHAUST SYSTEM
q Fastener, Muffler Hanger — M8 x 1.25 x 16 (QTY.4) 18 ft-lbs (24.4 Nm)
w Clamp, Exhaust (QTY.3) 31 ft-lbs (42.0 Nm)
e Fastener, Rear Head Pipe Hanger — M8 x 1.25 x 20 18 ft-lbs (24.4 Nm)

(QTY.4)
r Clamp, Worm Drive 31 in-lbs (3.5 Nm)
t Clamp, Worm Drive 31 in-lbs (3.5 Nm)
y Oxygen Sensor (QTY.2) 14 ft-lbs (19.0 Nm)
u Fastener, Head Pipe Trim Cover — M6 x 1.0 x 20 84 in-lbs (9.5 Nm)

(QTY.4)
i Nut, Head Pipe — M8 x 1.25 (QTY.4) 15 ft-lbs (20.3 Nm)

© Copyright 5.13
EXHAUST SERVICE
M U F F L E R R E M O VA L 3. Remove the four fasteners e securing each
muffler to the rear hanger.
WARNING
Exhaust systems may contain fibrous materials that
could cause irritation to respiratory system, eyes,
and skin. While servicing, replacing ,or removing
exhaust system components, avoid inhalation, skin,
or eye contact with fibers. Operations such as
sawing, blowing, and tear out may generate airborne
fibers.
WARNING
Engine and exhaust components get hot and remain
hot for a period of time after the engine is stopped.
Wear insulated protective clothing or wait for
components to cool sufficiently before working on
the machine. 4. Slide the muffler assemblies rearward to remove
from the head pipe and cross over pipe.
1. Using a flat head screwdriver, loosen (do not
remove) the rear heat shield clamps q.
2. Loosen the forward muffler clamps w between the

head pipe / cross over pipe and muffler.

5.14 © Copyright
C R O S S O V E R P I P E R E M O VA L
5. Disconnect the rear oxygen sensor connector e.
WARNING
Engine and exhaust components get hot and remain
the machine.

2. Using a flat head screwdriver, loosen the heat
shield clamps on both sides of the motorcycle until
the ends can be opened up. Remove the heat
shields q.
Connector is tucked into the RH side frame panel.

6. Loosen rear head pipe and cross over pipe
exhaust clamps r and remove rear head pipe
5
support fasteners t.
3. Remove left and right muffler assemblies page

5.14.
4. Remove cross over pipe support fastener w from
left hand side of the motorcycle.

© Copyright 5.15
7.
WARNING
Heat sink edges are extremely sharp and could
cause personal injury. Wear gloves while removing
from the cylinder head assembly.
Remove the two fasteners y and the heat sink trim

cover u to access the head pipe flange nuts i.
Remove flange nuts.
8. Slide the rear head pipe and cross over pipe

assembly back to remove from the front head
pipe.
9. Remove the cross over pipe from the rear head
pipe.

5.16 © Copyright
H E A D P I P E R E M O VA L
4.
WARNING
Engine and exhaust components get hot and remain WARNING
Heat sink edges are extremely sharp and could
cause personal injury. Wear gloves while removing
from the cylinder head assembly.
the machine.
1. Remove cross over pipe / rear head pipe Remove the fasteners e securing the heat sink
assembly. page 5.15 trim cover to the cylinder head and remove cover.
2. Remove the two fasteners q securing the RH 5. Remove the flange nuts r from the head pipe and
floorboard to the frame. Keeping the master remove head pipe from motorcycle..
cylinder reservoir in an upright position, move the
floorboard and master cylinder out of the way.
NOTICE
It is not necessary to remove the hydraulic line from
the master cylinder during this operation.
3. Locate the front oxygen sensor connector w, at the

front motor mount, and disconnect.

© Copyright 5.17
H E A D P I P E I N S TA L L AT I O N
1. Verify that the old head pipe gasket has been 5. Install front and rear heat sink trim covers and
removed from the front cylinder head exhaust port torque fasteners e to specification.
and install a new gasket q.
TORQUE
2. With the new gasket in position, slide the front
head pipe into position over the flange studs w Heat Sink Trim Cover Fasteners:
and tighten nuts finger tight. 84 in-lbs (9 N·m)
6. Reconnect front and rear oxygen sensors and

secure wires with cable ties.
7. Move RH floorboard into position and torque the
two support fasteners r to specification.
3. Install the cross over pipe / rear head pipe page

5.19 assembly.
4. Tighten front and rear head pipe flange nuts to
specification.
TORQUE
Head Pipe Flange Nuts: TORQUE
2017–2020: 15 ft-lbs (20 N·m) Floorboard Support Fasteners:
2021+:Step 1: Start all four nuts.Step 2: Torque 35 ft-lbs (48 N·m)
front upper nut to 88 in-lbs (10 N·m) and back off
nut 2 revolutionsStep 3: Torque front lower nut to
88 in-lbs (10 N·m).Step 4: Torque rear upper nut to
88 in-lbs (10 N·m) and back off nut 2 revolutions.
Step 5: Torque rear lower nut to 88 in-lbs (10 N·m).
Step 6: Final Torque 15 ft-lbs (21 N·m) in sequence
: Front upper, front lower, rear upper, rear lower.

5.18 © Copyright
C R O S S O V E R P I P E I N S TA L L AT I O N 5. Install heat sink trim covers and torque fasteners

Front head pipe must be installed before cross over to specification.
pipe / rear head pipe assembly can be installed.
TORQUE
1. Slide cross over pipe onto rear head pipe. Do not
tighten clamp q at this time. Heat Sink Trim Cover Fasteners:
84 in-lbs (9 N·m)
6. Tighten cross over pipe support fastener w and

rear head pipe support fasteners w to
specification.
TORQUE
Cross Over / Head Pipe Support Fasteners:
18 ft-lbs (24 N·m)
7. Tighten head pipe and cross over pipe exhaust

clamps e to specification.
2. Slide the cross over pipe / rear head pipe

assembly into position on motorcycle and install
5
head pipe flange nuts finger tight.
3. Rotate the cross over pipe into position and install
the cross over pipe support fastener w and rear
head pipe support fasteners w finger tight.
TORQUE
Exhaust Clamps:
40 ft-lbs (54 N·m)
8. Reconnect rear oxygen sensor.
4. Tighten head pipe flange nuts to specification.

TORQUE
Head Pipe Flange Nuts:
2017–2020: 15 ft-lbs (20 N·m)
2021+:Step 1: Start all four nuts.Step 2: Torque
front upper nut to 88 in-lbs (10 N·m) and back off
nut 2 revolutionsStep 3: Torque front lower nut to
88 in-lbs (10 N·m).Step 4: Torque rear upper nut to
88 in-lbs (10 N·m) and back off nut 2 revolutions.
Step 5: Torque rear lower nut to 88 in-lbs (10 N·m).
Step 6: Final Torque 15 ft-lbs (21 N·m) in sequence
: Front upper, front lower, rear upper, rear lower.

© Copyright 5.19
9. Install left and right heat shields r and torque NOTICE

front clamps to specification. Rear heat shield clamps should not be tightened until
the mufflers have been installed.
TORQUE
Heat Shield Clamps:
26 in-lbs (3 N·m)
10. Install left and right muffler assemblies page 5.20.
M U F F L E R I N S TA L L AT I O N
1. Slide the left and right mufflers into position so the 3. Tighten left and right muffler clamps w to
rear support fasteners can be installed. specification.
2. Install rear muffler support fasteners q into left

TORQUE
and right muffler assemblies finger tight.
Muffler Clamps:
40 ft-lbs (54 N·m)
4. Torque rear muffler support fasteners q to

specification.
TORQUE
Muffler Support Fasteners:
18 ft-lbs (24 N·m)

5.20 © Copyright
5. Torque rear heat shield clamps e to specification.
TORQUE
Heat Shield Clamps:
26 in-lbs (3 N·m) 5
6. Start engine and listen for exhaust leaks.

© Copyright 5.21
AIR CLEANER SERVICE

A I R B O X R E M O VA L 3. Using a T30 Torx wrench, remove the three
1. Using a 4mm hex wrench, remove the three fasteners e securing the air filter adapter plate to
the air box assembly and remove adapter plate.
fasteners q securing the air cleaner cover to the
air box.
NOTICE
When removing the adapter plate, start by applying
more pressure to the forward (LH) edge and pull
2. Using an 8mm socket, remove the three fasteners outward to release the valve cover vent hose from the
back side of the adapter plate.
w securing the air filter element to the adapter
plate and remove element.
4. Remove the two fasteners r securing the baffle
plate to the intake air boot.
5. Disconnect the multi-plug from the throttle body.

5.22 © Copyright
6. Using a 5 mm hex wrench, remove the four 8. Push the rubber harness seal through to the back
fasteners t securing the throttle body to the side of the air box and remove the air box from the
mounting plate and remove throttle body assembly. motorcycle.
A I R B O X I N S TA L L AT I O N
1. Install the four fasteners q securing the air box
mounting bracket to the engine and torque to
specification.
7. Using an 8 mm socket, remove the lower fastener

y securing the air box to the mounting plate. 5
TORQUE
Air Box Bracket Fasteners:
84 in-lbs (9 N·m)
2. Feed the throttle body electrical connector through

the hole in the air box and install the rubber
harness seal in the rectangular cutout.
NOTICE
Make sure that the harness seal is fully seated in the
air box cutout.
3. Fit the air box to the mounting bracket and press

breather hose w through the rubber grommet until
the air box sits flat against the bracket.
4. Install the intake air boot and baffle plate. Torque
baffle plate fasteners e to specification.

© Copyright 5.23
5. Install air box retainer fastener r and torque to 9. Install the three air filter adapter plate fasteners y
specification. and torque to specification.
TORQUE
Air Filter Adapter Plate Fasteners:
TORQUE 31 in-lbs (4 N·m)
Baffle Plate Fasteners:
31 in-lbs (4 N·m) 10. Install the air filter element and torque fasteners u
Air Box Retainer Fastener: to specification.
88 in-lbs (10 N·m)
6. Install throttle body o-ring and throttle body.

Torque throttle body fasteners t to specification.
TORQUE
Air Filter Fasteners:
62 in-lbs (7 N·m)
TORQUE
Throttle Body Fasteners:
88 in-lbs (10 N·m)
7. Connect throttle body electrical connector.

8. Install the air filter adapter plate and seal into the
airbox. Press the hose fitting on the adapter plate
into the breather hose until the plate is fully seated.

5.24 © Copyright
11. Install air box gasket and cover. Torque fasteners

i to specification.
TORQUE
5
Air Box Cover Fasteners:
88 in-lbs (10 N·m)

© Copyright 5.25
FUEL DELIVERY SERVICE

I N TA K E M A N I F O L D , R E M O VA L / 9. Torque the intake manifold clamps and boots to
I N S TA L L AT I O N specification.
1. Place motorcycle in an upright position with the TORQUE
Intake Manifold Clamps:
2. Remove the fuel tank. See Fuel Tank Removal
20 in-lbs (2 N·m)
page .
3. Remove the air box / throttle body assembly. See
Air Box Removal page 5.22. TORQUE
4. Remove the fuel injectors. See Fuel Injector, Intake Manifold Boots:
Removal / Installation page 5.55. 88 in-lbs (10 N·m)
5. Loosen the two clamps q securing the intake

manifold to the rubber boots at the front and rear
cylinders. FUEL PUMP PRESSURE INSPECTION
WARNING
Gasoline is extremely flammable. Work in a well
ventilated area. Open flames, sparks and cigarettes
must be kept away from gasoline. KEEP GASOLINE
OUT OF THE REACH OF CHILDREN!
CAUTION
Wear safety glasses or a face shield when working
around the fuel system to protect your eyes.
1. Depressurize fuel system and disconnect fuel line

at fuel rail. SeeFuel System Depressurization page
5.27 .
6. Remove the four fasteners securing the intake
boots to the cylinder head. 2. Install fuel pressure gauge PU-43506– A and fuel
pressure gauge adapter PV-48656.
7. Rotate the air box mounting flange up as shown
and remove the intake manifold from the engine. 3. Start engine and record fuel pressure (or press the
power switch ON and cycle the Engine Stop switch
to read pressure when pump cycles for 2-3
seconds).
Minimum Fuel pressure 3.51 BAR (351 kPa) (51
psi)

removal procedure.

5.26 © Copyright
4. Turn ignition switch off. Disconnect gauge adapter F U E L S Y S T E M D E P R E S S U R I Z AT I O N

and re-connect fuel line (Fuel Tank Installation
page 5.36). CAUTION
Fuel lines remain under pressure at all times. Use
FUEL PRESSURE TROUBLESHOOTING
caution when disconnecting lines for service. Always
FUEL PRESSURE TOO FUEL PRESSURE TOO depressurize the fuel system prior to service.
LOW: INSPECT HIGH: INSPECT
* Low fuel level (add * Plugged fuel return
fuel) (in tank on pressure WARNING
* Pump not running regulator) Allow engine and exhaust to cool completely before
(Fuel pump or circuit * Pressure regulator disconnecting fuel line or removing tank. Wear eye
malfunction) malfunction (located protection.
* Restricted fitting, fuel on pump).
supply line, or gauge
adapter hose 1. Remove the left-hand upper side panel.
* Fuel line kinked or
restricted (from tank
fitting to rail)
* Fuel line leaking
(leaking air in or fuel
out)
5
* Vent restriction
* Plugged fuel pickup
filter (located in fuel
tank)
* Pressure regulator
malfunction (located on
pump)
*Fuel pump malfunction
(Pump should run for
about 2 seconds the 2. Locate the fuel pump power fuse. See Electrical >
instant that the key Chassis Electrical > Fuse Box.
switch and Engine Stop
3. Pull the fuel pump relay and crank the engine over
switch are turned ON.
for 5 seconds to release pressure.
4. Remove the horn. See Horn Removal / Installation
page 17.16.
5. Wrap a clean shop towel around fuel line fitting q
and squeeze both release buttons.
CAUTION
Do not use anything other than fingers to remove the
quick connection. The use of tools can damage the
connection.

© Copyright 5.27
6. Squeeze both release buttons (one on each side of

fitting) and hold. Gently slide fitting straight off fuel
rail.
7. Cover fuel fittings to keep debris out.

5.28 © Copyright
F U E L TA N K R E M O VA L 5. Remove the two fasteners q, washer and rubber

isolator at the rear of the fuel tank.
WARNING
Allow engine and exhaust to cool completely before
disconnecting fuel line or removing tank. Protect fuel
tank finish when removing, storing, and installing
tank.
Be prepared to place the fuel tank in a secure location

with a drain pan positioned to catch any fuel that may
leak or drip from disconnected hoses or fittings.
1. Remove upper side covers.
6. Lift the rear of the tank and slide back

approximately 2” to expose the front console cover
fastener.
5
2. Remove the two fasteners retaining the driver seat

to the frame. Remove seat.
NOTICE
For models with a passenger seat, remove passenger
seat fastener.
7. Remove console cover fasteners w and the plastic
dart e.
3. Depressurize the fuel system. See Fuel System
Depressurization page 5.27
4. Disconnect the vent / EVAP line from the fuel tank.
• Chieftain / Roadmaster
For these models the front fastener does not have
to be removed. Remove rear fastener and slide
console forward to release it from the front
mounting grommet.

© Copyright 5.29
8. Disconnect electrical connectors at the security F U E L P U M P R E M O VA L

light, central locking and system power buttons
and remove console cover. WARNING
9. Disconnect the fuel pump electrical connector r, Replace all mounting screws and pump seal O-ring
and the evaporative vent line t. any time pump is removed for service. Do not kink or
bend fuel pickup hose upon removal. Review
10. Wrap a clean shop towel around fuel line fitting y gasoline warnings outlined in the beginning of this
and squeeze both release buttons. chapter. See SERVICE PRECAUTIONS.
CAUTION
Be careful when performing this procedure to avoid
damaging the fuel level float arm, jet pipe, fuel
pump, electrical wiring, or hoses when removing the
pump assembly. Always inspect wires and hoses
closely for damage after removing the fuel pump.
1. Remove the console cover from the fuel tank. See

STEPS 1–5 of Fuel Tank Removal page 5.29.
2. Disconnect the fuel pump electrical connector and
move out of the way.
CAUTION 3. Disconnect the fuel tank vent line q by sliding the
Do not use anything other than fingers to remove the rubber elbow off of the fitting.
connection.

pump.
13. Lift the rear of the fuel tank and slide rearward to
release from the front isolators.
4. With a shop rag wrapped around the fuel fitting,

squeeze both release buttons from the fuel supply
line connector w (one on each side of fitting) and
hold. Pull straight up to remove.
14. Lift the tank off of the motorcycle and store safely.

5.30 © Copyright
5. Remove fuel pump access cover nuts e in an 9. Reach in through the fuel pump access cover and
alternating or “star” pattern. gently press the fuel pump retaining tab t toward
the right-hand side of the fuel tank.
6. Raise the fuel pump access cover enough to

disconnect the fuel supply line r. Squeeze both
release buttons, on the quick fuel connector (one 10. Lift the fuel pump assembly out of the retaining
on each side of fitting), and hold. Gently slide bracket and carefully lift out of the fuel tank. 5
fitting straight off the fuel pump.
7. Cover fuel tank to keep debris out.

8. To disengage the electrical connector tab, gently
insert a flat-blade screwdriver between the
connector tab and fuel pump body as shown. Once
the tab is released from the fuel pump, remove the
electrical connector from the fuel pump.

© Copyright 5.31
F U E L F I LT E R R E P L A C E M E N T
NOTE
For MY16 Indian Motorcycle has implemented an updated, maintenance-free fuel pump. If you encounter a
maintenance-free pump, skip this procedure as there is no filter to be replaced. See below for details on each
pump.
FUEL PUMP (START OF PRODUCTION THROUGH FUEL PUMP (11/11/2015 THRU CURRENT
11/10/2015) PRODUCTION)
• Black in color • White in color
• 50,000 mile fuel filter service pump • No replaceable filter

• Extended life, maintenance-free pump
IMPORTANT
The fuel filter element should be replaced every
50,000 miles (80,467 km). The fuel filter cover screws
can only be removed once before the fuel pump
assembly must be discarded. The fuel pump
assembly MUST be replaced once the 2nd
replacement interval has been reached at 100,000
miles (160,934 km).
1. Remove fuel pump. See Fuel Pump Removal page

5.30.
2. Working from the top of the fuel pump housing,
remove the four screws q and lift lid off of filter
housing.

5.32 © Copyright
3. Remove the filter element.

4. Replace the filter element and o-ring.
5. Torque the four filter cover screws to specification.
TORQUE
Fuel Filter Cover Screws: 10 in-lbs (1.1 Nm)
6. Install fuel pump. See Fuel Pump Installation page

5.34.

© Copyright 5.33
F U E L TA N K V E N T I N S P E C T I O N F U E L P U M P I N S TA L L AT I O N
1. Refer to Maintenance chapter for tank vent 1. Lower the fuel pump assembly into the access hole
inspection and hose routing information. See Fuel with the level arm facing forward and the jet pipe
Tank Vent Inspection (49 State) page 2.32. resting on the left side of the tunnel.
2. Once the pump body is inside the tank, line up the

guide rails and retaining tab with the bracket q.
3. Slide the pump into position until the retaining tab

engages and the pump is locked in place.
4. Verify that the float arm moves freely through it’s

full range of motion.

5.34 © Copyright
5. Press a new sealing gasket w into the bottom of 7. Install fuel pump access cover nuts r and tighten
the fuel pump access cover. to specification following the torque sequence
shown.
6. Lower the fuel pump access cover into position

and connect the electrical connector and supply
line e.
5
TORQUE
Fuel Pump Access Cover:
IMPORTANT
Verify fuel supply line is properly seated and locked 8. Connect the fuel supply line, vent line and fuel
in place by listening for audible "click" when pump electrical connector to the top of the access
pressing into place. Pull gently on quick connector cover.
once seated to ensure a proper connection has been
made. IMPORTANT
Verify fuel supply line is properly seated and locked
in place by listening for audible "click" when
pressing into place. Pull gently on quick connector
once seated to ensure a proper connection has been
made.
9. Install the console cover.

10. Prime the fuel system, check for leaks, and verify
fuel pump operation. See Priming The Fuel System
page 5.39.

© Copyright 5.35
F U E L TA N K I N S TA L L AT I O N 4. Connect the fuel pump electrical connector e,

Place a protective cloth on the front of the tank when vent line r and fuel line t.
assembling tank to frame.
1. Install fuel cap assembly if removed.
2. Install the inner isolator / spacer assemblies q to
the rear fuel tank mounts as shown.
IMPORTANT
Verify fuel line is properly seated and locked in
place by listening for audible "click" when pressing
into place. Pull gently on quick connector once
3. Verify that forward tank isolators w are in position seated to ensure a proper connection has been
on the frame mounts and lower tank into position. made.
DO NOT slide forward into position at this time.
5. Install the console cover and torque fasteners to
specification.
TORQUE
88 in-lbs (10 N·m)
6. Slide tank forward until fully seated on forward

isolators.
7. Lower the rear of the tank into position over the
rear mounting bracket.
8. Install the fuel tank vent line to the chassis vent
line at rear of tank.

5.36 © Copyright
9. Install the outer isolators and washers onto the If fuel level readings are inaccurate when the
rear tank mount and install mounting fasteners y. motorcycle is powered up, or if the fuel gauge isn’t
indicating fuel level at all, perform the following test
and refer to resistance values located at the end of this
procedure.
1. Remove the fuel pump. See Fuel Pump Removal
page 5.30.
2. Set multimeter to measure resistance. Attach
suitable test probe adaptors to meter leads (from
kit PV-43526).
3. On the fuel pump side of the connector, measure
resistance across the sensor and compare to the
table.
10. Verify that the fuel tank vent line is routed

properly and torque the fuel tank mounting
fasteners to specification. 5
TORQUE
Fuel Tank Mounting Fasteners:
18 ft-lbs (24 N·m)
11. Install seat and side covers.

12. Prime the fuel system and verify fuel pump
operation. See Priming The Fuel System page 5.39
LEVEL SENSOR ARM APPROXIMATE
F U E L L E V E L S E N S O R R E S I S TA N C E T E S T POSITION RESISTANCE LIMITS
OVERVIEW OF OPERATION: Fuel level readings are Full (Top of Range) 97–103 Ω
measured by a variable resistance fuel level sensor q.
The fuel level sensor is located inside the fuel tank on Empty (Bottom of
the fuel pump. Range) 445–455 Ω
NEW IMAGE

© Copyright 5.37
F U E L P U M P S U P P LY V O LTA G E T E S T
Before performing this test, verify that battery is fully
charged and in good operating condition.
1. Remove the console cover and disconnect the fuel
pump / level sensor electrical connector. See Fuel
Pump Removal page steps 1–5.
2. Connect meter across terminals A & B on the wire
harness side of connector.
3. Press the POWER ON button to power up the

motorcycle electrical system.
4. Turn Engine Stop switch to RUN and read DC
voltage on meter when switch is first turned on.
Voltage reading should be close to battery voltage
for 2-3 seconds after switching Engine Stop switch
to RUN.
5. If low or no voltage is delivered to the fuel pump,
verify ground wire (Pin B, Black) has good
continuity to battery (-) post.
6. If ground is OK, check Gray wire from fuel pump
relay to ECM pin #42 . The Gray wire receives a
momentary ground from the ECM (for 2-3
seconds) and activates the fuel pump relay which
supplies power to the pump on the VT/YE wire.
7. Trace both power and ground circuits to
determine fault if battery voltage is not present for
2-3 seconds after power button and STOP / RUN
switch are turned on.
8. When a CPS signal is received by the ECM
(engine is cranking or running) the ECM maintains
the ground on Pin 42 (Gray wire), keeping the
pump powered.

5.38 © Copyright
F U E L P U M P C U R R E N T D R AW T E S T 4. Insert one meter lead in pin socket (4) and other

meter lead in pin socket (7) of relay block.
NOTICE
Fuel pump current draw is an indicator of pump
condition. Perform draw test if fuel pump operation is
suspect, or if fuel pump fuse is found open (blown).
NOTICE
When meter leads are inserted the pump will run,
and current draw will be displayed on the meter,
even with key and stop switch off. Fuel tank must be
completely installed and have enough fuel in it to
cover the fuel pickup screens for an accurate test.
1. Remove the LH upper side cover and fuse box

cover q.
5. Read fuel pump current draw on meter and
compare to specification.
6. Inspect fuel pump circuit wiring or replace fuel 5
pump if current draw exceeds specification.
SPECIFICATION: Fuel Pump Current Draw
Maximum: 6 DC Amps
PRIMING THE FUEL SYSTEM

Prime procedure should be performed:
• If a new fuel pump is installed or if tank is run
completely dry.
2. Remove fuel pump relay w by pulling straight • Whenever fuel system is serviced (fuel line is
upward. disconnected).
• Whenever battery disconnected.
1. Fill the fuel tank.

2. Turn Engine Stop switch OFF.
3. Press the power button to power up the
motorcycle.
4. Turn stop switch to RUN.
5. Allow switch to remain in RUN position until pump
stops running (about 2-3 seconds).
6. Turn stop switch OFF.
7. Press the power button to power down motorcycle.
8. WAIT approximately 10 seconds.
3. Set meter to DC Amps. Be sure red meter lead is in
the 10A jack, and black meter lead is in common 9. Repeat Steps 4-8 about 4 times to complete the
(-) jack. priming procedure.
NOTICE
Fuel level in tank must be high enough to submerge
pickup screen on fuel pump.

© Copyright 5.39
10. Once system is pressurized, carefully check all

fuel connections, joints and lines for leaks.
EFI SERVICE
FUEL INJECTION SYSTEM - OVERVIEW OF The fuel injectors inject fuel when they are grounded
O P E R AT I O N by drivers inside the ECM. The duration of an injector
pulse (length of time the injector circuit is grounded)
The Electronic Fuel Injection (EFI) system functions to is controlled by the ECM. Pulse duration determines
provide the engine with precisely metered fuel under the amount of fuel delivered to the engine (longer
varying loads and conditions. cycles = more fuel). The ECM selects the correct fuel
The Engine Control Module or “ECM”, is located injector pulse by calculating the airflow from the MAP
beneath the battery box. It is programmed to provide sensor measurement and referencing a three
the correct fuel/air mixture and ignition timing based dimensional “map” for the desired air-to-fuel ratio
on several sensor input signals (engine load, temp, (AFR). The ECM calculates an injection time based on
altitude, manifold pressure etc.). The ECM also the measured airflow and desired AFR.
provides grounds or voltage to other EFI related Although TMAP and engine RPM are the most
circuits of the electrical and fuel delivery systems. influential inputs for selecting a map reference point,
An Electronic Throttle Control (ETC) system takes the the ECM also evaluates feedback from minor sensors
place of a conventional, cable-operated throttle body. in the system, to obtain a more accurate “picture” of
The ETC controls throttle blade angle and provides the fuel needs at any given moment.
rate-of-change feedback to the ECM. The fuel control system is closed loop. When the
The ETC also serves as a plausibility check for the engine is at a warm idle and typical cruising engine
TMAP sensor. The MAP portion of the TMAP sensor is speeds and loads, the ECM will operate in “closed
the primary air flow and load sensing device. loop fuel control” mode. The oxygen sensors in each
headpipe will provide feedback to the ECM and the
An electric fuel pump, mounted inside the fuel tank injection time will be adjusted for each cylinder to
supplies fuel pressure to the injectors continuously achieve the target AFR.
when the engine is running or cranking. A pressure
regulator incorporated on the pump keeps fuel The locations of sensors and other EFI system related
pressure steady at approximately 3.51 Bar (350 kPa / components are outlined in this chapter. See Sensors
51 PSI). The fuel pump cycles “ON” for 2-3 seconds — Powertrain Management page 5.12.
when the motorcycle is powered up and the Engine
Stop switch is turned ON to pressurize the system for
start-up.

5.40 © Copyright
ECM CONNECTOR MAP
PIN ECM COLOR FUNCTION PIN ECM COLOR FUNCTION

1 2
1 - NOT USED 1 BK CPS NEGATIVE SIGNAL
2 - NOT USED 2 GY/DB REAR O2 SNR OUTPUT
3 YE/BK PPS 2 RETURN 3 OG/YE TPS 1 OUTPUT
4 BN/GN MAP SENSOR RETURN 4 BK THERMISTOR RETURN
5 BN/WH TPS RETURN 5 BG/WH REAR O2 SNR RETURN
6 WH/BK PPS 1 RETURN 6 BK/BU FUEL SENDER GROUND
7 - NOT USED 7 BG FRONT O2 SNR RETURN
8 - NOT USED 8 OG/BN CHT RETURN
9 - NOT USED 9 - NOT USED
10 - NOT USED 10 WH/RD PPS 1 – 5 VOLT REF
11 YE/GN PPS 2 OUTPUT 11 - NOT USED
12 BK/DG FUEL LEV SNR OUTPUT 12 DB LEFT FRONT TS OUTPUT
13 WH/OG NA 13 WH CPS POSITIVE SIGNAL
15 GY/BK ENGINE RELAY CNTL 15 OG/DB CHT SENSOR OUTPUT
16 PK K15 16 BN RH WARMER THERMISTOR
17 - NOT USED 17 YE/VT REAR BRAKE SWT OUTPUT
18 - NOT USED 18 OG/WH TIPOVER SENSOR
19 DB/OG CLUTCH SWT OUTPUT 19 OG/BN MAP SENSOR OUTPUT
20 - NOT USED 20 VT/RD TPS 2 SIGNAL

© Copyright 5.41
PIN ECM COLOR FUNCTION PIN ECM COLOR FUNCTION

1 2
21 WH/GN PPS 1 OUTPUT 21 - NOT USED
23 DB/PK RUN / STOP SWITCH 23 BN/PK TMAP POWER
24 WH/RD RR BRK SWT OUTPUT 24 DB/RD RIGHT FRONT TS OUTPUT
25 YE/RD PPS 2 – 5 VOLT REF 25 - NOT USED
26 RD/BU TIPOVER SNR – 5 VOLT REF 26 WH/DG LH WARMER THERMISTOR
27 - NOT USED 27 OG/DG IAT SENSOR OUTPUT
30 - NOT USED 30 GY/RD FRONT O2 SENSOR OUTPUT
32 YE CAN HIGH 32 - NOT USED
34 BN CRUISE SFTY SWT OUTPUT 34 - NOT USED
35 - NOT USED 35 DB/BK CANISTER PURGE VALVE
36 - NOT USED 36 DB LEFT REAR TS OUTPUT
37 - NOT USED 37 RD KNOCK SENSOR A
38 BN/DB TPS – 5 VOLT REF 38 BK KNOCK SENSOR B
39 - NOT USED 39 GY/YE REAR O2 SENSOR CONTROL
40 VT/DB AUX RELAY CONTROL 40 - NOT USED
41 OG/BN STARTER RELAY CNTL 41 - NOT USED
42 GY FUEL PUMP RELAY CNTL 42 - NOT USED
43 - NOT USED 43 WH/GY REAR FUEL INJECTOR DRIVER
44 DG CAN LOW 44 WH/DB FRONT FUEL INJECTOR DRIVER
46 - NOT USED 46 GY/WH FRONT O2 SENSOR CONTROL
47 BG/BK SIDESTAND SWT SIGNAL 47 BK/WH ECM GROUND
48 - NOT USED 48 DB/RD RIGHT REAR TS OUTPUT
50 YE/RD TRUNK BRAKE LAMP 50 DB/WH ECM GROUND
51 PK/DB BRAKE LIGHT POWER 51 PK/RD ETC MOTOR (+)
52 DG/YE TAIL LIGHT POWER 52 YE ETC MOTOR (-)
53 BK/WH ECM GROUND 53 - NOT USED
54 BK/WH ECM GROUND 54 BK REAR COIL SIGNAL
55 VT/PK ENG RELAY PWR OUTPUT 55 - NOT USED
56 VT-PK ENG RELAY PWR OUTPUT 56 WH FRONT COIL SIGNAL
TROUBLE CODES
SPN FMI COMPONENT CONDITION MIL P-CODE
29 3 Accelerator Position 2 Voltage Too High ON P1228

5.42 © Copyright

4 Voltage Too Low ON P1227
2 Not Plausible ON P1225

3 Voltage Too High ON P0123
2 Signal Out of Range (Not Plausible) ON P0121
51 0 Throttle Position Sensor 1 Voltage Above Critical Level ON P1123
1 Voltage Below Critical Level ON P1122
10 Abnormal Rate of Change ON P0120
13 Calibration / Adaption Failure ON P1120
ON P0500
0 Vehicle Speed Too High
ON C1057
1 Vehicle Speed Too Low ON P0502
2
Vehicle Speed Signal
Data Erratic or Intermittent (or Missing)
ON
ON
P0503
C1058
5
84
8 Sensor Frequency Outside Normal Range ON P0501
9 Abnormal Update Rate ON P160A
ON C1069
19 Received Vehicle Speed has error
ON P106B
91 4 Accelerator Position 1 Voltage Too Low ON P0227
2 Not Plausible ON P0225

96 16 Fuel Level Signal Above Normal Operating Range ON P1462
18 Below Normal Operating Range ON P1463
2 Signal Fault ON P0461
3 Pressure Too High ON P1527
98 4 Engine Oil Level Sensor Switch Pressure Too Low ON P1526

17 Oil Level Low OFF P250F

Manifold Absolute Pressure
102 2 Signal Out of Range ON P0106
Sensor
7 Pneumatic Fault ON P1106


105 Intake Air Temperature Sensor
2 Signal Out of Range ON P0111

© Copyright 5.43

2 Signal Out of Range ON P0116

110 Engine Temperature Sensor
16 Temperature Too High OFF P0217
0 Engine Overheat Shutdown OFF P1217
15 Temperature Above Normal Range OFF P1116
17 Temperature Too Low ON P0128
OFF P0563
3 Voltage Too High
ON C1063
OFF P0562
4 Voltage Too Low
ON C1064
System Power (Battery Potential
168 / Power Input)
0 Voltage Above Critical Level ON P1562
16 Voltage Above Warning Level ON P1564
1 Voltage Below Critical Level ON P1563
18 Voltage Below Warning Level OFF P1565
0 Speed Exceeded Max Limit ON P0219
0 Engine Speed Too High OFF C1059
1 Engine Speed Too Low OFF C1060
190 2 Engine Speed Data Erratic or Intermittent (or Missing) OFF C1061
7 CVT Threshold Exceeded ON P1219

31 Error in Engine Speed Computation ON P121C
19 Received Engine Speed has Error OFF C1066

523 Gear Sensor Signal
9 Abnormal Update Rate ON P1914
527 31 Cruise Control Panel Switches Switch/Switches Stuck ON P153D

596 31 Cruise Control Enable Switch Switch Stuck ON P1590
598 2 Clutch Switch Signal Signal Fault ON P0704
599 31 Cruise Control Set/Decel Switch Switch Stuck ON P1591

31 Cruise Control Resume/Accel Switch Stuck ON P1592
601
Switch
628 12 ECU Memory EEPROM Read / Write Failure ON P1602
8 Circuit Fault ON P0336

636 Crankshaft Position Sensor
2 Plausibility Fault ON P0335
5 Driver Circuit Open/Grounded ON P0261
651 3 Injector 1 Driver Circuit Short to B+ ON P0262

4 Driver Circuit Grounded ON P1262

5.44 © Copyright

652 3 Injector 2 Driver Circuit Short to B+ ON P0265

677 3 Starter Solenoid Driver Circuit Driver Circuit Short to B+ ON P0617

731 4 Knock Sensor 1 Voltage Too Low ON P0327
5 Open / Short ON C1030

904 Wheel Speed Sensor (Front)
2 Input Abnormal / Signal Failure ON C1031
2 Plausibility Fault ON C103D
3 Short to B+ ON C113D
4 Open/Short to GND ON C123D
907 Wheel Speed Sensor (Rear)
5 Open/Short ON C1036
8 Abnormal Frequency ON C133D

5
14 Incorrect Sensor / Improper Mounting ON C143D
1023 5 Trip Sudden Decelerations Open / Short ON C1045
1071 3 Fan Relay Driver Driver Circuit Short to B+ ON P1482

1268 3 Ignition Coil Primary Driver 1 Driver Circuit Short to B+ ON P1353

1269 3 Ignition Coil Primary Driver 2 Driver Circuit Short to B+ ON P1354

1347 3 Fuel Pump Driver Circuit Driver Circuit Short to B+ ON P0232

5 Open Circuit / Short to B+ ON C107E
2348 High Beam Lamp
6 Grounded Circuit ON C107F
5 Open Circuit / Short to B+ ON C107B
2350 Low Beam Lamp
6 Grounded Circuit ON C107C
5 Driver Circuit Open/Grounded OFF P1714
Left Turn Indicator Driver
2367 3 Driver Circuit Short to B+ OFF P1715
Circuit
4 Driver Circuit Grounded OFF P1716
5 Driver Circuit Open/Grounded OFF P1710
Right Turn Indicator Driver
2369 3 Driver Circuit Short to B+ OFF P1711
Circuit
4 Driver Circuit Grounded OFF P1712
3056 2 Oxygen Sensor 1 (Front) Signal Fault ON P0130

© Copyright 5.45

12 Bad Component ON P113A
3 Voltage High ON P0132
4 Voltage Low ON P0131
3 Voltage Too High ON P16A2
4 Voltage Too Low ON P16A1
0 Voltage Above Critical Level ON P16A3

3597 ECU Output Supply Voltage 1
16 Voltage Above Warning Level ON P16A5
1 Voltage Below Critical Level ON P16A6
18 Voltage Below Warning Level ON P16A7
3 Voltage Too High ON P16A9
4 Voltage Too Low ON P16A8
0 Voltage Above Critical Level ON P16AA

16 Voltage Above Warning Level ON P16AB
1 Voltage Below Critical Level ON P16AC
18 Voltage Below Warning Level ON P16AD
3 Voltage Too High ON P17AA
4 Voltage Too Low ON P17AB
0 Voltage Above Critical Level ON P17AC

16 Voltage Above Warning Level ON P17AD
1 Voltage Below Critical Level ON P17AE
18 Voltage Below Warning Level ON P17AF
5582 9 Static Roll Angle Abnormal Update Rate ON P1062
65590 7 Cylinder Not Identified Misfire Confirmed ON P0314
65591 7 Cylinder 1 Misfire Detected ON P0301
65592 7 Cylinder 2 Misfire Detected ON P0302
ETC Accelerator Position Sensor

65613 2 Outputs 1 & 2 Correlation Correlation Fault ON P1135
0 Voltage Above Critical Level ON P1223
520198 1 Throttle Position Sensor 2 Voltage Below Critical Level ON P1222
2 Signal Out of Range (Not Plausible) ON P0221
13 Calibration / Adaption Failure ON P1220
Condition Exists (engine disabled due to extended

520267 31 Kickstand Switch kickstand) ON P181C

520200 Tipover Sensor

5.46 © Copyright

14 Condition Exists (tip over condition detected) ON P1504
520202 3 Canister Purge Valve Driver Circuit Short to B+ ON P0443

17 System Too Lean 1 (Front) (Pre) ON P0171
520204 Fuel Correction
15 System Too Rich 1 (Front) (Pre) ON P0172
17 System Too Lean 2 (Rear) (Post) ON P0174

520205 Fuel Correction
15 System Too Rich 2 (Rear) (Post) ON P0175
520208 3 Chassis/Acc Relay Driver Circuit Short to B+ ON P1614


5
Oxygen Sensor Heater 1 (pre)
520209 (front)
3 Driver Circuit Short to B+ ON P0032
5 Oxygen Sensor Heater 2 (post) Driver Circuit Open/Grounded ON P0036

520210 (rear)
3 Driver Circuit Short to B+ ON P0038
520250 7 ABS Pulsar (front) COG Chip ON C1022
520251 7 ABS Pulsar (rear) COG Chip ON C1023
520252 5 ABS Solenoid (RRI) Open / Short ON C1024
520253 5 ABS Solenoid (RRO) Open / Short ON C1025
520254 5 ABS Solenoid (FFI) Open/Short ON C1026
520255 5 ABS Solenoid (FFO) Open/Short ON C1027
520256 5 ABS Solenoid (RFI) Open/Short ON C1028
520257 5 ABS Solenoid (RFO) Open/Short ON C1029
520258 11 ABS Actuator (front) Wheel Lock (or VSS failure) ABS On ON C1032
520259 11 ABS Actuator (rear) Wheel Lock (or VSS failure) ABS On ON C1033
8 Motor Lock ON C0020

520260 3 ABS Motor Off Stick ON C1020
4 On Stick ON C1021
520261 7 ABS Fail Safe Relay On/Off Stick ON C1034
4 Drop ON C1038
520262 ABS Source Voltage
3 Raise ON C1039
520263 31 ABS Tire Irregular Tire Size ON C1040
520264 12 ABS ECU ECU Error ON C1041

© Copyright 5.47
520265 7 ABS Module Incomplete Evacuation and Fill ON C1042
Accelerator Position/Brake
520275 31 Condition Exists ON P150A
Position Interaction
12 Throttle Position Sensor(1 or 2 Neither Position Sensor Passed Test ON P150B
520276 Indeterminable)
2 Position Sensor Correlation Fault (One okay, one failed) ON P150C
3 Maximum ON P150D
4 Minimum ON P150E
2 Throttle Body Control - Power Not Plausible ON P151A
520277 Stage
8 Signal Error ON P151B
31 Deactivated power stages due to 5V sensor supply error ON P153F
31 Throttle Body Control - Return Condition Exists

520278 Spring Check Failed ON P151C
31 Throttle Body Control - Condition Exists

520279 Adaption Aborted ON P151D
31 Throttle Body Control - Limp Condition Exists

520280 ON P151E
Home Position Check Failed
31 Throttle Body Control - Condition Exists
520281 Mechanical Stop Adaptation ON P15A
Failure
520282 31 Throttle Body Control Condition Exists ON P152B
3 Maximum ON P152C
520283 4 Throttle Body Control Minimum ON P152D

2 Outside of Pedal Range(Level 1) ON P152F
31 Throttle Body Control - Position Condition Exists ON P152E

520284
Deviation Fault
2 Brake Switch (1 or 2 Brake Switch Correlation Fault ON P153E
520285 Indeterminable)
520226 31 ECU Monitoring Error Condition Exists ON P1540
520287 31 ECU Monitoring Error (Level 3) Condition Exists ON P1541
31 ECU Monitoring of Injection Cut Condition Exists ON P1542

520288 Off(Level 1)
31 ECU Monitoring of Injection Cut Condition Exists ON P1543

520289 Off(Level 2)
31 Controller Option Settings not Condition Exists ON P1544

520290 Programmed
5 Open Circuit / Short to B+ ON C1075

520291 Left Fog Lamp
6 Grounded Circuit ON C1076
520292 Right Fog Lamp
5 Open Circuit / Short to B+ ON C122A
520293 Horn
6 Grounded Circuit ON C122B
520294 Windshield Motor Driver
520295 2 Windshield Motor Switch Both inputs are closed ON C1225

5.48 © Copyright
520296 12 Accelerometer Bad Component ON C1125
520297 31 System On Button Switch Stuck ON C1530

520298 Heated Grips
520299 Power Lock Motor
12 Battery Voltage too Low (Replace) OFF C1083
520300 17 Tire Pressure Sensor (Front) Pressure to Low OFF C1084

9 Abnormal Update Rate OFF C1085
12 Battery Voltage too Low (Replace) OFF C1088
520302 17 Tire Pressure Sensor (Rear) Pressure to Low OFF C1089

9 Abnormal Update Rate OFF C1090
520304 12 Key Fob Battery Voltage too Low (Replace) OFF P1633
31 Throttle Body Control - Condition Exists ON P1530

5
520305 requested throttle angle not
plausible
31 ECU Fault – Hardware Condition Exists ON P1537

520311 Disruption
520312 31 Power Lock Motor Switch Switch Stuck ON C1229
520313 11 ABS Actuator (front) Wheel Lock (or VSS failure) ABS Off ON C103A
520314 11 ABS Actuator (rear) Wheel Lock (or VSS failure) ABS Off ON C103B
5 Open Circuit ON P1593
520320 3 Brake Light Shorted to Battery ON P1594
4 Shorted to Ground ON P1595

520321 3 Tail Light Shorted to Battery ON P1597

520322 4 Front Brake Switch Voltage Too Low ON P159A
2 Signal Fault ON P159B
3 Voltage Too High ON P159C
520323 4 Rear Brake Switch Voltage Too Low ON P159D
2 Signal Fault ON P159E
520329 9 Operator Switch Status (pOSS1) Abnormal Update Rate ON P1063
13 Out of Calibration ON P1064

520330 Immobilizer
9 Abnormal Update Rate ON P106A

520331 Knock Sensor Positive Line
520332 3 Knock Sensor Negative Line Voltage Too High ON P132A

© Copyright 5.49

4 Voltage Too Low ON P132B
12 Bad Component ON P1139

520333 Oxygen Sensor (Pre) (BANK 2)
ECU Monitoring (Pedal Map

520336 31 Mismatch) Condition Exists ON P1545
524046 31 Start Button Switch Stuck ON C1512
524079 31 Cruise Control Input Checksum Checksum does not match ON U0405
31 Cruise Control Input Message Counter not incremented ON U1405

524080
Counter
524083 3 Secondary Air Control Valve Shorted to Battery ON P1076
SENSOR DIAGNOSTICS If multiple codes are set, refer to the wiring diagram
If a sensor fails or reads outside a “normal” range, a and focus your efforts on wiring and connections
“pre-programmed” (default) value is substituted by common to each of the sensors, such as a power
the ECM until sensor reading returns to normal. supply or common ground. Multiple sensor failure is
extremely unlikely.
Sensor values can be viewed in Digital Wrench® on
the “Sensor Data Grid Or Graphs” screen. Since the Many sensor tests described in this section are
sensor reading may either be actual feedback from performed at the ECM wire connector. This method
the sensor OR a default value set by the ECM in the ensures that the data from a sensor is reaching the
event of a fault in the sensor or wiring, it is important ECM. Sensor tests can be performed at the sensor if
to verify the condition of the sensor. easily accessible, but the wiring between the sensor
and the two 56–pin ECM connectors should always be
The Malfunction Indicator Light (MIL) may or may not closely examined and the path between the sensor
illuminate to alert the rider of a possible problem, and ECM verified if the sensor itself passes the test.
depending on which system fault has occurred. The
first step following illumination of the MIL is to perform Poor or corroded connections are the most common
a visual inspection to see if a cause can be cause of system faults. Always check the integrity of
determined. the male pins and female receptacles of the
connectors in the affected circuit. These may include
Connect Digital Wrench® to see what codes are the sensor connector, the ECM connector, and any
present in memory, and focus your diagnostics on that wiring between the two, such as jumper harnesses
sensor and the related wiring for that circuit. Refer to where applicable.
wiring diagrams and system break-out diagrams to
narrow a problem search.

5.50 © Copyright
ECM PINOUT TESTING • DO NOT attempt to use standard meter probes or

other devices to probe connector pin sockets. this
NOTICE
could expand a terminal socket or damage the
Tests in this section may require reading resistance connector, create a problem where none existed
and voltages at ECM connector. Once ECM before, and complicate the diagnostic process.
connector has been removed from the ECM:
• Sensor tests on the following pages can often be
performed at the sensor connector itself or at the
• Do not touch pins on ECM. Static electricity from ECM connector based on accessibility of the
your body can damage the ECM. connector or wiring.
• Do not attempt to perform tests on the ECM unit. • If a sensor tests within the specified range (OK),
then test the circuit wiring. This usually originates at
• Always use the appropriate test connector from the the ECM connectors, but may include other
Electrical Connector Test Adapter Kit (PV-43526) or connections.
an appropriate test probe that will not damage
(expand) the connector pin socket.

© Copyright 5.51
E C M C O N N E C T O R R E M O VA L E C M R E M O VA L / I N S TA L L AT I O N
1. Remove the RH upper side cover. See Side Cover 1. Disconnect the ECM connectors. See ECM
(Upper), Removal / Installation page 3.15. Connector Removal page 5.52.
2. Remove the RH lower side cover. See Side Cover 2. Remove the battery box. See Battery Box Removal
(Lower), Removal / Installation page 3.15. page 15.12.
3. To disconnect the two 56–pin ECM connectors: 3. Remove the four fasteners q securing the ECM to
the battery box.
• Locate the ECM connectors q.
4. Reverse the removal procedure to install.

• Slide the lock lever toward the front of the vehicle
until connector is disengaged from the ECM. 5. Torque ECM fasteners to specification.
• Lift the connector straight off of the ECM. TORQUE

ECM Fasteners:
ECM Connector Installation 36 in-lbs (4 N·m)
4. Carefully align the ECM connector straight with
the flange on the ECM. (Do not tip or rotate the
connector into the ECM).
5. Gently apply straight inward pressure on the
connector while sliding the lock lever back toward
the connector until the lever stops and the
connector is fully seated.
6. Install the upper and lower side covers.

5.52 © Copyright
T E M P E R AT U R E & M A N I F O L D A B S O L U T E P R E S S U R E S E N S O R ( T M A P ) R E P L A C E M E N T
Operation Overview TMAP Sensor Replacement
Mounted on the intake manifold, the TMAP sensor q 1. Remove the ignition coil assembly and associated
performs two functions in one unit. bracket. See Ignition Coil Removal / Installation
page 16.9.
2. Disconnect vehicle harness from TMAP sensor.
3. Remove TMAP sensor fastener w and remove
sensor from the intake manifold.
Air passing through the intake is measured by the

5
TMAP and relayed to the ECM. These signals,
comprised of separate air temperature and manifold
absolute pressure readings, are processed by the
ECM and compared to its programming for 4. INSTALLATION is performed by reversing the
determining the fuel and ignition requirements during removal procedure.
operation. The TMAP sensor provides the ECM with
engine load data. 5. Torque TMAP sensor fastener to specification.
TMAP Sensor Test TORQUE
The TMAP sensor is a non-serviceable item. If it is TMAP Sensor Fastener:
faulty, it must be replaced 44 in-lbs (5 N·m)
IMPORTANT
This sensor should only be tested using Digital
Wrench Diagnostic Software.

© Copyright 5.53
C Y L I N D E R H E A D T E M P E R AT U R E S E N S O R , T E S T / R E P L A C E
CHT TEST OVERVIEW
INDICATES INSPECT LOCATION
Voltage received at ECM from CHT Resistance readings through sensor and wiring at ECM Under front
sensor is outside of parameters. 2 connector (ECM disconnected). This will test will cylinder
inspect the wiring, connectors, and CHT sensor intake port.
resistance.
1. Disconnect ECM #2 connector. See ECM Connector Removal page 5.52.

2. Attach test lead adapters to meter leads.
3. Set multimeter to measure resistance.
4. Measure resistance between pin 8 and pin 15 of the ECM #2 connector and compare to specification. See
ECM Connector Map page .
5. If resistance is out of specified range, disconnect sensor and measure the resistance through each wire from
ECM connector to the sensor connector. Resistance should be less than 1 Ohm (good continuity).
6. If Step 5 continuity is good, measure the resistance through the sensor and compare to specification.
METER TEST SPECIFICATIONS (±10%)

COMPONENT
SETTING CONNECTIONS
CYLINDER HEAD 30.5 K Ohms +/- 13% @ 25o C (77o F)
OHMS Pin #8 to #15
TEMPERATURE SENSOR

5.54 © Copyright
F U E L I N J E C T O R , R E M O VA L / I N S TA L L AT I O N 5. Install fuel injector. See Fuel Rail Installation

page
1. Remove fuel rail from injectors. See Fuel Rail
Removal page .
2. Disconnect electrical connector from fuel injector. F U E L I N J E C T O R R E S I S TA N C E T E S T
Discard fuel injector AND injector o-rings.
IMPORTANT
3. Lubricate NEW injector o-rings with clean, Take note of front and rear fuel injector harness
silicone-free motor oil. connectors before disconnecting them.
NOTICE
Apply oil sparingly and avoid contaminating the The fuel injectors are non-serviceable. If diagnosis
pintle valve / jet surface and upper inlet port. indicates a problem with either injector, test the
resistance of the fuel injector(s) by measuring
between the two pin terminals q.
4. Install NEW o-rings onto top and bottom of injector
Fuel Injector Resistance Specification:

11.4 Ω — 12.6 Ω
ITEM PART NUMBER POSITION

q 1500198 TOP OF INJECTOR
w 5412891 BOTTOM OF
INJECTOR
IMPORTANT
Always install NEW o-rings when removing the fuel
rail or injectors.
IMPORTANT
Verify that the new top and bottom o-rings are
installed in the correct position.
IMPORTANT
Verify that both of the new o-rings have been
lubricated and installed correctly onto the injectors.

© Copyright 5.55
CRANKSHAFT POSITION SENSOR, TEST / REPLACE

CPS TEST CPS REPLACEMENT
1. Locate the CPS connector q behind the RH front 1. Remove starter motor. See Starter Motor, Removal /
down tube, and disconnect. Installation page 15.25.
2. Remove regulator / rectifier assembly and bracket.
See Rectifier / Regulator Replacement page 15.33.
3. Disconnect the CPS sensor from the vehicle
harness and release flying lead from plastic darts
and cable ties.
4. Remove the fastener e securing the CPS sensor to
the engine case and remove sensor.
2. Connect an ohmmeter between the pin terminals

w and compare resistance readings to
specification below.

removal procedure.
NOTICE
Apply rubber lubricant to the CPS sensor o-ring to
ease installation.
6. Torque the CPS retaining fastener to specification.

TORQUE
3. If resistance is correct, check to see that the sensor Crankshaft Position Sensor Retaining Fastener:
is mounted properly and that the tone wheel has 88 in-lbs (10 N·m)
not been damaged and is securely mounted to the
crankshaft assembly.
Crankshaft Position Sensor: 860 Ohms @ 20°C (68°F)

5.56 © Copyright
D E T O N AT I O N S E N S O R T E S T / R E P L A C E IMPORTANT
The detonation, or “Knock” sensor is a piezoelectric
The detonation sensor must be torqued to
sensor that advances or retards ignition based on
specification or it will not perform correctly. Sensors
load.
that have been over-tightened or under-tightened
may set a diagnostic trouble code and cause the MIL
CAUTION
to illuminate. Use a properly calibrated torque
The detonation sensor is torque sensitive and must wrench during installation.
be replaced if removed for any reason.
DETONATION SENSOR DIAGNOSTIC INFORMATION
COMPONENT LOCATION P-CODE SPN FMI DESCRIPTION

P0327 731 4 Knock Sensor 1: Voltage too low
P1327 3 Positive Line: Voltage too high
Rearward 520331
Detonation face of the P1328 4 Positive Line: Voltage too low
“Knock” Sensor front cylinder
P132A 3 Negative Line: Voltage too high
P132B
520332
4 Negative Line: Voltage too low
5
Test 1 6. Measure the resistance through each wire from
ECM connector to the sensor connector.
1. Disconnect the negative battery cable. See Battery
Resistance should be less than 1 Ohm (good
Removal page 15.10.
continuity). See ECM Connector MAP page 5.41
2. With the RH upper side cover removed, locate the for pin locations.
detonation sensor connector q just inside the RH
midcasting and disconnect. ECM2 Pin 37 to Detonation Sensor Connector Pin 1
should be less than 1Ω.
ECM2 Pin 38 to Detonation Sensor Connector Pin 2
should be less than 1Ω.
7. Measure the resistance across the detonation

sensor pins 1 & 2.
Resistance across Detonation Sensor Connector Pin 1
& Pin 2: Continuity
Resistance should be between 4.5–5.0 MΩ
8. If the resistance does not match the specified

value, replace the sensor.
Test 2
9. Using a multi meter with a low voltage AC
frequency scale, connect the meter leads to the
3. Inspect the sensor-side of the connector for connector pins of the detonation sensor.
moisture and / or corrosion. Make sure the
terminal pins are securely seated in the plug. 10. Allow the signal to stabilize to 0 Hz.
4. Remove the ECM from the motorcycle to access 11. Lightly tap the front cylinder near the knock
ECM connector 2. See ECM Removal / Installation sensor with a rubber mallet or other non-metallic
page 5.52. object.
5. Set multi meter to measure resistance. 12. Watch for frequency fluctuation.
13. If no frequency fluctuation is observed while
tapping on the cylinder, replace the sensor.
Replace

© Copyright 5.57
14. Remove the ignition coil assembly and mounting 17. Noting how the detonation sensor harness is
bracket. See Ignition Coil Removal / Installation routed, remove the sensor from the motorcycle.
page 16.9.
15. Remove the fuel tank. See Fuel Tank Removal removal procedure.
page .
19. Torque the detonation sensor fastener to
16. Remove the fastener w securing the detonation specification.
sensor to the forward cylinder.
TORQUE
Detonation Sensor Fastener:
15 ft-lbs (20 N·m)
T H R O T T L E B O D Y ( E T C ) R E M O VA L
1. To remove the Electronic Throttle Control
assembly, see Air Box Removal page 5.22.

5.58 © Copyright
CYLINDER MISFIRE DETECTION

The ECU monitors crankshaft speed via the crankshaft position sensor. A misfire will cause a fluctuation in
crankshaft speed. A code will set and flash the check engine light after an engine misfire threshold/rate is
detected that is above a pre-determined limit. This threshold varies based on engine speed.
One or more of the following codes will be set if a misfire occurs:
• P0301 (SPN 65591/FMI 7) Misfire Detected, Cylinder 1 (Front)
• P0302 (SPN 65592/FMI 7) Misfire Detected, Cylinder 2 (Rear)
• P0314 (SPN 65590/FMI 7) Misfire Confirmed
If a misfire is detected, the following events will occur:

• The check engine indicator lamp will begin to flash and fuel will be cut to the affected cylinder(s). The check
engine indicator lamp will continue to flash until the ignition switch has been moved to the off position.
Restarting the engine will clear the flashing indicator and restore fuel to both cylinders.
• If a 2nd misfire occurs, the check engine indicator lamp will resume flashing and fuel will once again be cut to
the affected cylinder(s).
• After the 3rd misfire, P0314 misfire fault is determined & set, the check engine light will remain on and fuel will
be cut to the affected cylinder(s). If this occurs, follow the troubleshooting section below. 5
In cases where cylinder misfire is intermittent, or has been repaired in the field (e.g. loose spark plug wire has
been reattached), Misfire Detection utilizes a self-healing feature to allow continued operation. Following the 1st
or 2nd misfire event, when the ignition is cycled OFF and ON again, the misfire code becomes historic and the
MIL turns off. When P0314 is set, after the 3rd misfire event, the MIL will stay on for 3 fault free drive cycles before
turning off.
If the MIL turned on solid due to P0314, it will stay on until the misfire condition has been removed and 3 fault free
drive cycles have occurred.
NOTICE
DRIVE CYCLE:
A drive cycle consists of cycling the ignition from OFF to ON, then start the engine and run at idle for a period of
approximately 4 minutes. Finally, turn off the ignition for approximately 2 1/2 minutes.
If it does not turn off, diagnose by verifying the following items:
TROUBLESHOOTING
• Ignition Coil and connections are good

• Spark plugs wires are secure
• The correct spark plugs are installed and the plugs are not fouled
• Crankshaft Position Sensor tests good
• Wiring to the Crankshaft Position Sensor, ECU and Ignition Coil are not damaged. Chassis ground is clean
and tight
• Fuel pressure is within specification
• Fresh/good quality fuel is in the fuel tank
• Engine mechanical is good (leak down, timing)
IMPORTANT
Once the systems is repaired and functioning normally, connect to Digital Wrench to clear active and historic
codes. Retest to verify the condition is no longer present.

© Copyright 5.59

5.60 © Copyright
CAN DIAGNOSTICS
CAN (CONTROLLER AREA NETWORK) Checking resistance between Yellow CAN High wire
DIAGNOSTIC OVERVIEW and Green CAN Low wire at the specified module
connectors below (while unplugged):
Overview
The speedometer and Engine Control Module (ECM) • VCM = 60Ω
have integrated 120Ω termination resistors. With the • ECM = 120Ω
speedometer unplugged, check resistance between
the CAN terminals at the speedometer connector. The • Speedometer = 120Ω
resistance should be 120Ω. With the speedometer • ABS Module = 60Ω
connector plugged in, and the ECM connector
unplugged the resistance will be 120Ω. With • Diagnostic Connector = 60Ω
speedometer and ECM connectors plugged in, the
resistance will be 60Ω
Baseline CAN Resistance Values

© Copyright 5.61
D I G I TA L W R E N C H
D I G I TA L W R E N C H D I A G N O S T I C S O F T WA R E Diagnostic procedures are added to subsequent
OVERVIEW versions of Digital Wrench as they become available.
Check your release version often and upgrade when
NOTICE available to be sure you are using the most current
Refer to Section 2, 3 and 4 in the Instruction Manual software available.
provided in the Digital Wrench Diagnostic Kit to
install the Digital Wrench diagnostic software on your
computer. D I G I TA L W R E N C H C O M M U N I C AT I O N E R R O R S
If you experience problems connecting to a vehicle or
The Digital Wrench diagnostic software allows the any other Digital Wrench related problem, visit the
technician to perform the following tests and Digital Wrench Knowledge Base for the most current
observations: troubleshooting information, FAQs, downloads and
software updates at: http://polaris.diagsys.com/.
• View or clear trouble codes
• Analyze real-time engine data
• Reflash ECU calibration files
• Perform guided diagnostic procedures
• Create customer service account records
• Perform output state control tests (some models)
D I A G N O S T I C S O F T WA R E V E R S I O N
Always use the most current version of the Digital
Wrench software to ensure you have the latest updates
or enhancements. New reprogramming files and
guided diagnostic procedures are added to these
updates as they become available. For information on
how to determine if you have the latest update D I G I TA L W R E N C H D I A G N O S T I C C O N N E C T O R
available, see Digital Wrench Version and Update ID The diagnostic connector q is located under the LH
page 5.63. upper side cover, below the fuse box.
ECM REPLACEMENT
Although the need for ECM replacement is unlikely, a
specific replacement procedure is required to ensure
that all essential data contained within the original
ECU is transferred to the replacement ECU.
Refer to procedure and carefully follow all instructions
provided in Digital Wrench.
G U I D E D D I A G N O S T I C AVA I L A B L E
Guided diagnostics are available within Digital
Wrench for most supported Diagnostic Trouble Codes
(DTCs). That is, any fault that will turn on the ‘Check
Engine’ indicator. Follow these steps to connect the diagnostic interface
In addition, guided diagnostics are also available for cable to the vehicle:
many other electrical sub systems. 1. Assemble the SmartLink Module and attach the PC
Interface Cable to your laptop.
2. Unplug the Digital Wrench connector from it’s
protective receptacle.

5.62 © Copyright
3. Connect the Vehicle Interface Cable to the Digital 2. Proceed to http://polaris. diagsys. com to see if a
Wrench diagnostic connector. newer update is available.
4. Press the ON button to power up the motorcycle
electrical system and switch the STOP / RUN
switch to the RUN position.
5. Select the appropriate vehicle and wait for the
status to display ‘Connected’ in the lower left
corner of the screen.
6. Once connected, proceed with using Digital
Wrench.
D I G I TA L W R E N C H S E R I A L N U M B E R
L O C AT I O N
Open the configuration screen by clicking on the
wrench icon. The serial number is located on the right
side of the screen. 3. If a newer update is available, it should be
downloaded before using Digital Wrench.
NOTICE 5
Always operate with the latest update.
D I G I TA L W R E N C H U P D AT E S
Updates are released for Digital Wrench via the
D I G I TA L W R E N C H V E R S I O N A N D U P D AT E I D Internet at: http://polaris.diagsys.com. The Digital
Knowing what Digital Wrench version and update is Wrench website can also be accessed through the
installed will help determine which updates are dealer website at: www.polarisdealers.com.
required. NOTICE
NOTICE Only authorized Indian Motorcycle dealers and
Versions and updates are subject to change. distributors can access the dealer website.
1. Log on to www.polarisdealers.com.
1. Open the Digital Wrench software. Locate the
version ID shown on the lower right side of the 2. Locate the Service and Warranty drop-down
Digital Wrench start-up screen. menu.
3. Click on Digital Wrench Updates.
4. The Digital Wrench portal website should appear

in a new web browser.

© Copyright 5.63
5. Click on Digital Wrench Version Updates. 7. Click on the link shown above, save the file to your
hard disk and then double-click the icon to start
the update process.
NOTICE
Do not "run" or "open" the file from where they are.
Select "save" and download them to your PC before
running the install.
8. When the update is complete, the version shown

on the right side of the Digital Wrench start-up
screen should match the update you just
downloaded.
NOTICE
You must already have the current version installed
before adding an update. Updates will not install if
you are using an older version loaded on your PC.
6. If the update file date listed is newer than your

current version and update, download the file.
NOTICE
Versions and updates are subject to change.

5.64 © Copyright
D I G I TA L W R E N C H F E AT U R E M A P

© Copyright 5.65
ENGINE CONTROLLER REPROGRAMMING • KNOW THE PROCESS: If you are not familiar with the
(REFLASH) entire reprogramming process, review the HELP
Process Overview section of the diagnostic software before you
attempt reprogramming. Click on the ? on the tool
The reprogramming feature is in the Special Tests bar or press F11. The information in the on-line help
menu on the Digital Wrench screen. Start Digital is the most current and complete information
Wrench and click on the Special Tests menu icon (red available. This should be your first step until you are
tool box). A technician should be familiar with the familiar with the process.
process and with computer operation in general
before attempting to reprogram an ECM. • COMMUNICATION PROBLEMS: If you have had
problems communicating with a vehicle while
The Digital Wrench Engine Controller performing diagnostic functions, do not attempt
Reprogramming (or “Reflash”) feature allows reprogramming until the cause has been identified
reprogramming of the ECM fuel and ignition map. To and fixed. Check all connections, and be sure
successfully reprogram the ECM, an Authorization Key battery voltage is as specified.
must be obtained by entering a Request Code in the
box provided on the Reflash Authorization site. The
Request Code is automatically generated by Digital • Proceed to http://polaris.diagsys.com for specific
Wrench during the reprogramming process. The information and FAQs on how to troubleshoot
Reflash Authorization site is located under the Service communication problems.
and Warranty drop down menu on the dealer website
• DON’T DISTURB THE PC: While reprogramming is in
at: www.polarisdealers.com.
progress, don’t move the mouse and don’t touch the
keyboard. The process only takes a few minutes,
NOTICE
and is best left alone until complete.
Failure to follow the reprogramming instructions
completely and correctly can result in an engine that Reprogramming (Reflash) Procedure:
does not run! Replacement ECMs are programmed
as “no-start” and require a reflash for them to work. If you are not familiar with the reprogramming
process, review the “Reprogramming (Reflash) Tips”
before you begin. Follow the on-screen instructions as
Reprogramming (Reflash) Tips: you progress through the steps. If you encounter a
problem, always check the On-Line help for current
• BATTERY VOLTAGE: The majority of problems with tips and information.
reprogramming can be attributed to a low battery.
Be sure the battery voltage (no load) is at least 13 1. Verify the most current update has been
volts and at least 12.5 volts with the key ‘ON’. downloaded and loaded into Digital Wrench.
Connect a battery charger if necessary to bring 2. Connect SmartLink Module cables to PC and
voltage level above minimum. Fully charge the vehicle.
battery before you attempt to reprogram.
3. Open the Digital Wrench program.
• DEDICATED LAPTOP: Best results are obtained
using a laptop computer that is “dedicated to Digital 4. Select the model year, product line and vehicle
Wrench”. A laptop that is used by a variety of description by selecting the “Change Vehicle
people and in several applications around the Type” icon.
dealership is more likely to cause a reprogramming 5. Select the “Special Tests” icon.
problem than one dedicated to Digital Wrench
diagnostics only. 6. Select “Engine Controller Reprogramming”.
• OBTAINING THE LATEST UPDATE: Reprogramming 7. Select the file you want to load into the ECU then
updates are provided periodically and contain the click the “Continue” icon to proceed to the
most recent calibrations. Integrity Check and obtain a Request Code.
• CLOSE NON-ESSENTIAL PROGRAMS: It is 8. Copy (CTRL +C) the Request Code that will be
recommended that you DO NOT install non-essential required on the dealer website in the next step.
programs on a Service Department laptop. Camera DO NOT CLOSE Digital Wrench or the Request
detection software, Virus Scanners, Tool Bars, etc. Code will be invalid. NOTE: All characters are
may clog up memory if running in the background letters; there are no numbers in a request code.
and make it harder for the diagnostic software to
NOTICE
operate.
Request Codes and Authorization Keys must be
entered EXACTLY as they appear on the screen.

5.66 © Copyright
9. Go to www. polarisdealers. com and click on 13. Enter or paste (CTRL +V) the Authorization Key in
“ReFlash Authorization” from the “Service and the box located on the Digital Wrench screen.
Warranty” drop-down menu. Click the ‘Continue’ button and follow instructions
provided on the screen to complete
10. Enter or paste (CTRL +V) the Request Code into reprogramming procedure.
the box.
14. At this point the reflash process will begin. Do not
11. Select the same file type from the list that you touch the vehicle or PC during the process.
selected previously while in Digital Wrench. Enter
the VIN/PIN along with the customer’s name and 15. Once the ECU reprogramming procedure is
address. When completed, click the Authorize complete, click the ‘Finish’ button on the screen.
button once to proceed. Verify the reflash was a success by starting the
vehicle.
12. An “Authorization Key” will appear in the upper
left corner of the screen. Copy (CTRL+C) this key
exactly as it appears.

© Copyright 5.67
TROUBLESHOOTING
F U E L S Y S T E M T R O U B L E S H O O T I N G , PA R T 1
PROBLEM POSSIBLE CAUSE AFFECTED PART(S) REPAIR RECOMMENDED
Engine turns over with Compression too low See engine section
electric starter, but won’t
start No spark at spark See ignition system
plugs
No fuel reaching intake Out of fuel Add Fuel
tract Blown Fuse Replace
Plugged fuel filters / Clean/Replace
lines Test / Replace
Fuel pump not working Test / Replace
Fuel pressure regulator Test / Replace
Faulty fuel pump relay Inspect / Repair
Open wiring / connector Inspect / Repair
Faulty connection at ECM
Excessively rich or Fuel pump Test / Replace
lean fuel mixture Fuel pressure regulator Test / Replace
Crank Position Sensor Test / Replace
Low Battery Test / Replace
TMAP sensor Test / Replace
CHT sensor Test / Replace
Fuel Injector Test / Replace
Spark at wrong time or Timing Wheel or CPS Install correctly, inspect for
no spark. installed incorrectly, proper air gap (gap is preset
Fuel delivery timing damaged, or dirty; faulty but cover, sensor, and timing
incorrect. CPS wheel must be clean and in
good condition).
Poor idle Excessively rich or Air Leaks Inspect throttle body and
lean fuel mixture Fuel Pump stepper motors
Fuel injector or fuel rail Inspect fuel pressure
obstructed or leaking Replace
Air Filter Replace
Wrong Fuel / Old Fuel Inspect / Replace
Crank Position Sensor Inspect / Replace
Poor Running in Higher Air intake restriction Air filter Inspect
RPM Range Oil Overfilled Ignition Coil(s) / plug Refer to ignition section.
Ignition problemsLow wires Charge or replace
Battery Voltage Battery Unplug connections - inspect
Loose, corroded, or ECM and wiring harness Inspect cylinder head &
wet connector(s) Valve springs, valve, valves
Valve train problems head

5.68 © Copyright
Engine Stalls Fuel Pump Problem Low battery voltage Battery/Charging system
Faulty fuel pump Check fuel pressure
No signal from ECM Repair Wiring
Wiring problem Repair/Chk Pump Relay
Excessive rich or lean TMAP Sensor Repair / Replace
fuel/air mixture Plugged fuel filter Test / Replace Pump Assembly
Fuel pump (pressure) Test / Replace
Fuel pressure regulator Test / Replace Pump Assembly
Vacuum leak Repair / Replace hoses
Wiring problem Repair
Air Filter Replace
Low battery voltage Ck battery & charging system
Control Circuit/ Fuel pressure regulator Test Pressure / Replace
Sensors not TPS Test / Replace
functioning correctly Engine speed sensor Test / Replace
Fuel pump relay
Rotor
Test / Replace
Inspect / Install correctly
5
Fuse Replace
ECM Relay Replace
Low battery voltage ECM Inspect Charging system
Valve train problems Refer to Engine chapter
or Compression low
Backfiring Low Battery Voltage Battery, spark plug Refer to battery section
Ignition Problem fouled, poor wire Replace plugs / diagnose
Air leaks connection for ignition or Inspect wiring connections
Restricted air intake or fuel injection, loose pin in Disconnect and check pin
throttle body multi-pin connector for connections
ECM or wiring harness Seal intake or exhaust leaks
Clean air inlet tract and throttle
Inlet and Exhaust body
Intake tract / Throttle
body

© Copyright 5.69
Poor Running in upper Control Circuit/ CPS Test / Replace
rpm ranges Sensors not ETC Test / Replace
functioning correctly Air temperature sensor Test / Replace
Manifold Absolute Test / Replace
Pressure sensor Repair/Replace
Intermittent wiring Test / Replace
/connector problem ECM
Fuel delivery incorrect Plugged or kinked fuel Repair/Replace
and/or vent hoses Test / Replace
Fuel pump Test Pressure / Replace
Fuel regulator Test / Replace Pump
Fuel filter Assembly
Battery/Charging System Charge/Replace (if
Fuel Injector plugged applicable)
Contaminated fuel (water, Clean/Replace
additives, etc.) Clean/Replace
Inadequate octane Use correct fuel
Defective ETC Test / Replace
Low battery voltage Charging system
Air intake restriction Dirty Air Cleaner Clean
Intake restriction Repair
Air Leak ETC gasket surfaces Repair/Replace
Intake manifold Repair/Replace
ETC Repair/Replace
Engine lacks power Engine component See Engine / Cooling /
problems Exhaust chapter
Ignition problems See Electrical chapter
Overfilled with oil See Maintenance chapter
Improper fuel delivery Plugged fuel injector Repair / Replace
Dirty air cleaner Replace
Vacuum leaks Repair
Fuel pump Test / Replace
Fuel pressure regulator Test / Replace
Air temperature sensor Test / Replace
TMAP sensor Test / Replace
Plugged vent hose Clear
Low battery voltage ECM Test batt./Charging system

5.70 © Copyright
Engine overheats Internal Engine Parts Cooling System Refer to Engine / Cooling /
Lubrication & Cooling Engine Oil Exhaust chapter
system Brake systems Refer to Engine / Cooling /
Low or incorrect oil Drive Belt Exhaust chapter
Brakes dragging Ignition Coils Refer to Brakes chapter
Drive belt too tight Faulty ECM Refer to Steering / Suspension
Ignition timing Charging System chapter
incorrect Faulty Battery Refer to Electrical chapter
Spark plug(s) Faulty Wiring Replace
Low battery voltage Test / Repair
Replace
Repair
Lean Air/Fuel mixture Fuel pressure regulator Repair / Replace
Air leak Repair
Fuel injector plugged Clean / Replace
CHT Test / Replace
Vent hose plugged / kinked
Air leak at throttle body to
Repair
Test / Repair
5
manifold seal
Won’t Accept Non-Current Go to Dealer website and
New Calibration Calibration File Set download the most current
Low Battery Voltage Indian Motorcycle Calibration
Attempting Re-Flash File Set
Without Proper VIN/
PIN, Calibration I.D. Attach Battery Charger
number, or calibration During Re-Flash, and Re-
authorization code Charge Battery When Re-
Flash Is Completed
Enter Authorization Code Sent

With Accessory Kit

© Copyright 5.71
NOTES

5.72 © Copyright
ENGINE REMOVAL / INSTALL
CHAPTER 6
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
ENGINE BRACKETS / FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PREPARATION FOR ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
REMOVING ENGINE FROM FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.11
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.11

© Copyright 6.1
SERVICE NOTES T O R Q U E S P E C I F I C AT I O N S
A floor jack or commercially available motorcycle
PART DESCRIPTION TORQUE
engine lift or hoist is required for engine removal.
SPECIFICATION
Arrange for assistance when removing and installing
the engine. ABS Module Bracket — 84 in-lbs (9.5 Nm)
M6 x 1.0 x 12 (QTY.4)
Once the engine is removed from frame, an engine
stand is recommended for engine disassembly and Battery Box — M6 x 1.0 x 84 in-lbs (9.5 Nm)
assembly. 12 (QTY.2)
Engine removal and installation methods may differ Brake Line Routing Tabs 84 in-lbs (9.5 Nm)
slightly depending on available equipment, but — M6 x 1.0 x 12 (QTY.4)
always be sure the engine and chassis are securely
supported at all times. Down Tube, Lower (Both 45 ft-lbs (60.0 Nm)
Sides) — M10 x 1.5 x 60
REQUIRES ENGINE CAN BE SERVICED (QTY.4)
REMOVAL FOR WITH ENGINE IN
SERVICE FRAME Down Tube, Lower LH — 45 ft-lbs (60.0 Nm)
M10 x 1.5 x 25 (QTY.1)
Camshaft(s) / Bearings Airbox Removal
Down Tube, Upper LH — 45 ft-lbs (60.0 Nm)
Crankshaft & Crankshaft Camshaft Chain / Guide M10 x 1.5 x 100 (QTY.2)
Component Service / Tensioner Assembly
Engine Mounts, Front — 18 ft-lbs (24.4 Nm)
Cylinder Heads Fuel Injectors / Throttle M8 x 1.25 x 20 (QTY.2)
Body / Fuel Rail
Engine Mounts, Rear — 75 ft-lbs (101.7 Nm)
Cylinders Voltage Regulator, M12 x 1.75 x 50 (QTY.4)
Stator, Rotor (Flywheel)
Ground Wire — M6 x 1.0 84 in-lbs (9.5 Nm)
Lifters Clutch x 12 (QTY.1)
Oil Pump Gearshift Linkage Side Stand Bumper — 84 in-lbs (9.5 Nm)
(External) M6 x 1.0 x 12 (QTY.1)
Balance Shaft Ignition System Side Stand Switch — M5 43 in-lbs (4.9 Nm)
Piston/Cylinder Oil Pump Drive x 0.8 x 16 (QTY.2)
Pushrods Output Shaft Seal Starter Solenoid — M6 x 84 in-lbs (9.5 Nm)

1.0 x 12 (QTY.2)
Transmission/All Torque Compensator
Internal Transmission Assembly
Parts
SPECIAL TOOLS
Valve Covers
Starter, Starter One-Way
Clutch, Starter Torque Engine Stand Adapter PF-51240
Limit Clutch
Motorcycle Table Lift / Commercially Available
Crankshaft Position Wheel Vise
Sensor Timing Wheel
12"x12" Platform Jack Commercially Available
Engine Hoist (Cherry Commercially Available
Picker)
ITEM SPECIFICATIONS Engine Stand Commercially Available
Approximately 293 lbs Bosch Automotive Service Solutions: 1–800–328–

Engine Dry Weight
(133 kg) 6657 or https://polaris.service-solutions.com/
Approximately 6.0
Oil Capacity (Dry Fill)
Quarts (5.7 Liters)

6.2 © Copyright
E N G I N E B R A C K E T S / FA S T E N E R S
L E F T S I D E B R A C K E T S / FA S T E N E R S
q Fastener, Engine Mount — M12 x 1.75 x 50 (QTY.2) 75 ft-lbs (102 N·m)
w Fastener, Engine Mount — M10 x 1.5 x 25 (QTY.1) 45 ft-lbs (60 N·m)
e Fastener, Engine Mount — M10 x 1.5 x 60 (QTY.2) 45 ft-lbs (60 N·m)
r Fastener, Frame Down Tube — M10 x 1.5 x 100 (QTY.2) 45 ft-lbs (60 N·m)
t Fastener, Front Engine Mount — M8 x 1.25 x 20 (QTY.2) 18 ft-lbs (24 N·m)

© Copyright 6.3
R I G H T S I D E B R A C K E T S / FA S T E N E R S
q Fastener, Engine Mount — M12 x 1.75 x 50 (QTY.1) 75 ft-lbs (102 N·m)
w Fastener, Engine Mount — M12 x 1.75 x 120 (QTY.1) 75 ft-lbs (102 N·m)
e Fastener, Engine Mount — M10 x 1.5 x 60 (QTY.2) 45 ft-lbs (60 N·m)

6.4 © Copyright
E N G I N E R E M O VA L
P R E PA R AT I O N F O R E N G I N E R E M O VA L 13. Loosen axle nut q and loosen belt tension
Remove the front fender with the motorcycle rest- adjustment nuts w and remove belt from drive
ing on it’s side stand, prior to placing the front tire sprocket.
in a wheel vise.
NOTICE
Different methods can be used to remove the
engine depending on the equipment available to
the technician. All methods require the front
wheel to be held securely in an upright position.
1. With the motorcycle resting on it’s side stand,

remove the front fender. See Front Fender
Removal page 3.24.
2. Support motorcycle securely in an upright
position. Clamp front tire securely in a wheel vise.
3. Remove upper side covers. See Side Cover
14. Remove air box. See Air Box Removal page 5.22.
4. Remove lower side covers. See Side Cover
(Lower), Removal / Installation page 3.15. 15. Remove the knock sensor e.
5. Remove the seat. See Seat, Removal / Installation - 16. Disconnect the TMAP sensor r.
Classic / Vintage / Chieftain page 3.19.
17. Disconnect the CHT sensor t. 6
6. Remove the battery. See Battery Removal page
15.10.
7. Remove the fuel tank. See Fuel Tank Removal
page .
8. Remove the complete exhaust system. See
EXHAUST SERVICE.
9. Remove the sprocket cover. See Drive Sprocket
Cover, Removal / Installation page 12.13.
10. Remove the ignition coil assembly. See Ignition
Coil Removal / Installation page 16.9.
11. Remove the RH and LH floorboard assemblies. See
Floorboard (Driver), Removal page 3.16.
12. Remove highway bars, if equipped. See Highway
Bar Removal page 3.22. 18. Remove both ends of the breather hose y from the
valve covers.

© Copyright 6.5
19. Disconnect electrical connectors from both fuel •

injectors and feed the electrical harness and all
NOTICE
plugs up through the fuel rail (distribution line)
and move out of the way. APPLICABLE TO CA AND INTERNATIONAL
MODELS ONLY.
20. Using a 10 mm socket, remove the top oil cooler
fastener u and release the oil cooler from the
lower mounting tabs i. • Noting position, disconnect hoses a from the
charcoal canister.
21. Disconnect the oil pressure switch. See Sensors —

Powertrain Management page 5.12.
22. Disconnect the gear position switch. See Sensors
— Powertrain Management page 5.12.
fasteners securing the sidestand switch and move
switch out of the way. See Sensors — Powertrain
Management page 5.12.
REMOVING ENGINE FROM FRAME

1. Perform the preliminary engine removal steps
outlined in this chapter. See Preparation For Engine
Removal page 6.5.

6.6 © Copyright
• Using a 5 mm hex wrench, remove the two 3. Using a 5 mm hex wrench, remove the fastener q
fasteners s securing the charcoal canister to the securing the clutch cable clip to the bottom of the
bracket. Remove canister. LH engine case.
• Remove the two fasteners d securing the 4. Remove the E-clip from the end of the clutch cable,
charcoal canister mounting bracket to the ABS rotate the clutch arm by hand and release the
bracket. clutch cable end from the arm.
5. Using a 6 mm hex wrench, remove the two front
motor mount fasteners w from the engine case.
6. Using an 8 mm hex wrench, remove the 4 fasteners
6
e r t securing the LH front down tube to the
frame top tube and lower engine boss.
7. Remove the LH frame down tube and side stand as
an assembly.
2. Place a platform jack beneath the engine and raise

enough to support crankcase (Jack should just be
touching the crankcase).
8. Disconnect the stator from the regulator.

© Copyright 6.7
9. 13. Using a 5 mm hex wrench, remove the four

NOTICE fasteners i securing the hard hydraulic lines to the
RH frame down tube and engine case.
It is not necessary to clip the cable ties securing the
stator / regulator harness to the mounting bracket as
they can be moved out of the way as an assembly.
Using a 5 mm hex wrench, remove the two

fasteners y securing the voltage regulator to the
mounting bracket and move the regulator enough
to access the mounting bracket fasteners.
14. Using an 8 mm hex wrench, remove the remaining

two fasteners o from the RH frame down tube and
remove.
10. Remove the three regulator mounting bracket

fasteners u securing the regulator bracket to the
engine case and move bracket out of the way.
15. Disconnect the main ABS electrical connector and

two brake switch connectors from the ABS Module.
11. Remove the starter motor. See Starter Motor,

12. Remove CPS. See Sensors — Powertrain

6.8 © Copyright
16. 19. Remove the two fasteners h securing the battery

NOTICE tray to the engine and the grounding fastener j
from the engine case.
It is not necessary to remove the hydraulic lines from
the ABS module during engine removal.
Remove the four fasteners f from the ABS bracket.
20. Working from the RH side, using a 16 mm socket,

remove the two fasteners k securing the rear of the
motor to the frame side panel.
17. Remove the two fasteners g securing the starter 21. Using a pick tool, remove the two spacers l from
solenoid to the ABS bracket. the RH side of the engine between the frame panel
and engine mounts. 6
18. Move the ABS Module / bracket and hydraulic

brake lines far enough away from the RH side of the
engine so that the engine can be lowered slightly.

© Copyright 6.9
22. Working from the LH side of the motorcycle,

remove the two fasteners 1( securing the rear of the
engine to the LH frame panel.
23. Push engine slightly to the RH side to free up from

alignment dowels. With an assistant, lower the
engine from the frame and remove from vehicle.

6.10 © Copyright
E N G I N E I N S TA L L AT I O N
E N G I N E I N S TA L L AT I O N 3. Position the engine on a platform jack to the left of
The following procedure is written assuming the en- the motorcycle and slide into position so the
gine has been assembled and is resting on an engine engine is orientated correctly front to back.
stand, ready for installation.
Refer toEngine Brackets / Fasteners page 6.3 in this
chapter for torque values and assembly views.
CAUTION
Arrange for assistance when installing engine. The
engine must be held securely to prevent damage to
engine, frame, wiring, or hoses. The engine is very
heavy and could cause severe personal injury if not
handled properly. Be sure engine is properly
supported before proceeding.
IMPORTANT
Be sure alignment dowels are in place in the left-
hand rear engine mounts prior to installation. 4. Slide the engine back until the rear mounting ears
are aligned with the mounting holes in the frame
1. Clean mating surfaces of frame and engine side panels. Adjust height of engine as needed to
crankcase. Install alignment dowels q. align rear mounts and dowel pins.
5. Slide the engine towards the left-hand frame panel 6
until the dowel pins are fully seated.
2. Place motorcycle in an upright position with the

6. Be sure all wiring and hoses are properly routed
before installing rear spacers and mounting
fasteners.
7. Install the two engine mounting fasteners into the
left-hand frame panel and tighten until the engine
is fully drawn into the frame panel. Do not torque
fasteners at this time.
CAUTION
Be sure engine is aligned at the proper height and
angle with the dowel pins. DO NOT force engine
alignment using the mounting fasteners, or the
dowel pins may be damaged! Adjust engine
height and angle continuously as required while
drawing up the fasteners.

© Copyright 6.11
8. Working on the right-hand side of the engine, 12. Install the four fasteners y securing the ABS
slide the spacers w into position between the module bracket to the rear of the engine and
right-hand frame panel and the engine crankcase. torque to specification.
9. Install the two engine mounting fasteners e into
the right-hand frame panel, through the spacers
and torque to specification. See Engine Brackets /
Fasteners page 6.3.
TORQUE
ABS Module Bracket Fasteners:
84 in-lbs (9 N·m)
10. Torque the left hand rear engine mounting
fasteners to specification. 13. Reconnect the main connector and brake switch
connectors to the ABS module.
TORQUE 14. Install the two fasteners u securing the starter
Rear Engine Mounting Fasteners: solenoid to the ABS bracket and torque to
75 ft-lbs (102 N·m) specification.
11. Install the two fasteners r securing the battery

box to the engine and the grounding wire fastener
t and torque to specification.
TORQUE
Starter Solenoid Mounting Fasteners:
88 in-lbs (10 N·m)
TORQUE 15. If applicable, install the mounting bracket and

Battery Box Fasteners: charcoal canister to the back of the ABS module
84 in-lbs (9 N·m) bracket and reconnect vapor hoses.
TORQUE
Grounding Wire Fastener:
88 in-lbs (10 N·m)

6.12 © Copyright
16. 19. Install the regulator / rectifier mounting bracket

and the regulator / rectifier. See Rectifier /
NOTE
Regulator Replacement page 15.33
Pay attention to brake line routing while installing the
right-hand down tube. The brake line with a 90° bend 20. Place the left-hand frame down tube in position on
above the oil cooler should run forward of the down the motorcycle with the clutch cable a properly
tube while the brake line running up toward the head routed.
tube runs to the rear of the down tube.
Place the right-hand frame down tube in position

and install the lower two fasteners i to the engine
case and torque to specification. See Engine
Brackets / Fasteners page 6.3.
21. Install the two fasteners s, two fasteners d and

two fasteners f securing the left-hand down tube
to the motorcycle and torque to specification. See
Engine Brackets / Fasteners page 6.3. 6
17. Using a 5 mm hex wrench, install the four fasteners

o securing the hard hydraulic brake lines to the
engine case and right-hand down tube and torque
to specification.
TORQUE
Brake Line Mounting Fasteners:
84 in-lbs (9 N·m)
18. Install the starter motor. See Starter Motor,


© Copyright 6.13
22. Install side stand bumper fastener g and side 32. Install ignition coil and cover. See Ignition Coil
stand switch fasteners h and torque to Removal / Installation page 16.9.
specification.
33. Install the sprocket cover. See Drive Sprocket
34. Install the complete exhaust system. See EXHAUST
SERVICE.
35. Install the lower side covers. See Side Cover
(Lower), Removal / Installation page 3.15.
36. Install the battery. See Battery Installation page
15.11.
37. Install the fuel tank. See Fuel Tank Installation
page 5.36.
38. Install the seat. See Seat, Removal / Installation -
39. Install the upper side covers. See Side Cover
TORQUE
40. Install new oil filter and fill engine to proper level
Side Stand Bumper Fastener: with Indian Motorcycle engine oil.
88 in-lbs (10 N·m)
41. Check operation of all cables and controls and
adjust as necessary.
TORQUE 42. Add fuel to fuel tank and prime fuel system.
Side Stand Switch Fasteners: 43. Start engine and set oil to proper level.
43 in-lbs (5 N·m)
44. Pump front brake lever and rear brake pedal to
23. Connect the gear position switch, side stand seat pads against disc. Test brakes to be sure
switch and oil pressure switch. See Sensors — operation and pedal pressure are normal. Bleed
Powertrain Management page 5.12. brake system if necessary.
24. Install the oil cooler to the frame. See Oil Cooler 45. Test ride motorcycle and check all systems for
Installation page 4.15. proper operation.
25. Working on the right-hand side of the motorcycle, 46. When test ride is completed, check entire vehicle
route the fuel injector harness down through the and engine for fluid leaks and be sure all fasteners
fuel distribution line (fuel rail) and reconnect the have been properly torqued.
fuel injectors, TMAP sensor, CHT sensor and 47. Inspect oil level and adjust if necessary.
knock sensor. See Sensors — Powertrain
26. Install the air cleaner assembly and throttle body.
See Air Box Installation page 5.23.
27. Fit the drive belt over the drive sprocket and set
belt tension / wheel alignment. See Drive Belt
Adjustment page 2.42.
28. Remove motorcycle from wheel vise and place
on side stand for remainder of engine
installation procedure.
29. If equipped, install the highway bar. See Highway
Bar Installation page 3.22.
30. Install front fender. See Front Fender Installation
page 3.26.
31. Install the left-hand and right-hand floorboard
assemblies. See Floorboard (Driver), Installation
page 3.17.

6.14 © Copyright
CYLINDER HEAD / VALVES
CHAPTER 7
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
CAM CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
LIFTERS / PUSHRODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.10
CAMSHAFT TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.11
CAM CHAIN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.12
LOCKING THE CRANKSHAFT FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.12
CAM CHAIN COVER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.12
CAM CHAIN TENSIONER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13
CAM CHAIN TENSIONER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.14
CAM CHAIN TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.14
CAM CHAIN GUIDE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.15 7
CAM CHAIN GUIDE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.15
CAM CHAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.15
CAM CHAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.16
CAMSHAFT / LIFTER SERVICE - ENGINE OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.17
LIFTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.17
LIFTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.18
CAMSHAFT CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19
CAMSHAFT CARRIER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.20
CAMSHAFT CARRIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.22
CAMSHAFT CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.24
CAMSHAFT SERVICE - IN BIKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.26
CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.26
CAMSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.41
CYLINDER HEAD SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.52
VALVE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.52
VALVE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.52
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.54
ROCKER ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.54
ROCKER ARM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.55
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.55
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.56
VALVE SPRING FREE LENGTH INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.56

© Copyright 7.1
VALVE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.57

VALVE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.58
VALVE GUIDE REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.59
VALVE SEAT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.59
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.59
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.60
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.60
TROUBLESHOOTING, CYLINDER HEAD AND VALVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.62

7.2 © Copyright
The Thunder Stroke 111 uses a single cam chain SPECIAL TOOLS
system to drive a centrally located camshaft (intake).
The central camshaft uses a gear drive to turn two TOOL DESCRIPTION PART NUMBER
outer camshafts (exhaust). Each cylinder is equipped Valve Spring Compressor PV-1253
with two valves that are opened and closed via self-
adjusting hydraulic lifters and pushrods. Crankshaft Locking Tool PF-51235
SERVICE NOTES Crankshaft Rotation Tool PF-51239

Seal and Bearing Driver Set PV-43558
• This chapter covers service of the cylinder heads,
camshafts, cam chain and tensioner, cam chain Camshaft Service Tool PF-51455
guide and roller / rocker arms.
Camshaft Holding Tool PF-52544
• Refer to Engine / Cooling / Exhaust chapter for
engine removal and installation.
*Special Tool PF-51455-A includes both PF-51455 AND
• If cylinder heads are removed the cylinder base PF-52544
gasket must be replaced also.
• Mark and store all mating parts for correct engine 6657 or https://polaris.service-solutions.com/
assembly.
• Use Moly Assembly Paste - P/N: 2871460 or Indian
Motorcycle Synthetic 20W/40 Engine Oil to
lubricate parts where indicated.
• Handle and store all parts in such a way that they
will not be damaged or contaminated.
• Some fasteners have a pre-applied locking agent,
and must be replaced if loosened or removed.
Always replace fasteners that have a pre-applied
locking agent or as directed in this service manual. 7
• There are some precision machining steps to be
performed in this section. If you are not sure of your
capabilities in these areas, have a competent
machinist perform these operations.
• Valve guide and seat reconditioning should be
performed by a technician proficient in cylinder
head reconditioning techniques using high quality
equipment with grinding stones. Do not attempt
cylinder head repair without the proper equipment
or experience in cylinder head reconditioning
techniques.
• The intake and exhaust valves cannot be re-faced.
• Cleanliness of parts is critical to engine life and
accurate parts inspection. Use clean solvent to clean
all disassembled parts. Dry parts with compressed
air and lubricate before engine inspection and
engine assembly.

© Copyright 7.3
T O R Q U E S P E C I F I C AT I O N S
PART DESCRIPTION TORQUE SPECIFICATION
Cam Chain Cover Fasteners — M6 x 1.0 x 40 (QTY.4) / 88.5 in-lbs (10.0 Nm)
M6 x 1.0 x 65 (QTY.6)
Camshaft Carrier Bearing Retainer Plate Fasteners — 62 in-lbs (7.0 Nm)
M5 x 0.8 x 12 (QTY.6)
Camshaft Carrier Fasteners — M8 x 1.25 x 30 (QTY.3) 15 ft-lbs (20.0 Nm)
Camshaft to Carrier Bearing Fasteners, Exhaust — 52 ft-lbs (70.0 Nm)
M10 x 1.5 x 40 (QTY.2)
Cam Chain Guide Fasteners — M6 x 1.0 x 40 (QTY.2) 71 in-lbs (8.0 Nm)
Cam Chain Tensioner Fastener — M8 x 1.25 x 40 15 ft-lbs (20.0 Nm)
(QTY.1)
Camshaft Sprocket Fastener, Intake (Timing Gear) — 52 ft-lbs (70.0 Nm)
M10 x 1.5 x 40 (QTY.1)
Crankshaft Sprocket Fastener (Timing Gear) — M10 x 52 ft-lbs (70.0 Nm)
1.5 x 40 (QTY.1)
Cylinder Head Nut — M8 x 1.5 (QTY.8)
STEP 1: 22 ft-lbs (30.0 Nm); STEP 2: Back Nut Off
Completely; STEP 3: 40 ft-lbs (54.0 Nm)
Lifter Block Fasteners — M6 x 1.0 x 25 (QTY.6) 88.5 in-lbs (10.0 Nm)
Lifter Retaining Plate Fastener — M5 x 0.8 x 12 (QTY.2) 62 in-lbs (7.0 Nm)
Rocker Arm Fastener 22 ft-lbs (30.0 Nm)
Spark Plug 13 ft-lbs (17.0 Nm)
Valve Cover Fasteners, Inner — M6 x 1.0 x 20 (QTY.18) 88.5 in-lbs (10.0 Nm)
Valve Cover Fasteners, Outer — M6 x 12 x 14 (QTY.6) 88.5 in-lbs (10.0 Nm)
CAMSHAFT DATA
DESCRIPTION SPECIFICATION
111 c.i. 116 c.i.
Over Head Valve / 2 valves per cyl
Valve Train
1 Intake Valve / 1 Exhaust Valve
Intake Valve Opens At
2.0° BTDC 4° BTDC
1 mm Lift
CAMSHAFT Intake Valve Closes At
43.0° ABDC 44° ABDC
DATA 1 mm Lift
Exhaust Valve Opens
44° BBDC 48° BBDC
At 1 mm Lift
Exhaust Valve Closes
4° ATDC 10° ATDC
At 1 mm Lift

7.4 © Copyright
DESCRIPTION SPECIFICATION
Max Lobe Lift
INTAKE (7.20 mm) (7.55 mm)
EXHAUST (7.20 mm) (8.40 mm)
Max Valve Lift
INTAKE (12.8 mm) (13.32 mm)
EXHAUST (12.8 mm) (14.8 mm)

© Copyright 7.5
CYLINDER HEAD & VALVE TRAIN DATA

Cam Chain Ratchet / Spring - -
Tensioner
Lobe Height
INTAKE 1.6299" (41.401 mm) 1.6260” (41.301 mm)
EXHAUST 1.5827" (40.202 mm) 1.5788” (40.102 mm)
Cam Shaft .9835 - .9840" (24.979

Journal O.D. (Exhaust) .9832” (24.973 mm)
- 24.993 mm)
.9835 - .9840" (24.979
Journal O.D. (Intake) .9832” (24.973 mm)
- 24.993 mm)
Cylinder Head Warpage (Distortion) - .004” (.10 mm)
Non-Serviceable.
Rocker Arm, Non-Serviceable. Replace as an
Rocker Arm: IN/EX Replace as an
Shaft, & Lifter assembly.
assembly.
Hydraulic/Self
Valve Clearance -
Adjusting
0.69 — 0.72” (17.7 —
Valve Guide Installed Height -
18.3 mm)
Valve Stem O.D. .3131 — .3138” (7.953

INTAKE – 7.973 mm) .3128” (7.945 mm)
EXHAUST .3131 — .3138” (7.953 .3128” (7.945 mm)
– 7.973 mm)
Valve, Valve Valve Stem Deflection (INTAKE

- .005” (.13 mm)
Guide, Valve & EXHAUST)
Seat Valve Seat Width
INTAKE .047" (1.2 mm) -
EXHAUST .053" (1.35 mm) -
Valve Stem Runout - .0005” (.013 mm)
Valve Head Radial Runout - .002” (.05 mm)
Valve Installed Height 2.184 - 2.224" (55.49 -

INTAKE 56.49mm) -
EXHAUST 2.184 - 2.224" (55.49 - -
56.49mm)
111 c.i. =0.504" (12.8
mm)
Intake Valve Maximum Lift -
116 c.i. =0.524”
(13.32 mm)
111 c.i. =0.504" (12.8
Valve Spring
mm)
Exhaust Valve Maximum Lift -
116 c.i. =0.583” (14.8
mm)
1.929 - 2.007" (49.00 -
Spring Installed Height -
51.00 mm)

7.6 © Copyright
CAM CHAIN
NUMBER PART DESCRIPTION TORQUE SPECIFICATIONS (IF 7

APPLICABLE)
q Cam Cover Fastener 10 ft-lbs (13 N·m)
w Cam Cover —
e Cam Cover Gasket —
r Timing Chain Tensioner Fastener 15 ft-lbs (20 N·m)
t Timing Chain Tensioner —

y Snap Ring, Tensioner Arm —
u Tensioner Arm, Timing Chain —
i Timing Chain Guide Fastener 71 in-lbs (8 N·m)
o Pivot, Tensioner Arm 15 ft-lbs (20 N·m)

a Guide, Timing Chain —
s Timing Gear Fastener 52 ft-lbs (70 N·m)
d Washer, Timing Gear —

f Timing Gear, Crankshaft —
g Timing Gear, Camshaft (Intake) —
h Timing Chain —

© Copyright 7.7
CAMSHAFTS
NUMBER PART DESCRIPTION TORQUE SPECIFICATIONS (IF

APPLICABLE)
q Fastener, Bearing Retainer Plate - M5 x 0.8 x 12 (QTY.6) 62 in-lbs (7 N·m)
w Retaining Plate, Cam Bearings -
e Fastener, Timing Gear - M10 x 1.5 x 40 (QTY.2) (Exhaust Camshafts) 52 ft-lbs (70 N·m)
r Washer, Timing Gear (QTY.3) -
t Timing Gear, Camshaft (Intake) -
y Bearings, Camshaft (Outer) -
u Fastener - M8 x 1.25 x 30 (QTY.3) / M8 x 1.25 x 40 (QTY.1) 15 ft-lbs (20 N·m)
i Bearing Carrier, Camshaft (QTY.6) -
o External Snapring -
a Washer, Belleville -
s Retainer, Camshaft Gear (Split) -
d Camshaft Gear, Split (Exhaust) -
f Spring, Camshaft Gear (Split) -
g Camshaft Gear, Split (Exhaust) NOT SERVICEABLE -
h Camshaft Gear (Intake) SERVICEABLE AS ASSEMBLY ONLY -
j Camshaft, Exhaust (Front) -
k Camshaft, Intake (Center) -
l Camshaft, Exhaust (Rear) -

7.8 © Copyright
LIFTERS / PUSHRODS

APPLICABLE) 7
q O-ring, Pushrod Tube -
w Pushrod Tube -
e Pushrod -
r Fastener, Lifter Block - M6 x 1.0 x 25 (QTY.3 per cylinder) 88 in-lbs (10 N·m)
t Lifter Block -
y Gasket, Lifter Block -
u Fastener, Retaining Plate - M5 x 0.8 x 12 (QTY.1 per cylinder) 62 in-lbs (7 N·m)
i Dowel, Lifter Guide -
o Lifter -

© Copyright 7.9
CYLINDER HEAD

APPLICABLE)
q Valve, Exhaust -
w Valve, Intake -
e Gasket, Cylinder Base -
r Cylinder Head -
t Valve Guide -
y Spring Seat / Valve Stem Seal Asm -
u Spring Seat / Valve Stem Seal Asm -
i Valve Spring -
o Retainer, Valve Spring -
a Keepers, Valve Spring -
s Rocker Arm Assembly 22 ft-lbs (30 N·m)

d Nut, Cylinder Head - M10 x 1.50 (QTY.4 per cylinder) Refer to procedure
f Gasket, Valve Cover -
g Inner Valve Cover -
h Fastener, Inner Valve Cover - M6 x 1.0 x 20 (QTY.9) 88 in-lbs (10 N·m)

j Outer Valve Cover -
k Fastener, Outer Valve Cover - M6 x 12 x 15 (QTY.3) 88 in-lbs (10 N·m)

l Cylinder Head Temperature Sensor (CHT) 71 in-lbs (8 N·m)

7.10 © Copyright
CAMSHAFT TIMING

© Copyright 7.11
CAM CHAIN SERVICE

LOCKING THE CRANKSHAFT FOR SERVICE C A M C H A I N C O V E R R E M O VA L /
This procedure describes how to lock the crankshaft in I N S TA L L AT I O N
the Top Dead Center (TDC) position using 1. Remove the right-hand floorboard / master
commercially available hand tools. cylinder assembly and move out of the way. See
1. Remove the spark plugs. See Spark Plug Removal Floorboard (Driver), Removal page 3.16
page 2.34.
NOTICE
2. Remove the stator. See Stator Removal page 15.31. The right-hand floorboard and rear brake master
3. Using special service tool PF– 51239, rotate the cylinder can be removed as an assembly. It is not
crankshaft counterclockwise (primary side) until necessary to disconnect the brake line from the
the front piston is at TDC. See Cylinder Head page master cylinder while performing this procedure.
7.10.
2. Remove the ten fasteners q securing the cam
4. Lock the crankshaft by inserting a 5/16” pin punch
chain cover to the inner timing cover.
(or equivalent) into the locking hole q.
3. Remove the cam chain cover and gasket.

NOTICE 4. INSTALLATION is performed by reversing the
It may be necessary to rotate the crankshaft slight removal procedure.
forward or back to properly align holes.
5. Clean gasket mating surfaces and install cam
chain cover using a new gasket.

7.12 © Copyright
6. Torque cam chain cover fasteners following the 3. Remove the external snap ring w from the
specified torque sequence. tensioner arm and remove arm and spring as an
assembly.
TORQUE
Cam Chain Cover Fasteners:
10 ft-lbs (13 N·m)
C A M C H A I N T E N S I O N E R R E M O VA L
CAUTION
Do not rotate engine with tensioner(s) removed.
7
1. Remove the cam chain cover. See Cam Chain
2. Remove cam chain tensioner fastener q and
remove the cam chain tensioner.

© Copyright 7.13
CAM CHAIN TENSIONER INSPECTION

1. Visually inspect ratchet plunger q for damage,
scoring, or burrs.
2. Lubricate ratchet plunger with engine oil. Depress
the release pawl and move plunger in and out of
housing w to check for smooth movement without
binding.
3. Inspect the ratchet pawl mechanism e and verify
proper spring operation.
4. Replace tensioner assembly if plunger doesn’t
fully extend when released from a compressed
state.
5. Inspect tensioner arm for excessive wear marks

from timing chain, cracks or fatigue.
6. Inspect the tensioner arm spring for cracks or
fatigue.
C A M C H A I N T E N S I O N E R I N S TA L L AT I O N
1. Verify that the engine is at TDC and the timing
marks are properly aligned. See Cylinder Head
page 7.10.
2. Slide the tensioner arm and spring over the pivot
pin and, using a needle nose pliers or similar tool,
loop the tensioner arm spring over the retainer pin
and slide down until fully seated.
3. Install the tensioner arm snap ring.
4. Compress the tensioner assembly and slide into
position over the alignment dowel.
5. Install tensioner fastener and torque to
specification.
TORQUE
Tensioner Fastener: 15 ft-lbs (20 N·m)
6. With a new gasket and both mating surfaces clean,

install the cam chain cover. See Cam Chain Cover,

7.14 © Copyright
C A M C H A I N G U I D E R E M O VA L C A M C H A I N R E M O VA L
1. Remove the cam chain cover. See Cam Chain 1. Place motorcycle in an upright position with the
Cover, Removal / Installation page 7.12 front wheel clamped in a wheel vise.
2. Remove the two fasteners q securing the cam 2. Drain the engine oil. See Engine Oil & Filter
chain guide to the engine and remove the guide Change in the Maintenance Chapter.
and spacers. 3. Remove spark plugs. See Spark Plug Removal
page 2.34.
4. Place an oil drain pan beneath the engine to catch
any residual oil when primary and cam chain
covers are removed.
5. Remove the cam chain cover. See Cam Chain
6. Perform the crankshaft locking procedure. See
Locking the Crankshaft for Service page 7.12.
7. Remove the cam chain tensioner and tensioner
arm assemblies. See Cam Chain Tensioner
Removal page 7.13.
8. Remove the cam chain guide. See Cam Chain
Guide Removal page 7.15
9. Remove the camshaft and crankshaft sprocket
C A M C H A I N G U I D E I N S TA L L AT I O N fasteners q .
1. If removed, install the cam chain. See Cam Chain
Installation page 7.16.
2. Install cam chain guide q and fasteners w .
Torque to specification.
7
10. Pull the camshaft sprocket, crankshaft sprocket

and cam chain off as an assembly.
11. Collect the woodruff key from the crankshaft.
TORQUE
Cam Chain Guide:
71 in-lbs (8 N·m)
3. Install the cam cover. See Cam Chain Cover,


© Copyright 7.15
C A M C H A I N I N S TA L L AT I O N 4. Working on a flat surface, assemble the timing

chain onto the crankshaft and camshaft sprockets
CAUTION as shown.
The Thunder Stroke 111 is an INTERFERENCE 1. Align timing marks r .
ENGINE. If the camshafts and crankshaft must be
turned independently of each other to set valve 2. Position the chain on the sprockets so that the
timing, the camshafts must be set to TDC prior to dark chain links line up with sprocket
rotating the crankshaft. Failure to do this may cause hashmarks.
the pistons to contact the valves resulting in engine
damage.
1. Verify that the camshafts are set to TDC. Camshaft

timing marks q & w should be aligned as shown.
The camshaft sprocket alignment dowel e should
be at 12 o’clock.
5. Slide the chain and sprockets onto the crankshaft

and center camshaft as an assembly.
6. Verify that the crankshaft woodruff key is still in
place and that the timing marks are still aligned.
7. Install crankshaft and camshaft sprocket fasteners
and washers and torque to specification.
2. Perform METHOD 1 of the crankshaft locking
TORQUE
procedure. This will ensure the crankshaft is
locked in the TDC position. See Locking the Camshaft / Crankshaft Sprocket Fasteners:
Crankshaft for Service page 7.12. 52 ft-lbs (70.0 Nm)
3. Place the woodruff key in the end of the
crankshaft. 8. Install the cam chain guide. See Cam Chain Guide
9. Install the cam chain tensioner and tensioner arm
assemblies. See Cam Chain Tensioner Installation
page 7.14.
10. Install the cam chain cover. See Cam Chain Cover,
11. Remove the crankshaft locking pin installed
during the crankshaft locking procedure in step 2.
12. Install stator.Stator Installation page 15.32.
13. Install flywheel. See Flywheel Installation page .
14. Install clutch assembly and clutch rack. See Clutch
15. Install torque compensator. See Torque
Compensator Installation page 9.22.
16. Install primary cover. See Primary Cover

7.16 © Copyright
CAMSHAFT / LIFTER SERVICE - ENGINE OUT

L I F T E R R E M O VA L 4. Using a T25 Torx, remove the fastener e securing
the lifter retaining plate to the inner cam chain
IMPORTANT
cover and remove plate.
Keep mated parts together for assembly. It is
important to put lifters and lifter blocks back in the
same location.
1. Remove cylinder heads and push rods from

engine. See Cylinder Head Removal page 7.54.
2. Remove push rod tubes q by pulling out of the
lifter blocks to release the o-rings.
5.
IMPORTANT
When removing the lifter guides, be careful not to
drop them into the inner cam chain cover.
Remove lifter guides r and pull lifters out of bore.

3. Starting with the front lifter block, remove the
three fasteners w and the lifter block.
7
6. Repeat steps 3–5 to remove the rear lifters.

© Copyright 7.17
L I F T E R I N S TA L L AT I O N 8. Torque lifter block fasteners to specification.

1. Apply a light coat of engine oil to each lifter and
slide into bore in the same position from which it TORQUE
was removed. Lifter Block Fasteners:
2. Rotate each lifter so that the flat surface q is 88 in-lbs (10 N·m)
parallel with the lifter guide slot.
9. Install push rod tubes t with new o-rings y.
3. Starting at the front cylinder, install lifter guides w
.
10. Install cylinder heads. See Cylinder Head

4. Install lifter retaining plate e with bevelled Installation page 7.60.
fastener relief facing up. 11. Install inner and outer valve cover gaskets. See
Valve Cover Installation page 7.52.
5. Install retaining plate fastener r and torque to
specification.
TORQUE
Lifter Retaining Plate Fastener:
62 in-lbs (7 N·m)
6. Repeat steps 3–5 for the rear cylinder lifters.

7. Install new gaskets into lifter blocks and install
lifter blocks and fasteners finger tight.

7.18 © Copyright
C A M S H A F T C A R R I E R R E M O VA L C A M S H A F T C A R R I E R D I S A S S E M B LY
NOTICE IMPORTANT
Base and head gasket seal is released when Camshafts are slip-fit to carrier bearings. Once the
removing camshaft carrier. Replacement of both carrier assembly has been removed from the engine,
head and base gasket is recommended to prevent oil the intake (center) camshaft will be held in place by
leaks. Keep mated parts together. gear preload only. Use caution while working on the
carrier assembly so that camshafts do not fall from
1. Remove the engine from the frame and place on carrier and become damaged.
an engine stand. See Removing Engine From
Frame page 6.6. 1. Remove the camshaft carrier assembly. See
Camshaft Carrier Removal page 7.19.
2. Remove lifters. See Lifter Removal page 7.17.
2. Remove the six fasteners and the bearing retainer
3. Remove cam chain, cam chain tensioner and
plate q from the carrier assembly.
guide. See Cam Chain Removal page 7.15.
4. Remove the three remaining camshaft carrier
fasteners q .
7
3. Place the camshaft carrier in a soft-jawed vise and
use nylon strapping or rope w to create an
interference between the camshaft gear teeth, thus
5. Grasp the camshaft carrier w and pull straight out locking the camshafts.
to remove the three camshafts, outer bearings and
4. Loosen, do not remove, the exhaust camshaft
carrier as an assembly.
fasteners e .
NOTICE
The camshaft ends are slip-fit to the inner bearings
and should come out by hand.
5. Remove the camshaft carrier assembly from the

vise and remove camshaft fasteners. Care should
be taken so camshafts don’t fall out of the carrier
during this process.

© Copyright 7.19
6. Noting position in the carrier for reassembly, 8.

remove the camshafts and sprockets r from the NOTICE
carrier bearings.
The following procedure is to INSPECT split gear
springs only. If the split gears are damaged they
MUST be replaced as an assembly as parts are not
individually serviceable.
To separate split gears, wrap a shop rag around

the teeth of the gear so springs are contained and
remove external snap-ring t .
9. Separate components of gear as shown.
7. Camshaft carrier bearings can be removed using a

suitable press or bearing driver. Pressure must be
applied from the backside of the carrier plate and
bearings pressed through the front.
CAMSHAFT INSPECTION
For the following camshaft inspection procedure,
refer to the camshaft service specifications sec-
tion. See Service Specifications page 7.4.

7.20 © Copyright
1. Visually inspect camshaft journal surfaces for

scoring or signs of insufficient lubrication. Replace
camshaft if heavy scoring or damage is noted.
2. Inspect height of each cam lobe. Exhaust cam
7
lobes q and intake cam lobes w.
3. Measure O. D. of each camshaft journal. Exhaust
journals e and Intake journals r .

© Copyright 7.21
C A M S H A F T C A R R I E R A S S E M B LY
3. Install the spring retainer e, Belleville washer r,
CAUTION
and the snap-ring t to complete split gear
Wear eye protection while assembling split camshaft assembly.
gears.
IMPORTANT
The following procedure details split gear assembly
following inspection. If the split gears are damaged
they MUST be replaced as an assembly as parts are
not individually serviceable.
1. Load springs q into the inner cam gear spring

pockets.
4. If replacing camshaft carrier bearings, press or

drive new bearings into the carrier from the front
side until seated against shoulder.
5. Install the bearing retainer plate y with the
countersunk fastener holes facing out.
6. Install fasteners and torque to specification.
2. Install the outer cam gear onto the inner cam gear
making sure the alignment holes w are positioned
as shown.
TORQUE
Bearing Retainer Plate Fasteners:
62 in-lbs (7 N·m)

7.22 © Copyright
7. Install woodruff keys u and split gear assemblies 9.

i onto the exhaust camshafts and set aside. IMPORTANT
Care must be taken when installing the exhaust
camshafts into the carrier bearings to ensure they are
in the correct location. The lobe of the RH exhaust
camshaft d should be closer to the bearing carrier
than the LH exhaust camshaft lobe.
8. Install intake camshaft o into helical gear a and

slide into the center carrier bearing s. Woodruff
key should be positioned at 12 o’clock.
10.
NOTICE
It may be necessary to use a flat screwdriver or
similar tool to release the preload on the split gear
teeth when engaging the helical gear.
7
Install the LH and RH exhaust camshafts so the

timing marks line up as shown.

© Copyright 7.23
11. Install exhaust camshaft fasteners f and washers C A M S H A F T C A R R I E R I N S TA L L AT I O N

g into carrier assembly so they are finger tight. NOTICE
Base and head gasket seal is released when
removing camshaft carrier. Replacement of both
head and base gasket is recommended to prevent oil
leaks.
1. Lift the camshaft carrier assembly q into position

so that each of the camshaft ends fits into the inner
bearings.
12. Place the camshaft carrier in a soft-jawed vise and

use nylon strapping or rope h to create an
interference between the camshaft gear teeth, thus
locking the camshafts.
2.
NOTICE
and should slide in by hand.
Press the camshaft carrier assembly into the inner

bearings until carrier is fully seated on the inner
cam chain cover.
3. Install the three fasteners w and torque to
13. Torque exhaust camshaft fasteners to specification. specification.
TORQUE
Exhaust Camshaft Fasteners:
52 ft-lbs (70 N·m)
TORQUE
Camshaft Carrier Fasteners:
15 ft-lbs (20 N·m)

7.24 © Copyright
4. Install cam chain, cam chain tensioner and guide.

See Cam Chain Installation page 7.16.
5. Install lifters. See Lifter Installation page 7.18.
page 6.11.

© Copyright 7.25
CAMSHAFT SERVICE - IN BIKE

C A M S H A F T R E M O VA L • Clean the area around the drain plugs q. Place a
drain pan under both drain plugs.
IMPORTANT
Camshaft removal with the engine installed in the

frame requires:
• Special Service Tools:
– Crankshaft Locking Pin PF-52135 or 5/16” pin
punch
– Crankshaft Rotation Tool PF–51239
– Camshaft Holding Tool PF-52544 or PF-51455-A
(Combination Kit)
NOTICE
Secure the woodruff keys or place a shop towel
under camshaft drive gears to ensure keys don’t fall
into the engine.
• Remove the drain plugs. Allow the oil to drain
completely.
P R E PA R AT I O N
5. Remove and retain upper and lower side covers
IMPORTANT and saddlebags.
Protect all finished surfaces during these operations.
Take careful notes of wire routing and cable tie
locations during disassembly to ensure proper
reinstallation.
Special care should be taken on higher mileage
bikes during disassembly. Especially when removing
fasteners threaded into engine block and cylinder
heads (For example: Exhaust manifold bolts, Primary
cover bolts, etc.) Thread repair kit may be necessary
if threads become damaged.
1. Turn key or ignition switch to OFF position and

remove key. If equipped with keyless fob, remove
fob from proximity of vehicle.
2. Ensure motorcycle is parked on a flat surface,
kickstand is fully extended, and vehicle is stable
prior to installation.
3. Support motorcycle securely in an upright position.
Clamp front tire securely in a wheel vise.
4. Drain engine oil.

7.26 © Copyright
RIGHT FLOORBOARD REMOVAL 3. Remove and keep two bolts E and remove RH
floorboard assembly F from frame.
1. Remove cotter pin A and washer B from brake
master cylinder pushrod.
2. Remove and keep two screws C from brake master

cylinder D, disengage pushrod from brake pedal
assembly, and remove brake master cylinder D
from RH floorboard assembly and move out of the
way.
IMPORTANT
Do not bend or kink flexible brake line during
floorboard removal. Master cylinder assembly
should be kept in an upright position and properly
supported at all times.
7

© Copyright 7.27
SEAT REMOVAL INTAKE REMOVAL
• Seat Removal / Installation - All (except Roadmaster) 1. Using a 4mm hex wrench, remove the three
page 3.19 fasteners q securing the air cleaner cover to the
air box.
• Seat Removal / Installation - (Roadmaster) page 3.20
• Seat Removal / Installation - (Dark Horse) page 3.21
2. Using an 8mm socket, remove the three fasteners

w securing the air filter element to the adapter
plate and remove element.

7.28 © Copyright
3. Using a T30 Torx wrench, remove the three 6. Using a 5 mm hex wrench, remove the four
fasteners e securing the air filter adapter plate to fasteners t securing the throttle body to the
the air box assembly and remove adapter plate. mounting plate and remove throttle body assembly.
NOTICE 7. Push the rubber multi-plug seal through the back

When removing the adapter plate, start by applying of the air box housing. Disconnect intake hose and
more pressure to the forward (LH) edge and pull remove air box housing.
outward to release the valve cover vent hose from the
back side of the adapter plate.
4. Remove the two fasteners r securing the baffle

plate to the intake air boot.
8. Using an 8 mm socket, remove the lower fastener

y securing the air box to the mounting plate.
5. Disconnect the multi-plug from the throttle body.

© Copyright 7.29
DEPRESSURIZE THE FUEL SYSTEM
CAUTION
Fuel lines remain under pressure at all times. Use
caution when disconnecting lines for service. Always
depressurize the fuel system prior to service.
WARNING
Allow engine and exhaust to cool completely before
disconnecting fuel line or removing tank. Wear eye
protection.
1. Remove the left-hand upper side panel.
2. Locate the fuel pump power fuse.
3. Pull the fuel pump relay and crank the engine over
for 5 seconds to release pressure.
4. Remove the horn:.

7.30 © Copyright
• Remove the three fasteners q securing the horn 6. Squeeze both release buttons, on the quick fuel
cover to the bracket and remove cover. connector (one on each side of fitting), and hold.
Gently slide fitting straight off the fuel rail.
• Disconnect the horn electrical connector w .

• Using a 10mm wrench, remove the fastener e CAUTION
securing the horn to the ignition coil bracket. Do not use anything other than fingers to remove the
Remove the horn. quick connection. The use of tools can damage the
connection.
CAUTION
Always wear eye protection
7. Cover fuel fittings to keep debris out. 7
DISCONNECT THE BATTERY

Disconnect the negative (-) battery cable q from the
battery terminal. Position the cable well clear of the
terminal.
5. Wrap a clean shop towel around fuel line fitting.

© Copyright 7.31
FUEL TANK REMOVAL 4. Remove console cover fasteners w and the plastic
dart e.
Be prepared to place the fuel tank in a secure location
with a drain pan positioned to catch any fuel that may
leak or drip from disconnected hoses or fittings.
1. Disconnect the vent line from the fuel tank.
• Chieftain / Roadmaster
For these models the front fastener does not have
to be removed. Remove rear fastener and slide
console forward to release it from the front
mounting grommet.
2. Remove the two fasteners q, washer and rubber
isolator at the rear of the fuel tank. 5. Disconnect electrical connectors at the security
light, central locking and system power buttons
and remove console cover.
6. Disconnect the fuel pump electrical connector r,
and the fuel vent line t.
7. Wrap a clean shop towel around fuel line fitting y
and squeeze both release buttons.
3. Lift the rear of the tank and slide back

approximately 2” to expose the front console cover
fastener.
CAUTION
Do not use anything other than fingers to remove the
connection.

pump.

7.32 © Copyright
10. Lift the rear of the fuel tank and slide rearward to SPARK PLUG REMOVAL
release from the front isolators.
CAUTION
HOT COMPONENTS
Wear insulated gloves and/or allow engine and
exhaust to cool before handling these parts.
NOTICE
The front spark plug can be removed without having
to remove the fuel tank by using a 3” extension and
standard 5/8” spark plug socket.
1. With the engine at room temperature, grasp the

spark plug boot q and rotate back and forth
11. Lift the tank off of the motorcycle and store safely. slightly to release from the spark plug. DO NOT
pull on the wire or spark plug wire may be
damaged.
2. Grabbing only the base of the spark plug boot, pull

straight out of spark plug well.
3. Clean out spark plug wells with compressed air to

remove any loose dirt or debris.
4. Using a 3” extension and a 5/8” spark plug socket,
remove spark plugs.

© Copyright 7.33
T H R O T T L E B O D Y R E M O VA L
1. Disconnect throttle body electrical connector and
remove the throttle body wiring from the holder.
2. Remove four throttle body screws and throttle body

.
3. Remove and keep four screws L and four washers

M from airbox support bracket N. Remove support
bracket.

7.34 © Copyright
REMOVE FUEL INJECTORS 2. Using a 'L' shaped allen wrench remove the two
NOTICE fasteners k securing the fuel rail to the intake
manifold. Carefully remove fuel rail from the right-
The fuel rail design will vary by year. The torque for hand side of the motorcycle.
the fuel rail fasteners is the same for both designs.
See the images below for model year variations.
2017–19
NOTICE
When removing fuel rail from injectors, wrap a rag
around both ends of the fuel rail to collect fuel.
2020+ 3. Leave electrical connector in place, remove fuel

injectors from intake.
1. Disconnect fuel injector electrical connectors.

IMPORTANT
Disengage Red CPA connection lock before
disconnecting injector.

© Copyright 7.35
4. Remove o-rings from the top and bottom of the REMOVE CAMSHAFTS
injectors and discard o-rings.
1. Remove and retain ten fasteners A and B, make
note of different sizes and locations. Remove cam
chain cover C and gasket.
2. Ensure indents on gear faces align with each other

as shown. If they do not, repeat crankshaft locking
procedure and align them.
3. Loosen, but DO NOT REMOVE four screws D.

7.36 © Copyright
4. Remove and retain chain tensioner fastener E and 7. Remove screws D and washers L from crankshaft
chain tensioner F. and camshaft. Pull camshaft sprocket M, crankshaft
sprocket N and cam chain P off as an assembly
and set aside. Collect woodruff key Q from
crankshaft and set aside.
5. Remove and retain external snap ring G and chain

tensioner arm and spring assembly H.
NOTICE
Secure the woodruff keys or place a shop towel
under camshaft drive gears to ensure keys don’t fall
into the engine.
8. Remove the exhaust camshaft fasteners q.
6. Remove and retain two fasteners J and Camshaft

Chain Guide K.

© Copyright 7.37
9. Install Special Tool PF-52544 as shown. 12. On Special Tool PF-51455, loosely assemble the
lower camshaft retainer plate y to the main plate
using two fasteners u.
10. Remove the remaining camshaft carrier fasteners

w.
13. Install the camshaft special tool assembly onto the

camshafts and tighten fasteners i until they are
hand-tight.
NOTICE
The lower camshaft retainer plate should be tight
enough to support the outboard camshaft bearing
journal.
11. Remove the camshaft bearing carrier assembly e.
14. Install special tool spacer o (has dowel hole) onto

the intake camshaft and spacers a onto the
exhaust camshafts.

7.38 © Copyright
15. Install camshaft gear washers and fasteners until 18. Use the second etched line (marked “B”) to
they are hand-tight. determine when the shaft is fully seated in the hole
marked “B”. The lifter is now held in place by the
retaining pin.
NOTICE
The crankcase has been removed in this picture to
show the correct retaining pin position.
16. With the flat side of the retaining pin s aligned

perpendicular to the rear exhaust camshaft push-
rod tube, slide the pin in hole marked “B” d until it
stops.
NOTICE
It will be necessary to rotate the camshaft
(clockwise) with a wrench to seat the pin. 19. Repeat steps 10-12 for the forward exhaust
camshaft.
NOTICE
7
For the front exhaust camshaft you will use the hole
marked “A” and the line marked “A”.
20. Slide the third retaining pin into the front cylinder
intake camshaft position (hole marked “A”) until it
stops.
NOTICE
It will be necessary to rotate the camshaft
(clockwise) with a wrench to seat the pin.
17. Rotate the camshaft using a suitable wrench while

pressing on the retaining pin until it seats.

© Copyright 7.39
21. Rotate the camshaft using a suitable wrench while 24. Remove fasteners f and lower camshaft retaining
pressing on the retaining pin until it seats at the plate g.
line marked “A”.
25. Carefully pull each of the camshafts out from its

22. Slide the fourth retaining pin into the rear cylinder respective bore.
intake camshaft position (hole marked “B”) until it
stops. NOTICE
NOTICE It may be necessary to rotate the camshaft by hand
during removal so the camshaft lobes can clear the
It will be necessary to rotate the camshaft retaining plate.
(clockwise) with a wrench to seat the pin.
23. Rotate the camshaft using a suitable wrench while

pressing on the retaining pin until it seats at the
line marked “B”.

7.40 © Copyright
C A M S H A F T I N S TA L L AT I O N 3. Using a suitable wrench, rotate each camshaft

while pulling the respective retaining pin out of the
1. With the retaining plate and pins installed and the
plate bore to release the lifters.
lifters held in place, install the two exhaust
camshafts q and intake camshaft w.
NOTICE
It may be necessary to rotate the camshaft by hand
during installation so the camshaft lobes can clear
the retaining plate.
4. Remove the retaining plate assembly.

5. Lift the camshaft carrier assembly q into position
so that each of the camshaft ends fits into the inner
bearings.
2. Assemble the lower camshaft retaining plate e to

the main plate and tighten fasteners r until the are
7
hand-tight.
6.
NOTICE
and should slide in by hand.
Press the camshaft carrier assembly into the inner

bearings until carrier is fully seated on the inner
cam chain cover.

© Copyright 7.41
7. Install the three fasteners w and torque to C A M G E A R A N D C H A I N I N S TA L L AT I O N

specification.
1. Place the woodruff key in the end of the crankshaft.
2. Working on a flat surface, assemble the timing
chain onto the crankshaft and camshaft sprockets
as shown.
• Align timing marks r .
• Position the chain on the sprockets so that the
dark chain links line up with sprocket
hashmarks.
TORQUE
Camshaft Carrier Fasteners:
15 ft-lbs (20 N·m)
8. Verify that the camshafts are set to TDC. Camshaft

timing marks q & w should be aligned as shown.
The camshaft sprocket alignment dowel e should
be at 12 o’clock.
3. Slide the chain and sprockets onto the crankshaft
and center camshaft as an assembly.
4. Verify that the crankshaft woodruff key is still in
place and that the timing marks are still aligned.
5. Install crankshaft and camshaft sprocket fasteners
and washers and torque to specification.
TORQUE
Camshaft / Crankshaft Sprocket Fasteners:
52 ft-lbs (70 N·m)

7.42 © Copyright
6. Install cam chain guide and fasteners q . Torque to 12. Install the ten fasteners q securing the cam chain
specification. cover to the inner timing cover.
TORQUE 13. Torque cam chain cover fasteners following the

specified torque sequence.
Cam Chain Guide:
71 in-lbs (8 N·m)
IMPORTANT
Verify that the engine is at TDC and the timing marks
are properly aligned.
7. Slide the tensioner arm and spring over the pivot

pin and, using a needle nose pliers or similar tool, 7
loop the tensioner arm spring over the retainer pin
and slide down until fully seated.
8. Install the tensioner arm snap ring.
9. Compress the tensioner assembly and slide into
position over the alignment dowel.
TORQUE
10. Install tensioner fastener and torque to
specification. Cam Chain Cover Fasteners:
10 ft-lbs (13 N·m)
TORQUE
Tensioner Fastener:
15 ft-lbs (20 N·m)
11. Clean gasket mating surfaces and install cam chain

cover using a new gasket.

© Copyright 7.43
T H R O T T L E B O D Y I N S TA L L AT I O N 3. Install the NEW throttle body K and throttle body

screws J. Torque fasteners to specification.
1. Install four screws L and four washers M to the
airbox support bracket N. Torque fasteners to
specification.
TORQUE
Throttle Body Fasteners:
Air Box Support Fastener:
84 in-lbs (9 N·m) 4. Connect throttle body electrical connector H and
route the throttle body wiring to the holder.
2. Install throttle body gasket aligned into the notches
of the bracket as shown.

7.44 © Copyright
F U E L I N J E C T O R I N S TA L L AT I O N F U E L TA N K I N S TA L L AT I O N
1. Always lubricate injector O-rings with clean, Place a protective cloth on the front of the tank when
silicone-free motor oil. assembling tank to frame.
CAUTION 1. Install the inner isolator / spacer assemblies q to

the rear fuel tank mounts as shown.
Apply oil sparingly and avoid contaminating the
pintle valve / jet surface and upper inlet port.
2. Install NEW fuel injectors to the fuel rail.

IMPORTANT
Make sure injectors tabs align with fuel rail for
proper installation.
3. Install fuel injectors q by carefully pressing into

manifold.
2. Verify that forward tank isolators w are in position

on the frame mounts and lower tank into position.
DO NOT slide forward into position at this time.
4. Install fuel rail screws and torque to specification.

TORQUE
Fuel Rail Screws:
88 in-lbs (10 N·m)

© Copyright 7.45
3. Connect the fuel pump electrical connector e, 8. Install the outer isolators and washers onto the rear
vent line r and fuel line t. tank mount and install mounting fasteners y.
IMPORTANT 9. Verify that the fuel tank vent line is routed properly
Verify fuel line is properly seated and locked in and torque the fuel tank mounting fasteners to
place by listening for an audible “click” when specification.
pressing into place. Pull gently on quick connector to
TORQUE
make sure a proper connection has been made.
Fuel Tank Mounting Fasteners:
18 ft-lbs (24 N·m)
4. Install the console cover and torque fasteners to
specification.
10. Install the fuel pump relay.
TORQUE
88 in-lbs (10 N·m)
5. Slide tank forward until fully seated on forward

isolators.
6. Lower the rear of the tank into position over the
rear mounting bracket.
7. Install the fuel tank vent line to the chassis vent line
at rear of tank.

7.46 © Copyright
C O N N E C T T H E B AT T E R Y I N S TA L L I N TA K E
Connect the negative (-) battery cable q to the 1. Feed the throttle body electrical connector through
battery terminal. Torque fastener to specification. the hole in the air box and install the rubber
harness seal in the rectangular cutout.
NOTICE
Make sure that the harness seal is fully seated in the
air box cutout.
2. Fit the air box to the mounting bracket and press

breather hose w through the rubber grommet until
the air box sits flat against the bracket.
3. Install the intake air boot and baffle plate. Torque
baffle plate fasteners e to specification.
4. Install air box retainer fastener r and torque to
specification.
TORQUE
Battery Terminal Fastener:
40 in-lbs (5 N·m)
TORQUE
Baffle Plate Fasteners:
31 in-lbs (4 N·m)
Air Box Retainer Fastener:
88 in-lbs (10 N·m)

© Copyright 7.47
5. Install throttle body o-ring and throttle body. 9. Install the air filter element and torque fasteners u
Torque throttle body fasteners t to specification. to specification.
TORQUE TORQUE
Throttle Body Fasteners: Air Filter Fasteners:
88 in-lbs (10 N·m) 62 in-lbs (7 N·m)
6. Connect throttle body electrical connector. 10. Install air box gasket and cover. Torque fasteners
7. Install the air filter adapter plate and seal into the i to specification.
airbox. Press the hose fitting on the adapter plate
into the breather hose until the plate is fully seated.
8. Install the three air filter adapter plate fasteners y
TORQUE
Air Box Cover Fasteners:
Air Filter Adapter Plate Fasteners:
31 in-lbs (4 N·m)

7.48 © Copyright
R I G H T F L O O R B O A R D I N S TA L L AT I O N 3. Apply a thin coat of grease to pushrod pivot pin

1. Install floorboard assembly F and attach with two and install retained washer B and cotter pin A
retained screws E. Torque screws to specification. onto brake master cylinder pushrod.
TORQUE
Floorboard assembly screws E:
35 ft-lbs (47 N·m)
4. Test foot brake and verify pedal feels firm and no

air has entered hydraulic circuit. Bleed brakes if
necessary.
2. Lower brake master cylinder D in place, engaging

pushrod onto brake pedal assembly and attach
with two retained screws C. Torque screws to
specification.
IMPORTANT 7
Master cylinder assembly should be kept in an
upright position and properly supported at all times.
If master cylinder is not kept upright, brake system
must be bled of air.
TORQUE
Brake Master Cylinder Mounting Screws C:
18 ft-lbs (24 N·m)

© Copyright 7.49
S E AT I N S TA L L AT I O N 9. With the semi-dry sump lubrication system, the en-

gine oil level on the dipstick will fluctuate, depend-
• Seat Removal / Installation - All (except Roadmaster) ing on the motorcycle’s position and engine
page 3.19 temperature when checked. To ensure a proper
• Seat Removal / Installation - (Roadmaster) page 3.20 reading of the engine oil level, follow all inspection
procedures closely.
• Seat Removal / Installation - (Dark Horse) page 3.21
WARNING
OIL FILL AND LEVEL CHECK Operating with insufficient, deteriorated or
1. Install new sealing washers on the drain plugs. The contaminated engine oil will cause accelerated wear
sealing surfaces on drain plugs and engine should and may result in engine or transmission seizure,
be clean and free of burrs, nicks or scratches. which could result in loss of control and serious
injury or death. Check the oil level frequently.
2. Reinstall the drain plugs. Torque to specifications.
Always check the oil after running a cold engine at
idle for 30 seconds. The oil fill/dipstick is located
on the left side of the motorcycle. Always use the
recommended oil.
a. Position the motorcycle on level ground in the
fully upright and centered position.
b. Start the engine (from cold) and allow it to idle
for 30 seconds. Stop the engine.
c. Remove the dipstick q and wipe it clean.
TORQUE
Drain Plugs:
15 ft-lbs (20 N·m)
3. Lubricate the o-ring on the new filter with a film of

fresh engine oil. Check to make sure the o-ring is
in good condition.
4. Install the new filter and rotate it clockwise by hand
until the filter gasket contacts the sealing surface,
then turn it an additional 3/4 to one full turn. d. Thread the dipstick until fully seated.
5. Remove the dipstick. Add only 4.5 qts. (4.25 l) of e. Remove the dipstick and view the oil level.
the recommended oil at this step. Do not overfill. NOTICE
6. Reinstall the dipstick securely. Do not overfill. Overfilling can result in loss of engine
7. With the motorcycle in an upright, centered performance and an oil-saturated air filter. Use a
position, start the engine and idle for 30 seconds. suction device to remove excess oil if overfilled.
8. Stop the engine and add the additional 1 - 1.5 qts.

(0.95 - 1.42 L) of engine oil. Do not add oil if oil
level is between the ADD and FULL marks.
Overfilling can result in loss of engine performance
and an oil-saturated air filter. Use suction device to
remove excess oil if overfilled.
IMPORTANT
Total fill with oil filter change will be approximately
5.5 - 6.0 US quarts.

7.50 © Copyright
f. Add the recommended oil as needed to bring

the level between the ADD and FULL marks. Do
not add oil if between the ADD and FULL marks.
NOTICE
The approximate volume between the FULL w and
ADD e marks on the dipstick is 32 oz. (.94 L).
g. Reinstall the dipstick securely.
CAUTION
Oil level will NOT be accurate if checked on a cold
engine. DO NOT ADD oil to bring to FULL mark on a
cold engine, as this can result in overfilling.
7
10. Dispose of used filter and oil properly.

11. Check for leaks around drain plug and oil filter.
NOTICE
Recycle used oil and oil filter in accordance with
local regulations.

© Copyright 7.51
CYLINDER HEAD SERVICE

VA LV E C O V E R R E M O VA L 3. Using an 8mm socket, remove the fasteners w
1. Remove engine from frame and place on an securing the inner valve covers to the cylinder
engine stand. See Removing Engine From Frame head.
page 6.6.
2. Using a T40 Torx Plus, remove the three fasteners
q from each of the outer valve covers and remove
covers.
4. Remove inner valve covers and gaskets.
VA LV E C O V E R I N S TA L L AT I O N
Front Valve Cover, Inner Rear Valve Cover, Inner

Torque Sequence Torque Sequence

7.52 © Copyright
1. Using new gaskets, install the inner valve covers

and thread fasteners q in finger tight.
2. Reference the torque sequence at the beginning of

this section and torque inner valve cover fasteners
to specification.
TORQUE
Inner Valve Cover Fasteners:
88 in-lbs (10 N·m)
3. Install the outer valve covers and torque fasteners

to specification.
TORQUE 7
Outer Valve Cover Fasteners:
88 in-lbs (10 N·m)

© Copyright 7.53
C Y L I N D E R H E A D R E M O VA L R O C K E R A R M R E M O VA L
1. Remove rocker arm fasteners q and remove
CAUTION rocker arms as an assembly.
Cylinder and Cylinder Head heat sink edges are
extremely sharp. Gloves should be worn whenever
handling these components to prevent personal
injury.
1. Remove engine from frame and place on an

engine stand. See Removing Engine From Frame
page 6.6.
2. Remove inner and outer valve covers. See Valve
Cover Removal page 7.52.
3. Alternately loosen cylinder head nuts q to relieve
valve spring pressure. Remove nuts and washers.
4. Remove cylinder heads w and head gaskets e .

7.54 © Copyright
ROCKER ARM INSPECTION C Y L I N D E R H E A D D I S A S S E M B LY

NOTICE CAUTION
Rocker arms are non-serviceable and must be
Wear eye protection while removing valve springs.
replaced as an assembly.
1. Visually inspect rocker arms and needle bearings NOTICE

for scoring or damage.
Keep mated parts together for assembly.
2. Inspect oil passage q at the push rod cup and
clean thoroughly. Use only clean solvent. 1. Remove the valve keepers q using a valve spring
compressor tool PV-1253. Use a small magnet to
remove valve keepers.
2. Remove upper valve spring retainers w and
springs e .
3. Rotate rocker arm. Rocker arm should move

smoothly without excessive play or binding.
Check for excessive radial movement.
4. Replace rocker arm assembly if pad or push rod
7
cup show signs of wear, cracks, nicks or burrs. 3. Remove the valves r .

© Copyright 7.55
4. Remove and discard the spring seat / valve stem CYLINDER HEAD INSPECTION
seal assemblies t . 1. Visually inspect cylinder head for cracks or
damage. Pay close attention to the areas around
spark plug q and valve seats w .
5. Clean carbon deposits from combustion chamber.

6. Clean gasket surfaces.
2. Inspect cylinder head for distortion with a straight
edge and feeler gauge. Check in different
directions and locations on the cylinder head. For
cylinder head service limits, see Service
Specifications page 7.4.
VA LV E S P R I N G F R E E L E N G T H I N S P E C T I O N
1. Measure free length of valve springs. Replace
springs that do not meet specification. See Service
NOTICE
Intake and exhaust springs are identical.

7.56 © Copyright
VA LV E I N S P E C T I O N 4. Insert valves into their original locations in

cylinder head.
NOTICE
Valve service specifications can be found at the 5. Inspect that each valve moves up and down
beginning of this chapter. See Service Specifications smoothly without binding in guide.
page 7.4. 6. Measure valve stem deflection for each valve to
determine if valve or valve guide requires
1. Place valves on V-blocks as shown and measure replacement.
valve stem runout q using a runout gauge or
similar tool..
A. Raise valve 10mm (0.400") off of seat.

2. Inspect the valve face for damage from burning, B. Position dial indicator as shown. Measure
pitting or uneven contact. deflection in two directions perpendicular to each
other (X & Y axis).
3. Place valves on V-block as shown and inspect
valve head radial runout w . C. If valve deflection exceeds service limit
measure valve stem diameter.
7
7. Replace valve and repeat step 6 if valve stem O.D.
measures outside standard range. If valve stem
deflection exceeds service limits with a new valve
installed, valve guide must be replaced.
8. Installation of new valve guides and/or new valves
requires valve seat reconditioning. This work
should be performed by an experienced
technician properly equipped to perform cylinder
head reconditioning.

© Copyright 7.57
VA LV E I N S P E C T I O N
CONDITION ILLUSTRATION POSSIBLE CAUSE CORRECTIVE ACTION
Uneven seat width Bent valve stem, worn Replace valve and reface
valve guide seat
Damaged valve face Burnt, pitted, foreign Replace valve and reface
material damage seat
Contact area too high Wear, settling of valve seat Lower with 30o stone
Contact area too low Wear, settling of valve seat Raise with 60o stone
Contact area too wide Wear, settling of valve seat Narrow with both 30o stone
and 60o stone
Contact area too narrow Use 45o stone
Contact area free of pitting Correct None

and damage, centered in
seat, proper width.

7.58 © Copyright
VA LV E G U I D E R E M O VA L / I N S TA L L AT I O N VA LV E S E AT I N S P E C T I O N
NOTICE
CAUTION
Valves cannot be ground. If valve face is burned or
Replacement of valve guides requires an oven, badly worn, replace the valve.
special equipment and experience to do the job
correctly. If you are unsure of your ability to do the
repair professionally it is best to sublet the labor to a 1. Remove carbon deposits from valves and seats.
competent machinist. Valve seat reconditioning is 2. Inspect valve face for burning, pitting or uneven
required when valve guides are replaced. contact.
3. Apply a light coating of machinist’s layout fluid or
1. Support cylinder head and place valve guide
paste to valve face.
remover into valve guide from the combustion
chamber side. 4. Install valve into valve guide.
2. Drive or press old valve guides out of cylinder 5. Tap valve several times to make a clear impression
head. on the valve face. Do not rotate valve.
CAUTION 6. Remove valve and measure contact area (valve

seat width). See Service Specifications page 7.4.
The cylinder head can be easily damaged if the
procedure is done carelessly.
3. Apply 90 weight oil to outside of new valve guides.

4. Drive or press new guides from rocker arm side of
head.
5. Measure valve guide height from spring seat:
Valve Guide Installed Height:
17.7–18.3 mm
7
6. Ream new valve guides to size to obtain specified
stem-to-guide clearance. Ream from combustion
chamber side of head.
7. Clean cylinder head thoroughly with clean
solvent. 7. If valve seat is incorrect, recondition as needed.
8. Inspect and recondition valve seats.

VA LV E S E AT R E C O N D I T I O N I N G
NOTICE
Valve seat reconditioning should be performed by a
technician proficient in cylinder head reconditioning
techniques using grinding stones. The use of carbide
cutters is not recommended. Follow
recommendations of the manufacturer of the valve
seat reconditioning equipment being used. Do not
grind seats more than necessary to provide proper
seat width and contact point on valve face.

© Copyright 7.59
C Y L I N D E R H E A D A S S E M B LY C Y L I N D E R H E A D I N S TA L L AT I O N
CAUTION NOTICE
Wear eye protection during assembly. The base gasket seal is broken when the cylinder
head is removed and must be replaced. See Cylinder
1. Lubricate valve stems with assembly lube. Rocker arms must be removed from cylinder head
2. Install valve in head before installing seal. Hold prior to installation.
valve against seat wipe off the portion that extends
above the guide.
1. If previously removed, lubricate push rod tube o-
3. Apply Indian Motorcycle engine oil to valve guide rings with a small amount of engine oil and press
seal and install seal on valve, rotating the seal as them into the lifter blocks until fully seated.
you install it.
2. Verify that locating dowels q are in position on the
4. Press seal firmly in place on top of guide. Be cylinder deck.
careful not to dislodge spring from seal.
3. Thoroughly clean cylinder and cylinder head
5. Install valve spring and upper retainer. mating surfaces.
CAUTION NOTICE
Do not compress valve springs more than necessary Gaskets and gasket sealing surfaces must be free of
to install keepers. oil and grease during assembly.
Support cylinder head so valves will not be
damaged. 4. Slide push rods through push rod tubes until seated
in lifters.
6. Compress valve springs using a valve spring
compressor and adapter. NOTICE
All push rods and rocker arms are identical, although
7. Apply a small amount of grease to both sides of a
an effort should be made to put parts back into the
valve keeper.
same location from which they were removed.
8. Insert both valve keepers in place on valve.
9. Remove spring compressor. 5. Install a new head gasket w .
10. Repeat previous steps for remaining valves.
11. Be sure all keepers are fully seated in groove.
NOTICE
Use care not to damage, tear or displace push rod
tube o-rings when fitting the cylinder head to the
cylinder.
6. Set cylinder head in place on cylinder and press

down over the push rod tubes until fully seated.
7. Apply assembly lube to the tops of the valve stems.

7.60 © Copyright
8. Install washers and nuts on cylinder studs. Tighten

finger tight.
9. Fully torque cylinder head following the procedure

below to ensure accurate final torque:
TORQUE
Cylinder Head Nuts:
Step 1: 26 ft-lbs (35 N·m)Step 2: Turn additional
50°Step 3: Turn additional 90°

© Copyright 7.61
T R O U B L E S H O O T I N G , C Y L I N D E R H E A D A N D VA LV E T R A I N
NOTICE
Cylinder head, valve train and piston/cylinder problems are usually detected by an engine compression test.
Other problems associated with this area of the engine are external fluid leaks, excessive oil consumption or
abnormal noises.
The troubleshooting tables that follow list possible causes of engine mechanical problems. Always thoroughly
investigate before disassembling an engine.
PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR

RECOMMENDED
Worn Valve Guide(s) Replace Valve Guide(s)
Poor Seating of Valve(s) Repair or Replace
Broken Valve Spring(s) Replace
Spark Plug Not Seated Torque to Specification
Incorrect Valve Timing Repair / Retest
Valve Stuck Open Repair / Retest
Cylinder Head Gasket Leak Repair / Retest
Hard Starting / Won’t Low Compression
Start Slow Starter Motor Refer to Electrical chapter
Worn Rings, Piston, or Refer to Engine / Cooling /
Cylinder Exhaust chapter
Collapsed Hydraulic Lifter Bleed Air from Lifter(s) /
(s) Run at high idle for 10
minutes
Ignition Problem Refer to Electrical chapter
Fuel Problem Refer to Fuel Delivery / EFI
chapter
Excessive carbon build-up De-carbon Combustion
in combustion chamber Chamber
High Compression Compression Release Inspect/Repair/Replace
Electric Starter Straining Mechanism Failure Compression Release
to Turn Engine Over Mechanism
Excessive Starter Load Internal Engine / Drive Determine Cause of
Components Seized or Seizure or Binding
Binding
Low Compression minutes
Poor idle Quality (Engine
Related) Valve Guides Replace
Excessive Oil in Worn Rings, Piston, or Refer to Engine / Cooling /
Combustion Chamber Cylinder Exhaust chapter
Engine Oil Overfilled Correct Engine Oil Level
Engine Noise Valve Train Area minutes
Broken or Weak Valve Replace
Spring(s)

7.62 © Copyright

RECOMMENDED
Worn Camshaft or Rocker Replace
Arm
Rocker Arm Bearing Replace
Damage
Cam Bearings Worn or Replace
Damaged
Worn Pistons and / or Replace
Cylinders
Worn Wrist Pin, Wrist Pin Replace
Piston / Cylinder Area Bore and / or Connecting
Rod
Worn Piston Rings or Piston Replace
Ring Lands
General Exhaust Leak Reseal Exhaust
Chain / Sprocket Worn Replace
Timing Chain Area Chain Tensioner and / or Replace
Guide Worn
Bottom End Area Main Bearings Refer to Transmission /
Crankshaft chapter
Rod Bearings Refer to Transmission /
Crankshaft chapter
Loose Side Clearance Refer to Transmission /
Crankshaft chapter 7
Transmission Area Bearings Refer to Transmission /
Crankshaft chapter
Air Intake Problem - Refer to Fuel Delivery / EFI
chapter
Fuel Injection Problem - Refer to Fuel Delivery / EFI
chapter
Ignition Problem - Refer to Electrical chapter
Poor High-Speed Running
Valve Float Weak Valve Springs Replace
Insufficient Valve Travel Worn Camshaft / Rocker Replace
Arms
Valves Opening and Incorrect Valve Timing Correct
Closing at Wrong Time
Low Compression Worn Piston, Rings, Repair / Replace
Cylinder, Poor Valve
Seating
Valve Timing Incorrect Cam Chain and Sprockets Correct
Lack of Power in all RPM Valve Float Weak Valve Springs Replace
Ranges Insufficient Valve Lift Worn Camshaft / Rocker Replace
Arms
Ignition / Fuel Injection — Refer to Fuel Delivery / EFI
System or Electrical chapter
Oiling Problem Oil Overfilled Correct Engine Oil Level

© Copyright 7.63
NOTES

7.64 © Copyright
CYLINDER / PISTON
CHAPTER 8
CYLINDER / PISTON
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
CYLINDER / PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
CYLINDER / PISTON SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
PISTON RING PROFILE AND ORIENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
CYLINDER BORE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
PISTON TO CYLINDER CLEARANCE WORKSHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
CYLINDER WARPAGE MEASUREMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
PISTON & PISTON RING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
PISTON & PISTON RING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
PISTON PIN / PIN BORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.10
PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.11
CYLINDER STUD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.11
CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.11
TROUBLESHOOTING, CYLINDER / PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.13 8

© Copyright 8.1
CYLINDER / PISTON
SERVICE NOTES SPECIAL TOOLS
NOTICE TOOL DESCRIPTION PART NUMBER
Clean the machine thoroughly before removing Piston Ring Compressor PV-43570-A
engine from frame.
Clutch Shaft Holding Tool PF-51232
• This section covers service of the cylinder, piston Cylinder Bore Gauge PV-3017
and rings. The engine must be removed from the
frame to perform the procedures in this section. Crankshaft Rotation Tool PF-51239
Refer to Engine / Cooling / Exhaust chapter for Crankshaft Locking Pin PF-52135
engine removal and installation.
Engine Case Splitting Tool PF-51234
• Mark and store all mated parts for assembly.
Assemble engine by putting used parts that pass Straightedge, Feeler Commercially
inspection back in the same location. Gauge Available
• Machined mating surfaces are very delicate. Handle Protective Sleeves For Commercially
and store all parts in such a way that the mating Pistons / Studs Available
surfaces will not be damaged.
• Many parts require assembly lubrication. Follow the Bosch Automotive Service Solutions: 1-800-328-
assembly lubrication procedures carefully. 6657 or https://polaris.service-solutions.com/
• There are many precision measuring steps in this
section. If you are not sure of your capabilities in
these areas, have a competent machinist perform
the precision part inspection operations. DESCRIPTION TORQUE
• Cleanliness of parts is critical to engine life and SPECIFICATION
proper parts inspection. Use clean solvent and hot, Connecting Rod 22 ft-lbs (30.0 Nm)
soapy water to clean parts. Dry with compressed air Bearing Cap
before inspection and engine assembly. Coat parts
with fresh lubricant to prevent oxidation after Cylinder Studs 25 ft-lbs (34.0 Nm)
cleaning.
I.D. 100.987 - 101.013 Check taper and
(3.9759" - 3.9769”) out-of-round
Cylinder Out of Round Measure 66mm up from 0.05 mm (.002")

base gasket surface
Taper 0.05 mm (.002")
Gasket Surface Warpage - .1mm max. (.0039")
Piston Mark Direction Piston orientation is determined by arrow on piston
crown.
Position BOTH pistons so arrows point to front of engine.
Piston O.D. (Nominal) 100.966 - 101.004mm Replace if piston-to-
(Measured 12 mm up (3.975 - 3.976") cylinder clearance is
from bottom of skirt, 90 excessive with good
Piston
degrees to pin) cylinder
Piston Pin Hole I.D. 22.006 - 22.012 mm 22.047 mm
(.8664 - .8666") (.8680")
Piston Pin O.D. 21.995 - 22.000 mm 21.96 mm
(.8659 - .8661") (.864")

8.2 © Copyright
CYLINDER / PISTON

Piston to Cylinder .023 - .067 mm .15 mm
(.0009 - .0026") (.006")
Piston to Piston Pin .006 - .017 mm .035 mm
(.0002 - .0007") (.0014")
Ring End Gap - Top .15 - .40 mm .80 mm
(Installed) (.006 - .016") (.031")
Ring End Gap - 2nd .33 - .53 mm 1.11 mm
(Installed)Ring End Gap - (.013 - .021") (.043")
Piston Ring Clearances 3rd (Oil Control Rails) .15 - .35 mm .80 mm
(Installed) (.006 - .014") (.031")
Piston Ring Marks - “CTOP” mark must face
UP on all rings.
Top Ring .02 - .060 mm
.11 mm (.0043")
(1.2mm ring thickness) (.0008 - .0024")
Piston Ring to Ring 2nd Ring .02 - .060 mm

.11 mm (.0043")
Land (1.2mm ring thickness) (.0008 - .0024")
.03 - .17 mm
Oil Control Ring .26 mm (.010")
(.001 - .0067")

© Copyright 8.3
CYLINDER / PISTON
CYLINDER / PISTON
q Fastener, Connecting Rod Bearing Cap Reference Connecting Rod Installation page
10.33.
w Bearing Cap, Connecting Rod -
e Bearing, Connecting Rod (52 mm) -
r Circlip, Wristpin -
t Wristpin -
y Piston -
u Ring, Oil Control -
i Ring, Compression (top 2 rings) -
o Gasket, Cylinder Base -
a Cylinder -
s Gasket, Cylinder Head -

8.4 © Copyright
CYLINDER / PISTON
CYLINDER / PISTON SERVICE

P I S T O N R I N G P R O F I L E A N D O R I E N TAT I O N
NUMBER DESCRIPTION
q Arrows on piston crown indicating installation direction. Both arrows point toward the front of the engine.
w Rear piston is installed closest to the primary drive side of the engine.
e Front piston is installed closest to the camshaft side of the engine.
r Wrist pin circlip. Install the circlip with the gap positioned at 12 o’clock.
t Oil Control Ring
y Compression Ring No. 2
u Compression Ring No. 1

© Copyright 8.5
CYLINDER / PISTON
C Y L I N D E R R E M O VA L CYLINDER INSPECTION
1. Remove cylinder head (s). See Cylinder Head 1. Visually inspect cylinder bores for scratches and
Removal page 7.54. wear.
2. Remove cylinder (s). Support pistons to prevent 2. Inspect gasket surfaces for scratches or other
damage. Place a section of hose over the cylinder damage that may cause an oil leak.
studs to prevent damage to the piston rings.
CYLINDER BORE MEASUREMENT
1. Measure each cylinder bore in 6 places to
determine:
3. Remove cylinder base gasket q .
NOTICE
Bottom measurement should be taken 2.6 in (66 mm)
up from base gasket surface.
• Cylinder Bore Inside Diameter

• Cylinder Taper
• Out of Round
2. Use maximum measurement to determine wear.

3. Use the worksheet provided to record
measurements and calculate the clearance.
4. Clean gasket surfaces of cylinders thoroughly.
CAUTION
Careless handling of cylinder, pistons or rings may
cause irreparable damage. Do not damage gasket
surfaces during cleaning.
PISTON TO CYLINDER CLEARANCE WORKSHEET

Front Cylinder Recorded Measurement Specification
Top “X”
Middle “X”
Bottom “X” Taper Service Limit: .05mm (.002")
Top “Y”
Middle “Y”

8.6 © Copyright
CYLINDER / PISTON
Bottom “Y”
Difference between largest “Y” measurement Taper for “Y” axis:
and smallest “Y” measurement
Difference between largest “X” measurement Taper for “X” axis:
and smallest “X” measurement
Largest difference between any “X” axis Cylinder Out-of-Round: Out-of-Round Service Limit:
measurement and “Y” axis measurement .05mm (.002")
Piston Skirt Measurement

Difference between largest “X” axis Piston-to-Cylinder Clearance* Piston-to-Cylinder Clearance Service Limit: .15
measurement and piston measurement mm (.006")
Rear Cylinder Recorded Measurement Specification
Top “X”
Middle “X”
Bottom “X”
Top “Y”
Middle “Y”
Taper Service Limit: .05mm (.002")
Bottom “Y”
Difference between largest “Y” Taper for “Y” axis:
measurement and smallest “Y”
measurement
Difference between largest “X” Taper for “X” axis:
measurement and smallest “X”
measurement
Largest difference between any “X” axis Cylinder Out-of-Round: Out-of-Round Service Limit:
measurement and “Y” axis measurement .05mm (.002")
Piston Skirt Measurement

Difference between largest “X” axis Piston-to-Cylinder Clearance* Piston-to-Cylinder Clearance Service Limit: .15
measurement and piston measurement mm (.006")
8
Compare recorded measurement to specifications. If measured value exceeds service limit replace the
appropriate part.
NOTICE
• The cylinders are Ni-SiC plated and cannot be reconditioned by boring or honing. If excessive surface
damage, taper or out-of-round exists, the cylinder must be replaced.
• If the piston-to-cylinder clearance exceeds the service limit, measure a new piston and re-calculate the
clearance. If the piston-to-cylinder clearance exceeds the service limits with a new piston, the cylinder must
be replaced.
C Y L I N D E R WA R PA G E M E A S U R E M E N T P I S T O N & P I S T O N R I N G R E M O VA L
1. Inspect cylinder for warpage at cylinder head 1. Cover crankcase with a clean shop towel to
surface and base gasket surface. prevent piston circlip from falling into the
crankcase.
2. Place a straight edge diagonally across cylinder
mating surfaces in several positions. Attempt to
slide a .05mm (.002") feeler gauge under the
straight edge in each position.
3. Replace cylinder if warped beyond the service
limit.

© Copyright 8.7
CYLINDER / PISTON
2. Remove the left piston pin circlip q . PISTON & PISTON RING INSPECTION
1. Visually inspect piston for cracks, excessive wear,
scoring, etc.
2. Measure piston skirt O. D. (90° to pin and 12 mm
from bottom of piston skirt). Replace piston if worn
beyond the service limit. See Service
3. Push piston pin w out to left side of engine and

remove the piston e .
3. Calculate Piston to Cylinder Clearance. Subtract

piston O.D. from cylinder bore I.D. and compare to
specifications. See Service Specifications page
8.2.
4. Replace parts that do not meet specification.
NOTICE
If piston-to-cylinder clearance exceeds service limit,
measure a new piston and re-calculate clearance. If
piston-to-cylinder clearance exceeds service limits
with a new piston, cylinder must be replaced.
4. Rotate rings in piston grooves. Rings should rotate
freely in grooves. 5. Use a piston to push each ring squarely into
5. Clean carbon deposits from piston. cylinder bore from bottom (push rings 25-50 mm
into cylinder).
6. Spread rings only wide enough to remove them
from piston. Spreading rings too wide will damage
them.
7. Clean piston ring grooves. Break or cut a piston
ring in half. File or grind one edge square and
remove all burrs. Use this piston ring to carefully
clean piston ring grooves.
NOTICE
A soft wire brush may be used to only clean the top
of the piston. Do not use a wire brush to clean the
sides of piston or the piston ring grooves.
6. Measure installed ring end gap with a feeler

gauge and compare to specifications. See Service

8.8 © Copyright
CYLINDER / PISTON
7. Install rings onto a clean piston. Push rings in until PISTON PIN / PIN BORE INSPECTION
they are flush with piston. Using a feeler gauge, 1. Measure piston pin hole I. D. top to bottom (as
measure side clearances for the 1st & 2nd rings. shown) and as close to the circlip groove as
possible with a telescoping gauge. Record the
smallest measurement.
8. Replace parts that exceed service limit.

2. Measure piston pin O.D. at three locations. Record
largest measurement.
3. Calculate piston pin-to-piston clearance. Subtract

pin O.D. from pin hole I.D.
4. Measure connecting rod small end I. D. at two
locations.

© Copyright 8.9
CYLINDER / PISTON
5. Calculate connecting rod-to-piston pin clearance P I S T O N R I N G I N S TA L L AT I O N

by subtracting pin O.D from rod hole I.D.
CAUTION
6. Compare measurements to specifications and
replace any worn parts. See Service Specifications The rings may be damaged if they are over
page 8.2. expanded during installation.
1. Lubricate all rings with engine oil.

2. Carefully install oil control ring expander with end
gap located as shown. See Piston Ring Profile And
Orientation page 8.5.
3. Install top and bottom rails with end gap located
as shown. See Piston Ring Profile And Orientation
page 8.5
4. Install top ring (marked “C”) and second ring
(marked “CTOP”) with markings facing UP.
5. Compress each ring by hand and rotate to be sure
they rotate freely in grooves.
6. Locate ring end gaps as shown below in relation to
arrow on piston crown. See Piston Ring Profile And
Orientation page 8.5.

8.10 © Copyright
CYLINDER / PISTON
P I S T O N I N S TA L L AT I O N CYLINDER STUD REPLACEMENT

The pistons are marked with an arrow on the crown. 1. Use a stud extractor to remove 10 mm studs q .
Install pistons on connecting rods with arrow q facing
the FRONT of the engine.
2. Clean threads in cases thoroughly.

3. Apply engine oil to stud threads.
1. Place a clean shop towel over crankcase to prevent
foreign material from entering crankcase. 4. Install studs and torque them to specification.
2. Install a new circlip on one side of the piston with TORQUE
end gap facing UP (12:00 position).
Cylinder Studs:
IMPORTANT 25 ft-lbs (34 N·m)
Never reuse piston pin circlips.
3. Lubricate piston pin and I. D. of connecting rod C Y L I N D E R I N S TA L L AT I O N

small end with engine oil or moly lube.
NOTICE
4. Install piston over connecting rod with arrow on
piston crown facing FRONT of engine. Be sure all top end parts are ready for assembly.
Sealant on crankcase parting line must not be
5. Push piston pin w through rod and piston pin hole allowed to dry before top end is assembled and 8
until it is stopped by circlip. torqued.
6. Install remaining circlip e with end gap facing up
(12:00 position.) 1. First wash cylinders with clean solvent, then with
hot soapy water.
2. Rinse the cylinders with clear water and
immediately dry with compressed air. Cylinder
bore should be wiped with a clean white shop
towel and engine oil.
3. Apply a light coat of engine oil to piston and rings.
4. Ensure cylinder alignment dowel pins are in place
and gasket surfaces are clean and oil-free.
7. Make sure both piston circlips are seated properly

in the groove.

© Copyright 8.11
CYLINDER / PISTON
5. Apply a small amount of crankcase sealant to the 10. Carefully install cylinder (s) over piston/ring
crankcase parting lines on base gasket surface as assembly. Do not force cylinder over piston.
shown. Monitor rings carefully. If a piston ring becomes
dislodged from the ring compressor; remove
cylinder, inspect ring carefully for damage.
6. Install new cylinder base gaskets onto crankcase.

IMPORTANT 11. Remove piston ring compressor when rings are
Inspect all sealing surfaces carefully for scratches or fully captive in cylinder.
imperfections. DO NOT allow oil or grease to contact
gaskets or sealing surfaces during the assembly 12. Slide cylinder down over piston until seated to
process. base gasket and crankcase surface.
13. Repeat for other cylinder.
7. Apply a small amount of engine oil to inside 14. Install cylinder head (s). See Cylinder Head
surfaces of a piston ring compressor band. Installation page 7.60.
8. Install piston ring compressor over rings and
compress rings into ring grooves.
CAUTION
Be sure compressor band end gap does not align
with any ring end gap when compressing the rings.
NOTICE
Install cylinders in their original locations. Cylinder
with Knock Sensor is the front cylinder.
9. Remove protective covering from crankcase.

8.12 © Copyright
CYLINDER / PISTON
TROUBLESHOOTING, CYLINDER / PISTON

RECOMMENDED
Worn Valve Guide(s) Replace Valve Guide(s)
Broken Valve Spring(s) Replace
Spark Plug Not Seated Torque to Specification
Incorrect Valve Timing Repair / Retest
Valve Stuck Open Repair / Retest
Cylinder Head Gasket Repair / Retest
Leak
Hard Starting / Won’t Start Low Compression
Slow Starter Motor Refer to Electrical chapter
Worn Rings, Piston, or Refer to Clutch / Primary /
Cylinder Shift chapter
minutes
Ignition Problem Refer to Electrical chapter
Fuel Problem Refer to Engine / Cooling
/ Exhaust chapter
High Compression Excessive carbon build- De-carbon Combustion
up in combustion Chamber
Electric Starter Straining chamber
to Turn Engine Over Excessive Starter Load Internal Engine / Drive Determine Cause of
Components Seized or Seizure or Binding
Binding
8
Low Compression minutes
Poor idle Quality (Engine
Valve Guides or worn Replace
Related)
valve stem seals
Excessive Oil in Worn Rings, Piston, or Refer to Engine / Cooling
Combustion Chamber Cylinder / Exhaust chapter
Engine Oil Overfilled Correct Engine Oil Level
minutes
Broken or Weak Valve Replace
Spring(s)
Engine Noise Valve Train Area Worn Camshaft or Rocker Replace
Arm
Rocker Arm Bearing Replace
Damage
Cam Bearings Worn or Replace
Damaged

© Copyright 8.13
CYLINDER / PISTON

RECOMMENDED
Worn Pistons and / or Replace
Cylinders
Worn Wrist Pin, Wrist Pin Replace
Piston / Cylinder Area Bore and / or Connecting
Rod
Worn Piston Rings or Replace
Piston Ring Lands
General Exhaust Leak Reseal Exhaust
Chain / Sprocket Worn Replace
Timing Chain Area Chain Tensioner and / or Replace
Guide Worn
Bottom End Area Main Bearings Refer to Transmission /
Crankshaft chapter
Rod Bearings Refer to Transmission /
Crankshaft chapter
Loose Side Clearance Refer to Transmission /
Crankshaft chapter
Transmission Area Bearings Refer to Transmission /
Crankshaft chapter
Air Intake Problem - Refer to Fuel Delivery /
EFI chapter
Fuel Injection Problem - Refer to Fuel Delivery /
EFI chapter
Ignition Problem - Refer to Electrical chapter
Poor High-Speed Running
Valve Float Weak Valve Springs Replace
Insufficient Valve Travel Worn Camshaft / Rocker Replace
Arms
Valves Opening and Incorrect Valve Timing Correct
Closing at Wrong Time
Low Compression Worn Piston, Rings, Repair / Replace
Cylinder, Poor Valve
Seating
Cam Chain and Sprockets Correct
Valve Timing Incorrect
Damaged Cam Gears Replace
Lack of Power in all RPM
Ranges Valve Float Weak Valve Springs Replace
Insufficient Valve Lift Worn Camshaft / Rocker Replace
Arms
Ignition / Fuel Injection — Refer to Fuel Delivery /
System EFI or Electrical chapter
Oiling Problem Oil Overfilled Correct Engine Oil Level

8.14 © Copyright
CLUTCH / PRIMARY / SHIFT
CHAPTER 9
SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
PRIMARY COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
CLUTCH PINION SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
TORQUE COMPENSATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
PRIMARY COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
CLUTCH PINION SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
CLUTCH PINION SHAFT BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
CLUTCH PINION SHAFT SEAL REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
CLUTCH PINION SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10
SHIFT RATCHET REMOVAL & INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10
SHIFT RATCHET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.12
SHIFT SHAFT BEARING & SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.13
PRIMARY COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.13
CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15
CLUTCH RACK, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15
CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15
CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15
CLUTCH INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.17
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19
9
CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.20
TORQUE COMPENSATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21
TORQUE COMPENSATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21
TORQUE COMPENSATOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21
TORQUE COMPENSATOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.22
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.23
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.23
TROUBLESHOOTING, CLUTCH / PRIMARY / SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.24

© Copyright 9.1
S E R V I C E I N F O R M AT I O N TOOL DESCRIPTION PART NUMBER
• Clutch and external transmission shift linkage Crankshaft Locking Pin PF-52135
service can be accomplished with the engine in the
frame. Crankshaft Rotation Socket PF-51239
• Internal transmission or internal shifting mechanism Engine Stand Adapter PF-51240
service requires engine removal and crankcase
separation. Moly Assembly Paste 2871460
• Oil additives of any kind are not recommended by Bosch Automotive Service Solutions: 1–800–328–
Indian Motorcycle. Using oil additives or oil of the 6657 or https://polaris.service-solutions.com/
wrong viscosity can have a detrimental affect on
clutch performance, operation, and service life.
• Burnt clutch plates are not an indication of defective T O R Q U E S P E C I F I C AT I O N S
clutch plates. Burnt clutch plates indicate that a
problem exists within the clutch system, the clutch PART DESCRIPTION TORQUE
has been used improperly, or plates were SPECIFICATION
contaminated by improper oil or additives. Clutch Pinion Shaft Lever 88 in-lbs (10.0 Nm)
• Indian Motorcycle 20W/40 motorcycle oil is Fastener
recommended for all operating temperatures. If Clutch Stake Nut 125 ft-lbs (170.0 Nm)
Indian Motorcycle 20W/40 oil is not available, a high
quality JASO MA compliant/rated, 20W/40 Pressure Plate Fasteners 88 in-lbs (10.0 Nm)
motorcycle oil suitable for use in wet clutch
transmissions can be used. Primary Cover Fasteners 15 ft-lbs (20.0 Nm)
• Lubricate parts during assembly as described in the Stator Fasteners 88 in-lbs (10.0 Nm)
procedures.
Torque Compensator 83 ft-lbs (112.0 Nm)
• Corroded or sticking shift linkage pivot points can Fastener
cause abnormal shifting. Replace any linkage
Torque Compensator 88 in-lbs (10.0 Nm)
components that are damaged or do not move
Locking Plate Fastener
freely, and lubricate at regular intervals.
SPECIAL TOOLS S E R V I C E S P E C I F I C AT I O N S
Case Splitting / Assembly PF-51234
Tool
Clutch Shaft Holder PF-51232
ITEM SPECIFICATIONS
Clutch Type Wet, Multi-Disk
Clutch Operating Mechanism Manual / Cable Operated
Torque Compensator Belleville Spring Loaded Cam
Assembly
Clutch / Gear Shift / Linkage Primary Reduction Ratio 1.56 : 1
Transmission Shift Mechanism Manually Operated, Spring
Centered
Gearshift Pattern 1-N-2-3-4-5-6
Clutch Spring (Coil Type, QTY.5) 72.8 lbf @ Installed Height

9.2 © Copyright
ITEM SPECIFICATIONS
Clutch Lever Free Play (Cable) .50-1.50 mm (.020-.060")

© Copyright 9.3
PRIMARY COVER
NUM- PART DESCRIPTION TORQUE (IF APPLICABLE)

BER
q Fastener, Primary Cover - M8 x 1.25 x 35 (QTY.7) 15 ft-lbs (20 N·m)
w Fastener, Primary Cover - M8 x 1.25 x 75 (QTY.7) 15 ft-lbs (20 N·m)
e Primary Cover -
r Gasket, Primary Cover -

9.4 © Copyright
CLUTCH PINION SHAFT
q E-Clip, External -
w Washer -
e Seal, Shaft (Shift Shaft / Clutch Pinion Shaft) -
r Bearing, Shaft (Shift Shaft / Clutch Pinion Shaft) -
t End Bearing, Pinion Shaft -
y Pinion Shaft, Clutch - 9

u Lever, Clutch -
i Fastener, Clutch Lever - M6 x 1.0 x 25 (QTY.1) 15 ft-lbs (20 N·m)

© Copyright 9.5
T O R Q U E C O M P E N S AT O R
q Fastener, Compensator — M12 x 80 (QTY.1) 83 ft-lbs (112.0 Nm)
w Fastener, Locking Plate — M6 x 1.0 x 12 (QTY.2) 88.5 in-lbs (10.0 Nm)
e Locking Plate -
r Spring Retainer, Compensator -
t Spring Cup, Compensator -
y Spring, Compensator -
u Slider, Compensator -
i Gear, Compensator -
o Washer -
a Sleeve, Compensator -
s Rotor, Stator -
d Fastener, Stator — M6 x 1.0 x 35 (QTY.3) 88.5 in-lbs (10.0 Nm)
f Stator -

9.6 © Copyright
CLUTCH

q Retaining Ring, Clutch Rack -
w Plate, Clutch Lifter -
e Bearing, Clutch Rack -
r Clutch Rack -
t Stake Nut, Clutch - M20 x 1.5 125 ft-lbs (170.0 Nm)
y Belleville Spring (QTY.1) -
u Washer, Flat (QTY.1) -
i Fastener, Pressure Plate - M6 x 1.0 x 45 (QTY.5) 88 in-lbs (10.0 Nm)
o Pressure Plate, Clutch -
a Spring, Clutch (QTY.5) -
- 9
s Plate, Friction A (QTY.1)
d Plate, Seperator B (QTY.2) -
f Plate, Friction C (QTY.5) -
g Plate, Seperator (QTY.4) -
h Plate, Friction B (QTY.1) -
j Seat, Judder Spring -
k Spring, Judder -
l Clutch Hub -
1( Thrust Washer -
2) Clutch Basket -
2! Gear -
2@ Bearing, Needle -
2# Collar, Clutch Bearing -

© Copyright 9.7
SERVICE PROCEDURES
P R I M A R Y C O V E R R E M O VA L 7. Remove primary cover fasteners e .
2. Drain the engine oil. See Engine Oil & Filter
Change in the Maintenance Chapter.
3. Remove left-hand floorboard and shift linkage as
an assembly. See Floorboard (Driver), Removal
page 3.16
4. Remove clutch arm fastener q and remove clutch
arm from shaft.
8. Tap cover with a soft face mallet to loosen.

9. Pull primary cover outward evenly at front and
rear of cover to remove.
10. Remove the shim r from the end of the shift shaft
noting position for reassembly.
5. Release the clutch cable end from the clutch arm.

6. Remove the external snap ring w from the clutch
cable and withdraw from the mounting boss.

9.8 © Copyright
C L U T C H P I N I O N S H A F T R E M O VA L C L U T C H P I N I O N S H A F T S E A L R E M O VA L &
1. Remove the Primary Cover. See Primary Cover I N S TA L L AT I O N
Removal page 9.8. 1. Remove clutch pinion shaft. See Clutch Pinion
2. Remove the E-clip q and washer from the end of Shaft Removal page 9.9.
the clutch pinion shaft as shown. 2. Carefully pry seal q out of primary cover.
3. Slide the pinion shaft w out through the bottom of 3. Lubricate outer edge of new seal with engine oil
the primary cover. and sealing lip with grease.
4. Drive seal into place with a suitable driver.
9
CLUTCH PINION SHAFT BEARING
INSPECTION
1. Apply engine oil to the bearings.
2. Temporarily install pinion shaft into primary cover.
3. Turn shaft by hand. Replace bearings that feel
rough, notched, or loose.

© Copyright 9.9
C L U T C H P I N I O N S H A F T I N S TA L L AT I O N S H I F T R AT C H E T R E M O VA L & I N S P E C T I O N
1. Lubricate and install clutch pinion shaft q until 1. Place motorcycle in an upright position with the
fully seated in bearings. front wheel clamped in a wheel vise.
2. Shift transmission into neutral.
3. Remove primary cover. See Primary Cover
Removal page 9.8.
4. Remove clutch assembly. See Clutch Removal
page 9.15.
5. Using a 4 mm hex wrench, remove the fastener q
securing the shift star w to the shift drum and
remove shift star.
2. Install washer w and E-clip e .
6. Rotate the detent lever e so the spring is relaxed.

Using a 10 mm socket, remove the fastener r
securing the detent lever to the engine case and
remove lever.

9.10 © Copyright
7. Pull the shift lever and spring assembly t out of 11. Inspect fit of rivet o on shift ratchet assembly. It
the bore. should allow for free movement, but not be
excessively loose.
8. Inspect shift shaft return spring y for cracks or

loss of tension. The spring should have enough 12. Inspect shift star a .
tension to keep the shift shaft centered.
13. Inspect detent roller arm s for wear or damage.
14. Inspect spring d for cracks or fatigue.
9. Inspect shift shaft u for wear or damage.

10. Inspect coil spring i for tension. The spring
should apply enough tension on the shift ratchet 9
mechanism to keep it engaged with the shift star.

© Copyright 9.11
S H I F T R AT C H E T I N S TA L L AT I O N 3. Rotate the detent arm and ratchet arm out of the

1. Lubricate shift shaft assembly q with engine oil way and install the shift star r and shift star
and slide into bearing until fully seated. Make sure fastener t. Torque fastener to specification.
that the spring pin w is located between the return
spring arms.
TORQUE
Shift Star Fastener:
NOTICE
88 in-lbs (10 N·m)
Be sure the washer is in place between the shift
ratchet and the crankcase upon installation. 4. Install clutch assembly. See Clutch Installation
page 9.20.
2. Apply Loctite 242 (Blue) to clean threads of detent
roller fastener w. Install detent roller arm e with 5. Install the primary cover. See Primary Cover
spring. Torque fastener to specification.
TORQUE
Detent Roller Fastener:
88 in-lbs (10 N·m)

9.12 © Copyright
SHIFT SHAFT BEARING & SEAL P R I M A R Y C O V E R I N S TA L L AT I O N

REPLACEMENT 1. Clean gasket surfaces of crankcase and cover.
Removal page 9.8. 2. Install the thrust washer q onto the shift shaft so it
rests on snap ring w.
2. Carefully pry shift shaft seal q from cover.
3. Using a suitable arbor and arbor press, press 3. Install a new primary cover gasket.
bearing w from inside of cover to outside. 4. Apply a thin layer of grease to the shift shaft seal.
5. Install the primary cover so the clutch arm is
angled correctly and install primary cover
fasteners so they are finger tight.
IMPORTANT
The clutch shaft must engage the clutch rack so that
the clutch arm is angled approximately 60° off of the
primary cover mating surface when fully seated.
9
4. Apply assembly lube to inner & outer surfaces of
new bearing.
Moly assembly paste PN: 2871460
5. Press bearing into place with numbered side out
until fully seated.
6. Apply a small amount of grease to lip of seal and
apply engine oil to outside of seal.
7. Drive seal into place with a seal driver slightly
smaller than the O.D. of seal.
9. After installing primary cover, be sure shift shaft
returns freely to the centered position after
rotating up or down.

© Copyright 9.13
6. Torque the primary cover fasteners to specification

following the torque sequence.
TORQUE
Primary Cover Fasteners:
15 ft-lbs (20 N·m)
Primary Cover Torque Sequence

9.14 © Copyright
CLUTCH SERVICE
C L U T C H R A C K , R E M O VA L / I N S TA L L AT I O N C L U T C H D I S A S S E M B LY
1. Using an internal snap ring pliers, remove snap
ring q and clutch rack w. CAUTION
Clutch is under spring pressure. WEAR EYE
PROTECTION.
1. Remove the clutch. See Clutch Removal page 9.15.

2. Remove the sleeve q and needle bearing w from
the back side of the clutch assembly.
2. INSTALLATION: Reverse the removal procedure

to install.
C L U T C H R E M O VA L
Removal page 9.8.
2. Remove clutch rack. See Clutch Rack, Removal / 3. With the clutch assembly resting on a clean, flat
Installation page 9.15. work surface, alternately loosen the five pressure
plate fasteners e in a star pattern until spring
3. Perform the crankshaft locking procedure. See tension has relaxed. Remove fasteners and
Locking the Crankshaft for Service page 7.12. springs.
4. Remove clutch nut q , Belleville washer w , and
flat washer e. Discard the stake nut.
5. Remove clutch assembly from clutch shaft.

6. A new stake nut must be installed upon assembly.

© Copyright 9.15
4. Remove pressure plate r. 6. Remove thrust washer y.
5. Lift the clutch assembly t out of the basket and NOTE

set aside.
The clutch assembly consists of three different
types of friction plates and two different types of
seperator plates. See Clutch page 9.7.
PART DESCRIPTION QUANTITY

Friction Plate A (thinner 1
fiber material)
Friction Plate B (large inner 1
diameter)
Friction Plate C 5
Seperator Plate A (TOP) 2
Seperator Plate B 4
(BOTTOM)
Spring, Judder Clutch 1
Seat, Judder Clutch 1
7. Remove Friction Plate A u, Seperator Plate A i ,

Friction Plate B o and Seperator Plate A i .

9.16 © Copyright
8. Alternately remove Friction Plates C a and CLUTCH INSPECTION

Seperator Plates B s . 1. Clean clutch plates, inner hub, and outer basket.
Clutch Basket
2. Inspect clutch gear teeth q for wear, cracks or
damage.
3. Inspect inside surfaces w of basket for cracks or
wear (grooves) from clutch plates.
9. Remove Friction Plate Bd , Judder Spring f and

Judder Spring Seat g .
4. Replace parts that fail inspection

5. Rotate hub bearing. Check for smooth rotation.
Inner race should have no detectable radial
movement.
6. Lubricate bearing e with engine oil.
Clutch Hub
7. Inspect spline teeth r for wear, cracks or damage.

© Copyright 9.17
8. Inspect surface of steel plate guides t on outer

edge of hub for wear, grooves, or damage. Check
all posts y for cracks or damage.
9. Visually inspect friction and steel plates for wear

or damage on both surfaces. Replace plates as a
set if any plate is worn or damaged.
10. Replace steel plates if grooved, distorted or
discolored. Inspect plates for distortion by placing
each plate on a precision flat surface. Insert a
feeler gauge between plate and flat surface in
several places.
Clutch Steel Plate Warp Service Limit:
.008 in (.20 mm)
11. Measure thickness of friction plates in several

places. Thickness should be the same at each
place. Replace plates that fail inspection.
Friction Plate Thickness (Minimum):
.126 in (3.2 mm)
Clutch Pressure Plate

12. Inspect pressure plate for cracks, scoring, or wear
on friction surface.
Clutch Springs
13. Inspect clutch springs for cracks or distortion.
Clutch Release Rack and Bearing
NOTICE
Clutch rack is serviceable as an assembly only.
14. Inspect clutch rack for broken or damaged teeth.

15. Inspect lifter bearing visually for any signs or wear
or discoloration. Rotate bearing inner race with
your finger and check for smooth movement and
no play.
16. Replace clutch rack assembly if necessary.

9.18 © Copyright
C L U T C H A S S E M B LY 6. Continue stacking oiled clutch plates into clutch

1. Install the thrust washer q and the clutch hub w basket alternating Friction Plate C y and
into the clutch basket. Seperator Plate u stopping at the fourth Friction
Plate B. There should be one Friction Plate C
remaining.
2. Apply engine oil to judder spring seat e and

spring r .
3. Install judder spring seat (flat ring), then judder 7. Install Seperator Plate A i followed by Friction
spring. Plate C o and Seperator Plate A i .
8. Install the final Friction Plate A a .
NOTICE
Judder spring must be installed with concave side
facing UP (toward outside of clutch). The tallest edge
of spring will be outermost.
4.
NOTICE
Refer to the Clutch Assembly View outlined in
this chapter for clutch plate orientation. See
Clutch page 9.7.
Apply engine oil to Friction Plate B t and install.

9
9. Apply engine oil to hub bearing s .
10. Install the hub bearing and sleeve d into the
clutch assembly.
5. Place an oiled Seperator Plate B into clutch basket.

NOTICE
If friction plates are new, soak them in clean engine
oil for a few minutes before installing.

© Copyright 9.19
11. Install the pressure plate f and clutch springs and C L U T C H I N S TA L L AT I O N

fasteners g . Alternately tighten the clutch 1.
spring fasteners in a star pattern until fully IMPORTANT
seated.
When installing clutch assembly on the input shaft,
make sure that the thrust washer between the clutch
basket and the clutch hub goes onto the shaft and
does not fall between hub and basket.
Slide the clutch assembly onto the transmission

input shaft until fully seated.
2. Install washer q , a new spring washer w and a
new stake nut e .
12. Torque clutch spring fasteners to specification.

TORQUE
Clutch Spring Fasteners:
88 in-lbs (10 N·m)
3. Lock the crankshaft. See Locking the Crankshaft

for Service page 7.12.
4. Torque the stake nut to specification.
TORQUE
Clutch Stake Nut: 125 ft-lbs (170 N·m)
5. Install clutch rack assembly. See Clutch Rack,

7. Check engine oil and fill to proper level.

9.20 © Copyright
T O R Q U E C O M P E N S AT O R S E R V I C E
T O R Q U E C O M P E N S AT O R R E M O VA L T O R Q U E C O M P E N S AT O R I N S P E C T I O N
1. Remove primary cover. See Primary Cover 1. Inspect all parts for excessive galling or damage.
Removal page 9.8.
NOTICE
2. Perform crankshaft locking procedure. See
Locking the Crankshaft for Service page 7.12. Some polishing will be evident between the
compensator gear and the compensator slider and is
3. Remove the two fasteners q , locking plate w , a normal condition. Replace assembly if ramps are
torque compensator fastener e and spring worn.
retainer assembly r from the crankshaft.
2. Measure free length of torque compensator spring
stack.
4. Remove the spring pack t , upper torque

compensator ramp y and torque compensator
drive gear u from the crankshaft. Compensator Spring Stack Height:
1.437–1.476 in (36.5–37.5 mm)

© Copyright 9.21
T O R Q U E C O M P E N S AT O R I N S TA L L AT I O N 5. Slide the torque compensator spring assembly

1. Apply engine oil to shaft splines, sleeve, washer, onto the crankshaft until the drive plate splines are
peaks, valleys and sliding ramps before fully seated.
installation.
6. Lock the crankshaft for service. See Locking the
2. Install the splined sleeve q , flange side down, Crankshaft for Service page 7.12.
over the crankshaft followed by thrust washer w . 7. Apply Loctite 262 to compensator fastener and
TORQUE
Compensator Fastener:
83 ft-lbs (112 N·m)
8. Install compensator locking plate and fasteners i

3. Install the torque compensator gear e and upper

ramp r .
TORQUE
Compensator Fastener Locking Plate:
88 in-lbs (10 N·m)

10. Fill engine oil to proper level.
4. Load the three Belleville spring packs t into the
spring retainer cup y and fit the drive plate and
fastener u into the spring retainer cup.

9.22 © Copyright
F LY W H E E L R E M O VA L F LY W H E E L I N S TA L L AT I O N
WARNING CAUTION
The flywheel contains powerful magnets. Use caution The flywheel contains powerful magnets. Use caution
when lifting flywheel off of stator to avoid personal when installing flywheel onto crankshaft to avoid
injury. personal injury.
1. Remove primary cover. See Primary Cover 1. Clean rotor and crankshaft thoroughly.
Removal page 9.8.
2. Thread two primary cover fasteners q into the
2. Remove clutch assembly. See Clutch Removal flywheel w and install onto crankshaft.
page 9.15
3. Remove torque compensator assembly. See
Torque Compensator Removal page 9.21.
4. Remove thrust washer q and compensator sleeve
w.
3. Install torque compensator. See Torque

4. Install clutch assembly. See Clutch Installation
page 9.20.
5. Thread two primary cover fasteners e into Installation page 9.13.
threaded holes on flywheel r.
6. Check engine oil and add as necessary.
6. Grasp the two fasteners and lift the flywheel off of

the stator.

© Copyright 9.23
TROUBLESHOOTING, CLUTCH / PRIMARY /

SHIFT
RECOMMENDED
Clutch lever pivot, Clutch lever pivot points Lubricate
bushings need
lubrication
Drive plates catching on Clutch primary driven Replace necessary parts
Clutch Lever Pulls primary driven gear gear / clutch plates
Excessively Hard basket
Clutch rack bearing Clutch rack Replace
damage
Clutch pinion shaft Pinion shaft bearings Replace
bearing binding
Clutch springs weak Clutch springs Replace
Pressure plate worn or Pressure plate Replace
distorted
Clutch plates worn, Clutch Friction / Replace plates as
warped or distorted Seperator Plates necessary
Clutch Slips Clutch rack mechanism Clutch rack mechanism Replace
sticking
Engine oil level low Oil level Correct oil level
Oil additives present in Oil quality Replace oil & filter (clutch
oil or used previously plates may need to be
replaced
Clutch lever, pivot, cable, Lever, pivots, bushings, Inspect
or lifter arm sticking bearings, cable
Oil additives present in Oil quality Replace oil & filter (clutch
oil or used previously plates may need to be
replaced
Dragging clutch (doesn’t Oil level too high Oil level Correct
disengage completely,
Oil viscosity too high Oil quality Replace oil & filter
creeping)
Pressure plate worn, Pressure plate Replace
warped or distorted
Clutch plate(s) worn, Driven plates and / or Replace
warped or distorted drive plates
Weak clutch springs Clutch springs Replace

9.24 © Copyright

RECOMMENDED
Transmission Will Not Broken shift drum Shift drum Replace shift drum
Shift Bent shift forks Shift fork Replace shift forks
Worn shift drum Shift drum Replace shift drum
Broken gears Transmission gears Replace broken gear(s)
Damaged/broken bearings Transmission, shift cam Replace bearings that fail
bearings inspection
Worn gear shift pawl ratchet Shift pawl mechanism Replace parts that fail
mechanism inspection
Broken or dislodged shift Shift shaft return spring Repair or replace
shaft return spring
Roller detent arm stuck Roller detent arm Repair or replace parts
Bent shift shaft (internal) Shift shaft Repair or replace
External shift linkagebinding External shift linkage Repair or replace
or damaged
Bent or distorted shift forks Shift fork Replace
Bent or distorted shift fork Shift fork rail Replace
rails
Broken transmission Transmission components Repair or replace
components
Transmission Hard to Improper clutch operation Clutch Inspect, repair
Shift Incorrect oil viscosity Oil quality Replace engine oil
Incorrect clutch cable - Adjust
adjustment
Shift shaft damaged Shift shaft components Repair or replace
Sticking pivot point, bent External shift linkage Repair or replace
external shift linkage
Bent or distorted shift forks Shift forks Replace
Damaged shift drum grooves Shift drum Repair or replace
Shift detent plunger stuck Shift detent plunger Repair or replace
Bent/binding shift fork rails Shift fork rails Repair or replace
Transmission Jumps Broken / loose stop pin Shift stop pin Replace
9
Out of Gear Worn shift drum or shift drum Shift drum or shift linkage Replace
ratchet
Broken shift return spring Shift return spring Replace
Damaged shift drum grooves Shift drum Replace
Bent or worn shift forks Shift forks Replace
Bent/binding shift fork rails Shift fork rails Replace
Worn engagement dogs on Transmission gears Replace
transmission gears
Transmission Noise Drive belt tension incorrect Drive belt Adjust or replace
Clutch plates bind or drag Clutch plates / hubs Adjust / repair / replace
when clutch is disengaged
Gear/bearing wear/damage Transmission components Inspect / replace

© Copyright 9.25
NOTES

9.26 © Copyright
TRANSMISSION / CRANKSHAFT
CHAPTER 10
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.6
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.6
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.7
CRANKCASE FASTENER LENGTH AND TORQUE PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.8
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.9
SHIFT DRUM / SHIFT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
BALANCE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
GEAR TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
BALANCE SHAFT SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
INNER CAM CHAIN COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
BALANCE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
BALANCE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
INNER CAM CHAIN COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
STARTER DRIVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
STARTER DRIVE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
STARTER DRIVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
STARTER DRIVE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
CRANKSHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
TRANSMISSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
CONNECTING ROD SIDE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
CONNECTING ROD REMOVAL / IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
CONNECTING ROD INSPECTION (BIG END) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30 10
CONNECTING ROD BEARING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
CONNECTING ROD BEARING CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
CONNECTING ROD BEARING SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
CONNECTING ROD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
CRANKSHAFT CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
MAIN BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
MAIN BEARING OIL CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
LEFT CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
RIGHT CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
CRANKSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38

© Copyright 10.1
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39

STAKE NUT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.42
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.43

10.2 © Copyright
SERVICE NOTES
• Remove engine from frame to service internal
transmission and/or crankshaft components. See
ENGINE REMOVAL.
• The crankcase must be separated to access internal
transmission components and crankshaft.
• Label and store parts neatly to speed the assembly
process and ensure that matched parts like
connecting rods, camshafts and bearings and
pushrods can be installed in their original location
• Crankshaft main bearing replacement requires line
boring. This procedure requires full machine shop
capabilities and specialized knowledge. It is
recommended that a qualified machine shop
perform this procedure if it becomes necessary or
replace the crankcase assembly
• Crankshafts and connecting rods are color coded
for manufacturing tolerances with a white or red
paint mark (or stamped “R” or W”).
• All torque specifications are "dry" unless specified
for oil or locking agent. Refer to exploded views
• When locking agents are required, use Loctite®
Primer N to clean fastener before applying locking
agent Primer N reduces cure time of thread locking
agent in addition to preparing the surfaces
SPECIAL TOOLS
Case Splitting / Assembly PF-51234
Tool
Clutch Shaft Holding Tool PF-51232
Crankshaft Locking Pin PF-52135
Crankshaft Rotation Socket PF-51239
Drive Sprocket Seal Installer PF-51243 10
Engine Stand Adapter PF-51240


© Copyright 10.3
CONNECTING ROD / CRANKSHAFT SPECIFICATIONS
PART PART SPECIFIC STANDARD SERVICE LIMIT
Connecting Rod Connecting Rod to .22 - .42 mm .65 mm (.025")
Crankshaft Side Clearance (.0087 - .0165")
Connecting Rod Bearing to .0254 - .0635 mm .11 mm (.0043")
Crankshaft Oil Clearance (.001 - .0025")
Connecting Rod Small End 22.01 - 22.02 mm 22.09 mm (.8694")
I.D. (.8665 - .8670")
Connecting Rod Width 21.01 - 21.11 mm 20.76 mm (.8173")
(.8271 - .8310")
Connecting Rod Big End 54.992 - 55.000 mm 55.030 mm (2.1665")
I.D. (White) (2.1650 - 2.1653")
Connecting Rod Big End 55.000 - 55.008 mm 55.038 mm (2.1668")
I.D. (Red) (2.1653 - 2.1656")
Crankshaft Main Connecting Rod Journal 42.42 - 42.50 mm 43.46 mm (1.711")
Bearing / Rod Journals Width (1.670 - 1.673")
Crankshaft Rod Journal 51.9920 - 51.9999 mm 51.9620 mm (2.0457")
O.D. (White) (2.0469 - 2.0472")
Crankshaft Rod Journal 52.0000 - 52.0080 mm 51.970 mm (2.0460")
O.D. (Red) (2.0472 - 2.0475")
Main Bearing Oil Left .013 - .060 mm .10 mm (.004")
Clearance (.0005 - .0023")
Right .014 - .061mm
(.0005 - .0024")
Left Main Bearing Journal 59.9523 - 59.9703 mm 59.9323 mm (2.3595")
O.D. (2.3603 - 2.3610")
Right Main Bearing Journal 64.9523 - 64.9703 mm 64.9273 mm (2.5561")
O.D. (2.5571 - 2.5578")
Balance Shaft Journal O.D., Left (Primary 24.980 - 24.992 mm /
Side) / Journal O.D., Right 24.969 - 24.979 mm -
(Cam Side)

10.4 © Copyright
TRANSMISSION SPECIFICATIONS
ITEM PART SPECIFIC STANDARD SERVICE LIMIT
Shift Fork 12.00 - 12.026 mm 12.05 mm (.4744")
Shift Fork I.D. (Rail)
(.4725 - .4732")
6.036 - 6.136 mm 6.02 mm (.2370")
Shift Fork Pin O.D. (.2376 - .2416")
Shift Fork Rail 11.948 - 11.972 mm 11.92 mm (.4693")
Shift Fork Rail O.D. (.4704 - .4713")
Shift Fork Rail Runout - .025 mm (.001")
Shift Drum Shift Drum Groove - Replace drum if any wear
is evident
ITEM SPECIFICATIONS
Drive Train (General) Transmission 6 Speed
Primary Reduction Ratio 1.56: 1
Final Reduction Ratio 2.2: 1
Drive Train (Gear Ratios) Gear Ratio: 1st Gear 2.73: 1
Gear Ratio: 2nd Gear 1.86: 1
Gear Ratio: 3rd Gear 1.38: 1
Gear Ratio: 4th Gear 1.10: 1
Gear Ratio: 5th Gear .94: 1
Gear Ratio: 6th Gear (Overdrive) 0.81: 1
10

© Copyright 10.5
CRANKCASE

q Fastener, Crankcase — M8 x 1.25 x 100 (QTY.12) 22 ft-lbs (30 N·m)
w Fastener, Crankcase — M8 x 1.25 x 110 (QTY.6) 22 ft-lbs (30 N·m)
e Bearing, Camshaft —
r Fastener, Bearing Retainer – M5 x 0.8 x 12 (QTY.16) 62 in-lbs (7 N·m)

t Retainer Plate, Bearing —
y Bearing, Balance Shaft —
u Bearing, Crankshaft (Camshaft Side) — Non-Serviceable —
i Crankcase, RH —
o Fastener, Piston Cooling Jet — M5 x 0.8 x 10 (QTY.2) 62 in-lbs (7 N·m)

a Bearing, Transmission Output Shaft —
s Retainer Plate, Bearing —
d Bearing, Shift Drum —
f Bearing, Transmission Input Shaft —
g Retainer Plate, Bearing —
h Bearing, Shift Drum —
j Bearing, Crankshaft (Primary Side) — Non-Serviceable —
k Bearing, Transmission Input Shaft —
l Crankcase, LH —
1( Bearing, Shift Shaft —

10.6 © Copyright
CRANKSHAFT
q Bearing, Crankshaft Main (RH) — Non-Serviceable —
w Fastener, Connecting Rod Bearing Cap (QTY.4) Reference Connecting Rod

e Bearing Caps, Connecting Rod —
r Bearings, Connecting Rod (big end) —
t Piston —
y Tone Ring, Crankshaft Position Sensor — Non- —

Serviceable
u Fastener, Tone Ring - M8 x 1.25 x 16 (QTY.3) —
— 10
i Bearing, Crankshaft Main (LH) — Non-Serviceable
o Wrist Pin, Piston —
a Circlip, Wrist Pin —

© Copyright 10.7
C R A N K C A S E FA S T E N E R L E N G T H A N D T O R Q U E PAT T E R N
NOTICE
Items 1, 3, 4, 11, 13 & 15 use Long fasteners. All other
items use Short fasteners.
Torque case fasteners to specification following the

torque sequence.
TORQUE
Crankcase Fasteners:
22 ft-lbs (30 N·m)

10.8 © Copyright
TRANSMISSION
Input Shaft
NUMBER DESCRIPTION
q Input Shaft, Transmission
w Gear, 5th — Drive
e Bearing, 5th Gear
r Bearing, 6th Gear
t Slider, Gear Dog
y Gear Dog, 5th & 6th
u Gear, 6th — Drive
i Gear, 4th — Drive 10

o Gear, 2nd — Drive
a Snap Ring (not used on 2014–16 models)

© Copyright 10.9
Output Shaft
NUMBER DESCRIPTION
q Snap Ring (not used on 2014–16 models)
w Spacer
e Gear, 1st — Driven
r Bearing, 1st Gear
t Slider, Gear Dog
y Gear Dog
u Gear, 3rd — Driven
i Bearing
o Gear, 5th — Driven
a Gear, 6th — Driven
s Gear, 4th — Driven
d Gear, 2nd — Driven
f Bearing, 2nd Gear
g Output Shaft, Transmission

10.10 © Copyright
SHIFT DRUM / SHIFT FORK
NUMBER DESCRIPTION
q Bearing, Shift Drum — Drive Sprocket Side
w Gear Dog
e Slider, Gear Dog
r Shift Fork, 5th & 6th
t Shift Rail
y Bearing, Shift Drum — Primary Side
u Shift Fork, 1st & 3rd
i Shift Fork, 2nd & 4th
o Shift Drum
10

© Copyright 10.11
BALANCE SHAFT
q Fastener, Balance Shaft Gear — M10 x 1.5 x 40 59 ft-lbs (80 N·m)

(QTY.1)
w Washer -
e Snap-Ring, Balance Shaft Split Gear -
r Gear, Balance Shaft (Outer) — Non-Serviceable -
t Springs, Pre-Load — Non-Serviceable -
y Gear, Balance shaft (Inner) — Non-Serviceable -
u Fastener, Bearing Retainer Plate — M5 x 0.8 x 12 62 in-lbs (7 N·m)

(QTY.3)
i Bearings, Balance Shaft -
o Balance Shaft -

10.12 © Copyright
GEAR TRAIN
1st Gear
2nd Gear
10

© Copyright 10.13
3rd Gear
4th Gear

10.14 © Copyright
5th Gear
6th Gear
10

© Copyright 10.15
BALANCE SHAFT SERVICE

I N N E R C A M C H A I N C O V E R R E M O VA L B A L A N C E S H A F T R E M O VA L
1. Remove the camshaft carrier assembly. See 1. Remove the inner cam cover. See Inner Cam Chain
Camshaft Carrier Removal page 7.19. Cover Removal page 10.16.
2. Remove inner cam chain cover fasteners q and 2. Remove the fastener q and balance shaft gear w .
inner cam chain cover w.
IMPORTANT
Be sure to collect the woodruff key from the end of
the balance shaft once the gear has been removed.
3. Separate the engine cases. See Crankcase

Separation page 10.22.
4. Rotate balance shaft e until counterweights are
clear of crankshaft. Grasp balance shaft and
remove it from case.
5. Check shaft for runout, or twisting.

6. Rotate right and left balance shaft bearings by
hand while observing bearing rotation. Bearings
should run smooth and quiet and shaft should be a
snug fit in bearing.
7. Visually inspect bearings for damage.

10.16 © Copyright
B A L A N C E S H A F T I N S TA L L AT I O N 8. Fit the driven balance shaft gear to the end of the

1. Lubricate balance shaft bearings with engine oil. balance shaft so the timing marks r are aligned as
shown.
2. Insert the balance shaft q into the primary side
bearing until fully seated. Woodruff key slot
should be facing the cam side of the engine.
9. Thread the driven balance shaft gear fastener t in

until seated.
3. Assemble the engine cases. See Crankcase
Assembly page 10.39.
4. Lock the crankshaft for service using Method 1.
See Locking the Crankshaft for Service page 7.12.
5. Install the balance shaft drive gear and torque
fasteners w to specification.
10. Torque the driven balance shaft gear fastener to

specification.
TORQUE
Balance Shaft Driven Gear:
59 ft-lbs (80 N·m)
11. Install the starter drive. See Starter Drive

10
TORQUE Installation page 10.20.
Balance Shaft Drive Gear:
10 ft-lbs (14 N·m)
6. Place the woodruff key into the end of the balance

shaft.
7. Place a pin punch, or other suitable tool, through
hole e and preload split gear teeth so they are
aligned.

© Copyright 10.17
12. Install the spacer y onto the crankshaft. 13. Install the inner cam cover. See Inner Cam Chain
Cover Installation page 10.18.
I N N E R C A M C H A I N C O V E R I N S TA L L AT I O N
1. Clean inner cam chain cover and crankcase 5. Install the camshaft carrier assembly. See
mating surfaces with a residue-free degreaser. Camshaft Carrier Installation page 7.24.
2. Apply Loctite 598 flange sealant to cover and
assemble to crankcase.
3. Thread inner cam chain cover fasteners into
crankcase so they are finger tight.
4. Tighten inner cam chain cover fasteners following
the specified torque sequence.
TORQUE
Inner Cam Chain Cover Fasteners:
15 ft-lbs (20 N·m)

10.18 © Copyright
S TA R T E R D R I V E S E R V I C E
S TA R T E R D R I V E R E M O VA L S TA R T E R D R I V E I N S P E C T I O N
1. Remove the inner cam cover. See Inner Cam Chain 1. Inspect gear teeth for chips, cracks or excessive
Cover Removal page 10.16. wear.
2. Remove the starter drive reduction gear q by 2. Inspect shaft surfaces q and bushing surfaces w
lifting the shaft and gear out as an assembly. e r for excessive wear and scoring.
3. Lift the sprag gear w and one-way clutch e off of 3. Inspect one-way clutch hub surfaces t y for
the crankshaft as an assembly. wear, scoring or damage.
4. Measure the I.D of the balance shaft gear bearing
surface t and the O. D. of the flywheel bearing
surface y and compare to specification.
4. Remove the torque limiter clutch r and shaft as an

assembly.
10
One-Way Clutch Hub I.D. (Balance Shaft Gear):
68.38 mm ±.013 mm
One-Way Clutch Hub O.D. (Flywheel):

51.71 mm ±.007 mm
5. Replace gear if wear or damage is evident.

© Copyright 10.19
S TA R T E R D R I V E I N S TA L L AT I O N 3. Install the torque limiter shaft e into the crankcase

1. bore followed by the limiter clutch assembly r .
NOTICE
Install starter clutch so the arrow is facing out.
Install one-way starter clutch bearing q into the

balance shaft gear hub.
4.
NOTICE
If previously removed, install starter motor at this
time.
2. Install flywheel w over crankshaft and into the Install the starter reduction gear shaft t into
one-way clutch bearing until fully seated. crankcase bore followed by the reduction gear y .
The raised shoulder on the reduction gear
should face the crankcase.

10.20 © Copyright
5. Install spacer u onto the crankshaft.
6. Install inner cam chain cover. See Inner Cam

Chain Cover Installation page 10.18.
7. Check engine oil and fill to proper level.
10

© Copyright 10.21
CRANKSHAFT SERVICE
C R A N K C A S E S E PA R AT I O N 19. Remove engine case fasteners.
2. Remove engine from frame. See Preparation For
Engine Removal page 6.5.
3. Mount engine securely on an engine stand using
Engine Stand Adapter tool PF-51240.
4. Remove cylinder heads. See Cylinder Head
Removal page 7.54.
5. Remove cylinders. See Cylinder Removal page
8.6.
6. Remove lifters. See Lifter Removal page 7.17.
Removal page 9.8.
20. Place the Engine Case Splitting / Assembly tool
8. Remove torque compensator. See Torque PF-51234 on a flat surface and assemble the M6
Compensator Removal page 9.21. threaded spacers q and M12 threaded spacer w
9. Remove clutch assembly. See Clutch Removal into the main plate e as shown. Use only holes
page 9.15. marked with the letter A.
10. Remove flywheel. See Flywheel Installation
page .
11. Remove stator. See Stator Removal page 15.31.
12. Remove the cam chain. See Cam Chain Removal
page 7.15.
13. Remove camshaft carrier assembly. See Camshaft
Carrier Removal page 7.19.
14. Remove the inner cam chain cover. See Inner Cam
Chain Cover Removal page 10.16.
15. Remove the starter drive. See Starter Drive
Removal page 10.19.
16. Remove the balance shaft driven gear and drive
gear. See Balance Shaft Removal page 10.16. 21. Rotate the engine stand so the engine is lying flat
with the output shaft pointing UP.
17. Remove the drive sprocket. See Drive Sprocket
Removal page 12.13.
18. Remove the gear position switch. See Gear
Position Switch Replacement page 17.35.
NOTICE
If applicable, collect the two switch contact pins and
springs from the end of the shift drum so they do not
get lost.

10.22 © Copyright
22. Position the main plate assembly r onto the 24. Main plate adjustment: Turn threaded spacers
engine case as shown. The threaded spacers in or out to raise, lower and level the main
should line up with the corresponding engine case plate.
fastener holes.
IMPORTANT
• Plate surface should be parallel to the surface of

the engine crankcase.
• Plate height is correct when the plate is resting on
the washer and the case splitting adapter contacts
the transmission output shaft.
• All threaded spacers must be in contact with
engine case prior to fastening on the plate
assembly.
23. Install the case splitting adapter through the

center hole in the main plate and thread into nut
and washer t until 1– 2 threads are exposed on
the other side.
25. Install M6 fasteners y and M12 fastener u into

threaded spacers and torque to specification.
10
TORQUE
Main Plate Mounting Fasteners (All):
88 in-lbs (10 N·m)

© Copyright 10.23
26. Holding nut i stationary with an open ended

wrench, turn the case splitting adapter clockwise
until the engine cases begin to part. STOP.
27. Using a soft-faced mallet, work around the seam of

the engine cases tapping lightly to release the
sealed bond.
28. Alternately turn the case splitting tool in until
resistance is felt, then work around the upper case
with a mallet until the cases are completely apart.

10.24 © Copyright
T R A N S M I S S I O N R E M O VA L 5. As an assembly, lift the input shaft e , output shaft

r , shift forks and shift fork rails t out of the
CAUTION engine case.
Gloves should be worn at all times while working on
the transmission assembly to avoid personal injury.
1. Remove the shift ratchet assembly. See Shift

Ratchet Removal & Inspection page 9.10.
2. Remove the balance shaft. See Balance Shaft
Removal page 10.16.
3. Lift both of the shift fork rails q out of the
crankcase just enough so the ends clear the
crankcase bores. Rotate rails and forks away from
the shift drum.
TRANSMISSION INSPECTION
Input Shaft
4. Lift the shift drum w out of the bearing.
10

© Copyright 10.25
NUMBER MEASUREMENT LOCATION DIAMETER SPECIFICATION

q Gear, 5th — I.D. 39.010 — 39.026 mm
w Bushing, 5th Gear — O.D. 38.955 — 38.980 mm
e Bushing, 5th Gear — I.D. 32.010 — 32.035 mm
r Input Shaft, Clutch Collar Journal 29.470 — 29.485 mm
t Input Shaft, Bearing Journal 29.976 — 29.990 mm

(Primary Side)
y Gear, 6th — I.D. 39.010 — 39.026 mm
u Bushing, 6th Gear — O.D. 38.955 — 38.980 mm
i Input Shaft, 2nd Gear Journal 27.987 — 28.0 mm

(Press Fit)
o Gear, 2nd — I.D. (Press Fit) 27.884 — 27.909 mm

10.26 © Copyright
Output Shaft
NUMBER MEASUREMENT LOCATION DIAMETER SPECIFICATION

q Gear, 2nd — I.D. 39.010 — 39.026 mm
w Bushing, 2nd Gear — O.D. 38.955 — 38.980 mm
e Bushing, 2nd Gear — I.D. 32.010 — 32.035 mm
r Gear, 4th — I.D. 39.010 — 39.026 mm
t Bushing, 4th Gear — O.D. 38.955 — 38.980 mm
y Gear, 3rd — I.D. 39.010 — 39.026 mm
u Output Shaft, Bearing Journal (Drive Sprocket 34.995 — 35.008 mm

Side)
i Bushing, 3rd Gear — O.D. 38.955 — 38.980 mm 10

o Gear, 1st— I.D. 37.010 — 37.026 mm
a Bushing, 1st Gear — I.D. 28.015 — 28.040 mm
s Bushing, 1st Gear — O.D. 36.965 — 36.990 mm
d Output Shaft, 1st Gear Journal 27.987 — 28.0 mm

© Copyright 10.27
NOTICE 9. Temporarily install shift drum into bearing and

rotate, checking for smooth bearing operation.
Refer to the Assembly View section in this chapter
for component locations and exploded diagrams. Shift Drum
See Crankcase page 10.6. 10. Inspect shift drum grooves for wear. Pay close
Refer to the Service Specifications section in this attention to corners of grooves where forks change
chapter for complete transmission specifications. direction.
See Service Specifications page .
11. Inspect surface of shift drum star for excessive
wear or damage.
Shafts
12. Inspect right side shift drum bearing.
1. Measure outside diameter of shafts and bearing
areas for wear and concentricity. Look closely at 13. Temporarily install shift drum in right hand case
splines for wear. Inspect ends of shafts for signs of bearing and inspect fit. Spin drum to check for
wear: smooth bearing operation.
• Dull finish
• Discoloration
C R A N K S H A F T R E M O VA L
1. Separate RH crankcase from LH case. See
• Rough or uneven surface Crankcase Separation page 10.22.
• Measurement outside of specification 2. Rotate balance shaft q until counterweights are
clear of crankshaft.
Gears
2. Visually inspect:
• Gear internal splines
• Gear teeth
• Gear dogs for rounding, cracks, chips
• Gear dog slots for rounding
• Bearing surfaces
• Shift fork grooves
Check each gear for damage, cracks, wear

(rounding of dogs or surfaces), or discoloration.
Shift Forks, Shift Fork Rails
3. Inspect all contact surfaces of each shift fork.
Replace a shift fork if any part is discolored
(overheated), unusually scored, warped, or worn
beyond service limit.
4. Inspect each shift fork pin for wear or damage and
compare to specifications.
5. Inspect shift fork rails for wear, scoring, or runout.
6. Measure shift fork rail O. D. for wear in 3 or 4
places along the length. The rail O. D. should be
consistent over the entire length.
7. Slide rails into crankcase holes and check for a
good snug fit.
8. Visually inspect the shift drum bearing in the left
crankcase for wear or damage. The bearing must
be fully seated in the case and held in position by
the retaining plate. Replace the bearing if it is
loose in the bore, or if any side play is detected.

10.28 © Copyright
3. Lift crankshaft assembly w straight up until clear C O N N E C T I N G R O D R E M O VA L /

of case. I D E N T I F I C AT I O N
NOTICE
The connecting rod caps are marked with paint from
the factory, however it is recommended that an
additional reference mark be added for clarity. Caps
are matched to rods and MUST be installed with
the proper orientation left to right and front to
back. DO NOT strike or stamp the connecting rod.
1. Use a permanent marker to mark orientation of

connecting rods and rod bearing caps. These
parts MUST be installed in their original
locations. EXAMPLE: Right connecting rod must
be assembled on the right side with the bearing
cap that was removed from it. The bearing cap and
connecting rod must be assembled in the same
NOTICE direction as it was removed using the same
Connecting rod bearings and main bearings are fastener.
easily damaged. Be careful not to cause damage to 2. Mark the outside of both connecting rods prior to
these parts when servicing items within the removal so they can be assembled in the same
crankcase. direction in relation to the crankshaft.
CONNECTING ROD SIDE CLEARANCE

INSPECTION
1. Move connecting rods to one side of crankshaft.
Insert a feeler gauge q between one connecting
rod and the crankshaft. Compare measurement to
specification outlined in this chapter. See Service
Specifications page .
3. Remove connecting rod fasteners and connecting

rod bearing caps.
NOTICE
It may be necessary to lightly tap the caps with a 10
plastic mallet to loosen them.
CAUTION
The mating surface of connecting rod and cap is
2. If clearance recorded exceeds service limit, the rough in appearance, which is a normal condition
crankshaft, connecting rod or both must be due to the manufacturing process. If rod caps are
inspected and worn parts replaced. See installed incorrectly and tightened, the precision
Crankshaft Inspection page 10.33. mating surfaces will be damaged. Replace the
connecting rod assembly if mating surfaces are
damaged.

© Copyright 10.29
CONNECTING ROD INSPECTION (BIG END) 3. Apply engine oil to threads of rod fasteners.
Torque fasteners to specification.
IMPORTANT
Connecting rod fasteners can only be reused
three times. Failure to replace fasteners after
completing three torque sequences may result in
severe engine damage. Each time a fastener has
been torqued to specification, it should be marked
with a center punch.
EXAMPLE:
• 1st Torque: Manufacturer installation of connecting
rod fasteners.
• 2nd Torque: Torque for inspection per this
procedure.
• 3rd Torque: Reinstallation following inspection.
Discard fasteners the next time they are
removed. TORQUE
Connecting Rod Fasteners:
1. Refer to Piston Pin / Pin Bore Inspection page 8.9 22 ft-lbs (30 N·m) + 90°
for connecting rod small end inspection.
CAUTION TORQUE
Be sure to match connecting rod caps with their I-18-06 Connecting Rod Fasteners:
respective rod and orient the cap properly before 46 ft-lbs (62 N·m)
installing the cap. Secure the big end of rods in a vise
equipped with soft, protective jaws before torquing
4. Measure I. D. of connecting rod big end for size
rod fasteners.
and out of round and compare to specification. See
Service Specifications page .
5. Visually inspect connecting rod upper and lower
ends for scoring, damage, or excessive wear.
CONNECTING ROD BEARING INSPECTION

1. Inspect bearing inserts for unusual wear, peeling,
scoring, damage etc. Replace as a set if damage is
noted. Inspect bearing clearance and refer to
Bearing Selection Chart. See Connecting Rod
Bearing Selection page 10.32.
CONNECTING ROD BEARING CLEARANCE

INSPECTION
2. Remove bearings and install caps on connecting 1. Assemble the connecting rod cap with bearings
rods. Be sure mating surfaces q of rod and cap are and torque to specification.
clean.
TORQUE
22 ft-lbs (30 N·m) + 90°
TORQUE
I-18-06 Connecting Rod Fasteners:
46 ft-lbs (62 N·m)

10.30 © Copyright
2. Measure the connecting rod big end bearing I. D.

with a dial bore gauge and record.
3. Measure the connecting rod journal on crankshaft

and record.
4. Subtract the journal diameter from the connecting
rod bearing diameter to calculate oil clearance
and compare to specification. See Service
5. If service limits are exceeded, install new rod
bearings and recheck oil clearance.
6. If service limits are still exceeded, determine if
crankshaft or connecting rods need to be
replaced.
10

© Copyright 10.31
CONNECTING ROD BEARING SELECTION 4. Refer to the chart below to select the proper
1. There are 3 sizes of connecting rod bearings bearing insert.
available: Black, Orange and Blue (see chart FOR EXAMPLE: If the CONNECTING ROD paint
below). mark is RED and the CRANKSHAFT stamp is W
2. To determine which bearing to use, look at the (white) (or not stamped), use BLUE bearing
color code on RH end of crankshaft. “R” for Red inserts.
and “W” for White. The letter will be stamped
onto the counterweight.
3. The color code on the connecting rod appears in
the form of a painted mark on the side facing away
from the center of the crankshaft.
CONNECTING ROD BEARING SELECTION CHART

Connecting Rod Color Crankshaft Color Bearing Color (P/N 3514790- Bearing Thickness
xxx)
WHITE Paint Mark RED (“R” Stamp) Black ( - 067 ) 1.474 — 1.479 mm
WHITE Paint Mark WHITE (“W” Stamp Orange ( - 159 )
or not marked)
1.478 — 1.483 mm
RED Paint Mark RED (“R” Stamp) Orange ( - 159 )
RED Paint Mark WHITE (“W” Stamp Blue ( - 027 ) 1.482 — 1.488 mm
or not marked)

10.32 © Copyright
CRANKSHAFT INSPECTION C O N N E C T I N G R O D I N S TA L L AT I O N
Record all measurements and compare to
1. Make sure proper bearing clearance is achieved
specifications. Replace crankshaft if any measurement
by using the correct colored bearing insert for a
is worn beyond the service limit. See Service
given color combination of connecting rod and
crankshaft.
1. Measure the width of the rod bearing journal.
2. Clean all oil off connecting rod, connecting rod cap
and bearing inserts.
3. Install bearing inserts into connecting rods and
caps. First, install bearing tab into groove, then
press the rest of the bearing into place.
NOTICE
Procedure during disassembly called for marking of
connecting rods and caps. Ensure that each part is
installed in original location including rod cap
fasteners.
2. Measure width of connecting rods at big end.
4. Apply assembly lube to connecting rod bearings
and crank pin.
5. Install rods and caps onto the crankshaft,
observing the paint mark on the connecting rods.
The paint mark must face away from the center
of the crankshaft. Be sure the identifier marks
made previously are aligned.
3. Visually inspect all bearing journals for scoring,
damage or excessive wear. 6. Identify connecting rods and torque fasteners.
4. Crankshaft and connecting rods are identified by CONNECTING ROD IDENTIFICATION
color. Be sure to compare measurements to
specifications for the proper color (or non- 2014–2021 Connecting Bulletin I-18-06
marked) connecting rod or crankshaft. Rods Connecting Rods
Measure O. D. of crankshaft rod journal in four Fasteners go through Fasteners go through
places and compare to specifications. the cap and into the the rod and into the
rod. cap.
5. Measure O.D. of main bearing journals.

10
TORQUE
22 ft-lbs (30 N·m) + 90°
Left Right
TORQUE
I-18-06 Connecting Rod Fasteners:
46 ft-lbs (62 N·m)

© Copyright 10.33
7. Check that the connecting rods rotate smoothly

and freely on crankshaft journal.

10.34 © Copyright
CRANKSHAFT CLEANING MAIN BEARING OIL CLEARANCE

1. Remove blind plug q from crankshaft to ensure INSPECTION
that passages are clear. 1. Measure main bearing I.D. and concentricity with
a dial bore gauge for right and left side. Compare
to specification. Subtract crankshaft main journal
diameter from main bearing diameter to calculate
oil clearance. See Service Specifications page .
2. After cleaning passages, install blind plug and

torque to specification. Plug should be flush with
surface of crankshaft.
TORQUE
2. If crankshaft dimensions are within tolerances and
Blind Plug: oil clearances are incorrect, the crankcase set
15 ft-lbs (20 N·m) must be replaced or new main bearings installed
and line-honed by a competent machinist.
NOTICE
MAIN BEARING INSPECTION Replace crankcase halves as a set.
1. Inspect crankcase main bearing surfaces q & w
for wear, peeling, scoring, or damage.
2. Inspect alignment of bearing lubrication hole in
left crankcase half and in right case half. Holes
must be aligned with their respective oil passage
in crankcase.
10

© Copyright 10.35
L E F T C R A N K C A S E A S S E M B LY R I G H T C R A N K C A S E A S S E M B LY
Prepare LEFT crankcase for assembly: Prepare RIGHT crankcase for assembly:
Refer to crankcase assembly view for locations and Refer to crankcase assembly view for locations and
torque values. See Crankcase page 10.6. torque specification. See Crankcase page 10.6.
1. Clean crankcase and oil passage q thoroughly. 1. Clean crankcase oil passages q thoroughly. Rinse
Rinse and dry with compressed air. and dry with compressed air.
2. Install new ball bearings in crankcase as required. 2. Install new bearings in crankcase as required.
• Apply a film of lithium grease to outer race of • Apply a film of lithium grease to outer race of
bearings to prevent galling upon installation bearings to prevent galling upon installation.
• Press on outer race of bearings using an arbor press • Press on outer race of bearings using an arbor press
and a suitable arbor that is slightly smaller than and a suitable arbor that is slightly smaller than
bearing outside diameter bearing outside diameter.
• DO NOT press on inner race of ball bearings • DO NOT press on inner race of ball bearings.
3. Install bearing retainers as required and torque to 3. Install bearing retainers as required and torque to
specification. specification.
4. Install scavenge filter screen assembly. See
Lubrication System page 4.8.
5. Install new oil passage o-ring w .

10.36 © Copyright
C R A N K S H A F T I N S TA L L AT I O N
NOTICE
Install left engine case onto an engine stand.
1. If balance shaft is already in place, rotate the

balance shaft counter weight q out of the way
prior to crankshaft installation.
2. Apply assembly paste to main bearings.

3. Hold crankshaft over left crankcase and position
rods so that left side rod is in cutout for rear
cylinder and right side rod is in cutout for the front
cylinder.
4. Place crankshaft w into left crankcase half.
10

© Copyright 10.37
T R A N S M I S S I O N I N S TA L L AT I O N 6. Rotate shift rails away from shift drum bore and

1. If transmission shaft bearings were replaced, be install shift drum u .
sure all bearing retainer plate fasteners are
installed and tightened to specification. See
Crankcase page 10.6.
2. Working on a flat surface, assemble the input shaft
q and output shaft w so the gears are properly
meshed.
3. Install shift rails e into shift forks and assemble to
input and output shafts.
7. Rotate shift drum to align proper grooves with

forks.
8. Move shift fork pins into drum grooves and seat
rails.
9. Install balance shaft. See Balance Shaft Installation
page 10.17.
10. Instal oil pump assembly. See Oil Pump
4. Lubricate parts with engine oil. Apply assembly
lube to ends of transmission shafts. 11. Install crankshaft. See Crankshaft Installation page
10.37.
5. Install input shaft r and output shaft t, shift forks
and rails y into the left crankcase. Make certain 12. Assemble crankcase. See Crankcase Assembly
both shafts are fully seated and rotate freely. page 10.39.

10.38 © Copyright
C R A N K C A S E A S S E M B LY 5. Place the Engine Case Splitting / Assembly tool

1. Clean crankcase mating surfaces to remove all PF-51234 on a flat surface and assemble the M6
grease, oil, and old sealant. threaded spacers r and M12 threaded spacer t
into the main plate y as shown. Use only holes
2. Check to be sure all shafts are seated properly
marked with the letter A.
(crankshaft, balance shaft, shift drum, shift forks,
input shaft, output shaft).
3. Check to be sure that a new oil passage o-ring q ,
alignment dowel pins and oil pipes, etc. are in
place.
6. Install case assembly adapter u , nut i and

washer o onto main plate.
4. Remove the drive sprocket spacer w and o-ring e

from the right-hand crankcase prior to installation.
10

© Copyright 10.39
7. Install the main plate assembly a to the right- 8. Apply a light even bead of LoctiteTM Ultra Black
hand crankcase and torque fasteners to 598 to entire case sealing surface.
specification.
9. Spread sealant into a thin even layer on entire case

mating surface. Be sure all areas are covered. DO
IMPORTANT
NOT ALLOW SEALANT TO DRY. CONTINUE
ASSEMBLY UNTIL CASES ARE SEALED AND ALL
• Plate surface should be parallel to the surface of FASTENERS ARE TIGHT.
the engine crankcase.
10. Lower the right-hand case onto the left-hand case
• All threaded spacers must be in contact with and install the case installation adapter onto the
engine case prior to fastening on the plate transmission output shaft.
assembly.
11. Pull crankcase together by tightening nut and
tapping on crankcase with a soft mallet.
NOTICE
The cases will mate before the output shaft is drawn
fully into bearing. IMPORTANT! Continue to turn
nut and tap case until sealant squeezes out along the
entire perimeter and resistance is felt when turning
nut.
12. Remove the tool.

13. Install crankcase fasteners and torque to
specification. See Crankcase Bolt Length And
Torque Pattern page 10.8.
14. Install a new output seal in right-hand crankcase
using seal installer PF-51243.
15. Install the o-ring and drive sprocket spacer
TORQUE removed in STEP 4 with tapered edge toward the
Main Plate Mounting Fasteners (All): o-ring.
88 in-lbs (10 N·m) 16. Install the gear position switch. See Sensors —
Powertrain Management page 5.12.
17. Install the drive sprocket. See Drive Sprocket
18. Install the balance shaft driven gear and drive
gear. See Balance Shaft Installation page 10.17.
19. Install the starter drive. See Starter Drive

10.40 © Copyright
20. Install the inner cam chain cover. See Inner Cam
Chain Cover Installation page 10.18.
21. Install the camshaft carrier assembly. See
Camshaft Carrier Installation page 7.24.
22. Install the cam chain. See Cam Chain Installation
page 7.16.
23. Install the stator. See Stator Installation page 15.32.
24. Install the flywheel. See Flywheel Installation
page .
25. Install the clutch assembly. See Clutch Installation
page 9.20.
26. Install the torque compensator. See Torque
27. Install the primary cover. See Primary Cover
28. Install lifters. See Lifter Installation page 7.18.
29. Install cylinders. See Cylinder Installation page
8.11.
30. Install cylinder heads. See Cylinder Head
page 6.11.
10

© Copyright 10.41
S TA K E N U T I N S TA L L AT I O N
• The Stake nut is located on the clutch side of the
transmission input shaft.
• It is important that they are torqued and staked
correctly for proper function
IMPORTANT
Do not reuse or reinstall any previously used stake
nut. A new stake nut needs to be installed every time
the nut is removed or loosened.
Use the following procedure to install the stake nuts

correctly:
1. Clean threads on shaft so there is no oil or
contaminants.
2. Thread NEW stake nut onto shaft finger tight.
3. Torque stake nut to specification.
4. Stake the stake nut using round side of punch. Do
not crack or tear staking lip. Do not use a sharp
chisel to stake the nut.

10.42 © Copyright
TROUBLESHOOTING
RECOMMENDED
Transmission Will Not Broken Shift Cam Shift Cam Replace shift cam
Shift
Bent Shift Forks Shift Fork Replace shift fork(s)
Worn Gearshift Pawl Shift Cam Replace shift cam
Broken Gears Transmission Gears Replace necessary parts
Damaged/Broken Transmission, Shift Cam Replace necessary parts
Bearings Bearings
Worn Gear Shift Ratchet Shifter Ratchet Refer to Clutch / Primary
Mechanism / Shift chapter
Broken or out-of-place Shift Ratchet Spring Refer to Clutch / Primary
spring on shift ratchet / Shift chapter
Shift Detent Ratchet Stuck Shift Ratchet Repair as necessary
Seized Pivot Point, Bent External Shift Linkage Repair as necessary
External Shift Linkage
Bent or Distorted Shift Shift Fork Rails Replace Shift Fork Rails
Fork Rails
Debris From Broken Parts Transmission Repair as necessary
Locking Transmission Components
Excessive Noise Related Worn Main Bearings Crankshaft and/or Repair as necessary
to Bottom End of Engine Crankshaft Bearings
Worn Connecting Rod Connecting Rod Bearings Repair as necessary
Bearings and/or Connecting Rod
and/or Rod Bearings
Worn Connecting Rod Connecting Rod, Repair as necessary
Small End Bushing Connecting Rod Bushing,
Piston Pin, Piston
Worn, seized, chipped or Transmission Gears Repair as necessary
broken gear teeth
Worn, seized, chipped or Transmission Bearings Repair as necessary
broken Transmission
Bearings 10
Originates from Primary Clutch, Torque Repair as necessary
Cover Compensator, Flywheel,
Oil Pump Drive
Oil Pump Oil Pump, Oil Pump Drive Refer to Engine / Cooling
/ Exhaust chapter
Cam Drive Cam Chain, Cam Refer to Engine / Cooling
Sprocket / Exhaust chapter

RECOMMENDED
Transmission Hard to Shift Improper Clutch Clutch Refer to Clutch / Primary
Operation / Shift chapter

© Copyright 10.43

RECOMMENDED
Incorrect Oil Viscosity Engine oil and filter Refer to Engine / Cooling
/ Exhaust chapter
Incorrect Clutch Clutch Adjustment Refer to Clutch / Primary
Adjustment / Shift chapter
Bent, Rubbing, Sticky, Shifter Ratchet Assembly Refer to Clutch / Primary
Broken Shift Shaft / Shift chapter
Sticking Pivot Point, Bent External Shift Linkage Repair or replace
External Shift Linkage components as necessary
Bent or Distorted Shift Shift Forks Replace bent shift fork
Forks
Damaged Shift Drum Shift Drum Replace damaged shift
Grooves drum
Shift Ratchet Bent / Stuck Shift Ratchet Repair as necessary
Bent or Distorted Shift Shift Fork Rails Replace Shift Fork Rails
Fork Rails
Transmission Jumps Out Broken Shift Stop Pin Shift Stop Pin Replace stop pin
of Gear
Worn Shift Drum Pawls or Shift Drum or Shift Replace damaged shift
Shifter Ratchet Linkage drum or shifter ratchet
Broken Shift Ratchet Shift Ratchet Spring Replace spring
Spring
Damaged Shift Drum Shift Drum Replace shift drum
Grooves
Bent, Worn, Distorted Shift Forks Replace shift forks
Shift Forks
Bent or Distorted Shift Shift Fork Rails Replace shift fork rails
Fork Rails
Worn Engagement Dogs Transmission Gears Replace necessary parts
on Transmission Gears

10.44 © Copyright
FRONT WHEEL / SUSPENSION
CHAPTER 11
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2
ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.4
HANDLEBAR CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.4
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.5
FRONT FORK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.6
TRIPLE CLAMP (16 INCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.7
FRONT WHEEL - CAST (16 INCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.8
FRONT WHEEL - SPOKED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.9
SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10
HANDLEBAR, REMOVAL / INSTALLATION (ALL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10
CLUTCH CABLE, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11
FRONT WHEEL, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12
FRONT AXLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13
FRONT WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13
BRAKE DISC REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13
FRONT WHEEL BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.14
FRONT WHEEL BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.15
FRONT FORK REMOVAL (ALL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.15
FRONT FORK DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.17
FRONT FORK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.20
FRONT FORK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.21
FRONT FORK INSTALLATION (ALL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25
TRIPLE CLAMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.27
FRONT FORK LOCK REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.29
TRIPLE CLAMP INSTALLATION / STEERING HEAD BEARING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 11.30
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.32
11

© Copyright 11.1
SERVICE NOTES SPECIAL TOOLS
WARNING TOOL DESCRIPTION PART NUMBER
Fork Spring Compressor PV-49463
Indian Motorcycles are produced using the
designated tires listed as original equipment. This Fork Spring Compressor
Adapter PV-49464
includes field testing to ensure stability and superior
handling. The use of tires other than original Cartridge Shaft Tool PV-49452
equipment may cause instability which could lead to
a crash, resulting in serious injury or death. Use only Damper Rod Holder PV-49453
the recommended tires inflated to the recommended Fork Oil Level Tool PV-59000-A
tire pressures based on load conditions as listed on Fork Seal Driver PV-49494
the tire information label.
Tubeless tires are used on certain Indian Motorcycle Wheel / Stem Bearing
PF-51324
models. Operating the motorcycle with damaged Removal / Installation Kit
rims creates a safety hazard including air pressure Spanner Socket
(Steering Stem) PV-43508
loss, steering imbalance and/or reduced steering
control. Do not attempt to repair or straighten
damaged rims.
CAUTION PART DESCRIPTION TORQUE
SPECIFICATION
Work performed to the front end of the motorcycle
usually involves supporting the machine with the ABS Pulse Ring / Brake Disc 22 ft-lbs (29.8 Nm)
front end elevated. Take precautions so that the Fasteners
motorcycle is securely supported when the front tire Cartridge Fastener, Fork 17 ft-lbs (23.0 Nm)
is off the ground. This reduces the possibility of Clutch Lever Cap Fastener 70 in-lbs (7.9 Nm)
personal injury or damage to the motorcycle.
Fairing Mount Studs
Fairing Support Nuts 12 ft-lbs (16.3 Nm)
Leaking front fork seals are a safety hazard and should
be replaced immediately if a leak is found. Fork oil Fork Cap to Jam Nut 11 ft-lbs (14.9 Nm)
could contaminate front brake components which Fork Cap to Outer Tube 16 ft-lbs (21.6 Nm)
could reduce stopping ability of the motorcycle. Front Axle 52 ft-lbs (70.5 Nm)
Contaminated brake discs or pads greatly reduce
available stopping force & increase stopping distance. Front Axle Pinch Fasteners 18 ft-lbs (24.4 Nm)
Brake discs can be cleaned using commercially Front Master Cylinder 70 in-lbs (7.9 Nm)
available brake cleaner. NEVER attempt to clean
contaminated brake pads. Replace pads as a set. Grip Retaining Fastener 35 in-lbs (4.0 Nm)
LH Switch Cube 31 in-lbs (3.5 Nm)
• Refer to MAINTENANCE chapter for front end RH Switch Cube 31 in-lbs (3.5 Nm)
components service.
Riser Fasteners 60 ft-lbs (81.3 Nm)
• Refer to Steering / Suspension chapter for TIRE
REMOVAL, REPAIR, & BALANCING Riser Cap Fasteners 18 ft-lbs (24.4 Nm)
Steering Lock Fasteners 18 ft-lbs (24.4 Nm)
• Refer to Brakes chapter for BRAKE SYSTEM
service and repairs. Steering Stem Adjuster Nut 29 ft-lbs (39.3 Nm)
Triple Clamp Nut, Top 72 ft-lbs (97.6 Nm)
Triple Clamp Pinch Fasteners 18 ft-lbs (24.4 Nm)
(All)

11.2 © Copyright
ITEM STANDARD SERVICE
Axle Runout - .20 mm (.008")
Front Wheel Runout Axial .50 mm (.020") 2.0 mm (.080”)
(Cast and Spoked Type)
3.5" x 16" Radial .50 mm (.020") 2.0 mm (.080”)
Cast 3.5” x 19”
Fork Tube Diameter 46 mm Not Applicable
Fork Tube Runout - .20 mm (.008")
Fork Oil Type Indian Motorcycle Fork Oil (PN: 2880015)
Fork Spring Pre-Load 1.3“ (34.5 mm) Not Applicable
56 - 114 lb/in (9.8 - 20.0
Fork Spring Rate Not Applicable
N/mm)
Fork Spring Free Length 457.9 mm (18.02 in) -
Measured with spring
Fork Oil Level (From Top of
removed, inner tube fully 136 mm (5.35") +1 mm (.039”)
Tube)
compressed.
Oil level must be measured
Fork Oil Capacity (per leg,
and adjusted to 550 cc (550 ml) Set Level
dry)
specification.
11

© Copyright 11.3
HANDLEBAR CONTROLS
q Bar End Trim Cap Push Evenly Until Fully Seated and Tabs Engage
w Clutch Lever Cap Fastener 96 in-lbs (11 N·m)

IMPORTANT
Torque the Clutch Lever Cap upper fastener first
and the bottom fastener second.
e Brake Lever Cap Fastener 96 in-lbs (11 N·m)
r Grip Retainer Fastener 35 in-lbs (4 N·m)
t Right-Hand Switch Cube 12 in-lbs (1 N·m)

Fastener
y Left-Hand Switch Cube 12 in-lbs (1 N·m)
Fastener

11.4 © Copyright
HANDLEBAR
q Riser Fastener (QTY.2) 60 ft-lbs (81 N·m)
w Washer -
e Isolator -
r Spacer -
t Riser Cap Fastener (QTY.4) 18 ft-lbs (24 N·m) Tighten front fastener
then rear.
11

© Copyright 11.5
F R O N T F O R K A S S E M B LY
q Fork Leg Assembly -
w Metal Slide -
e Washer -
r Oil Seal -
t Snap Ring -
y Dust Seal -
u Cap Assembly -
i Top Triple Clamp Nut 72 ft-lbs (98 N·m)
o Washer -
a Spring -
s Cylinder Assembly -
d Inner Fork Tube -
f Bushing -
g Oil Lock -
h Fork Cover -

11.6 © Copyright
TRIPLE CLAMP (16 INCH)

q Lower Triple Clamp -
Lower Fork Clamp Fastener (QTY.4) 18 ft-lbs (24 N·m)
w Lower Fork Clamp Fastener (QTY.4) -
23 ft-lbs (31 N·m)
Springfield models
e Steering Post Clip -
r Steering Stem -
t Sealed Bearing – 22 x 55 x 17 -
y Ball Bearing — 47 x 25 x 12 -
u Steering Lock Fastener (QTY.2) 18 ft-lbs (24 N·m)
i Steering Lock -
See Tightening Procedure Outlined in this
o Steering Head Nut
Chapter
a Upper Fork Clamp Fastener (QTY.2) 18 ft-lbs (24 N·m)
s Upper Triple Clamp - 11
d Washer -
f Top Triple Clamp Nut 72 ft-lbs (98 N·m)
IMPORTANT
A Service Kit is required to upfit a 16” to 19” front wheel. The service kit will include all the triple clamp parts
required for adequate clearance. See the polaris parts for specific kit details.

© Copyright 11.7
FRONT WHEEL - CAST (16 INCH)
q Outer Bearing Spacer -
w Pulse Wheel / Brake Disc Fastener (QTY.6 per disc) 22 ft-lbs (29.8 Nm)
e ABS Pulse Wheel -
r Brake Disc -
t Seal -
y Wheel Bearing -
u Inner Bearing Spacer -

11.8 © Copyright
FRONT WHEEL - SPOKED
q Outer Bearing Spacer -
w Pulse Wheel / Brake Disc Fastener (QTY.6) 22 ft-lbs (30 N·m)
e ABS Pulse Wheel -
r Brake Disc -
t Seal -
y Wheel Bearing -
u Inner Bearing Spacer -
11

© Copyright 11.9
SERVICE PROCEDURES
H A N D L E B A R , R E M O VA L / I N S TA L L AT I O N 7. Remove front brake master cylinder assembly. See
(ALL MODELS) Front Master Cylinder Service page 14.28.
WARNING CAUTION
Clutch cable must be routed, installed, and Keep brake reservoir in an upright position to
adjusted correctly to function properly. Note how prevent air from entering the system. Bleeding is
cable is routed and secured before removing the required if air enters the system.
cable. Permanent cable damage may result if the
inner cable is bent or twisted during installation.
8. Remove the clutch lever assembly. See Handlebar
If the cable is incorrectly routed, installed, or
Controls page 11.4.
adjusted, serious injury or death may occur.
9. Place a soft piece of cloth or padded material on
the top of the fuel tank if tank has not been
CAUTION removed.
Cover painted or chrome parts to prevent damage. 10.
Use care to protect fuel tank and front fender. Tank
removal is recommended. Secure, set aside, or NOTE
support parts as they are removed. Make an index mark on the handlebar along the
parting line of the riser cap to ensure proper
handlebar position upon reassembly.
front wheel clamped in a wheel vise. If risers will be removed, remove handlebars /
Chieftain / Roadmaster: risers as an assembly. If risers will not be removed,
hold the handlebars in place and loosen the rear
2. Remove outer fairing. See Outer Fairing Removal, handlebar clamp screws w , and then the front w .
Chieftain / Roadmaster page 3.40.
11. Remove the riser cap e.
3. Remove instrument cluster. See Instrument Panel
Removal / Installation - (Chieftain Dark Horse)
page 3.38.
4. Remove four nuts q and washers securing the
inner fairing support to the triple clamp assembly.
12. Lift handlebars out of riser clamps (or the risers off
of the upper triple clamp).
removal procedure.
5. Noting harness routing and connector locations, 14. Line up the handlebar index mark made in STEP 10
disconnect all fairing electrical connectors and and torque riser caps, starting with the front bolts,
remove inner fairing support. to specification.
Classic / Vintage / Dark Horse / Springfield: TORQUE
6. Remove headlight nacelle and headlight bucket Riser Cap Bolts:
assembly.
18 ft-lbs (24.4 Nm) Tighten Front Bolts First,
All Models: then Rear

11.10 © Copyright
15. If handlebar assembly was removed with risers 4. Withdraw the clutch cable from the mounting boss
intact, torque riser bolts to specification. located on the primary cover.
TORQUE 5. At the handlebar, pull the clutch cable casing
straight out until clear of lever perch and rotate
Riser Bolts: cable outward to align inner cable wire with slot in
lever.
Chieftain / Roadmaster:
6. Pull lever slightly until slotted opening in lever is
16. Install the inner fairing support and torque nuts q clear of perch and slide cable barrel end down and
to specification. out of lever.
TORQUE 7. Note routing of clutch cable through frame.
Inner Fairing Support: 8. Loosen the fasteners r securing the left-hand
12 ft-lbs (16.3 Nm) frame downtube to the engine and steering head.
C L U T C H C A B L E , R E M O VA L / I N S TA L L AT I O N
Clutch Cable Removal
2. Remove the side stand bumper fastener q and the
clutch cable E-clip w .
9. Remove the clutch cable.
3. Protect the clutch release arm e with a shop towel.

Using an adjustable wrench, rotate the release arm
inward. Disconnect clutch cable from release arm.
11

© Copyright 11.11
Clutch Cable Installation

CAUTION
CAUTION CALIFORNIA MODELS: Remove the charcoal canister
prior to raising motorcycle wheels off the ground. As
Do not kink, bend, or twist the inner cable or outer
the swingarm lowers it can contact the canister hose
cable casing during installation
fittings and damage them.
1. Route clutch cable in the same manner as removed. 1. Secure the motorcycle in an upright position with
tie-down straps and a platform jack positioned
2. Torque the left-hand frame downtube fasteners to beneath the engine cases.
specification. See Engine Brackets / Fasteners
page 6.3.
3. Apply multi-purpose grease to the lever end of the
cable and install it in the clutch lever at the
handlebar.
4. Install the casing in the lever perch at the
handlebar.
5. Install cable in the mounting boss located on the
primary cover.
6. At the release arm end of the cable, pull the inner
cable until fully extended. Be sure the upper end of
the cable casing is seated in the lever perch at
handlebar end.
7. Apply multi-purpose grease to the lower barrel
end of the cable. NOTICE
8. Rotate the release arm inward until cable can be Do not operate the front brake lever with the calipers
installed in release arm. or wheel removed.
9. Install the clutch cable E-clip at the mounting boss.
Removal
10. Install the side stand bumper and fastener. Torque
to specification. 2. Remove the front fender. See Front Fender
Removal page 3.24.
TORQUE
3. Loosen axle pinch fasteners q on lower right fork
Side Stand Bumper: leg.
88 in-lbs (10 N·m)
11. Adjust clutch cable free play. See Clutch Lever Free
Play page 2.24.
F R O N T W H E E L , R E M O VA L / I N S TA L L AT I O N
WARNING
This procedure requires raising and supporting
the motorcycle so that the front wheel is off the
ground. Precautions should be taken to ensure
the motorcycle is properly stabilized at all times.
Failure to properly support motorcycle may result
in personal injury or damage to the motorcycle.
CAUTION
Do not twist the brake hose or brake line. Do not
allow calipers to hang from the brake hose. Secure
calipers in such a way to avoid hose damage.

11.12 © Copyright
4. Support wheel and remove axle w . Be prepared FRONT WHEEL INSPECTION

to catch spacers on each side of the wheel and 1. Install front wheel in truing stand.
remove wheel.
NOTICE
Bearings must be in good condition to accurately
measure runout.
2. Set up a dial indicator to measure radial runout (up

and down) (A) and compare to specifications.
3. Position dial indicator to measure axial runout
(side to side) (B) and compare to specifications.
Installation
5. Install front wheel and spacers into fork.
6. Install the axle and torque to specification.
TORQUE
Front Axle:
52 ft-lbs (71 N·m)
4. Visually inspect wheel for cracks.
7. Tighten axle pinch fasteners to specification.
5. Replace wheel if it fails visual or measured
TORQUE inspection. Do not attempt to straighten cast or
wheels.
Axle Pinch Fasteners:
18 ft-lbs (24 N·m)
B R A K E D I S C R E M O VA L / I N S TA L L AT I O N
8. Install front fender. See Front Fender Installation 1. Remove front wheel. See Front Wheel, Removal /
page 3.26. Installation page 11.12.
2. Position wheel with brake disc and ABS tone ring
FRONT AXLE INSPECTION facing up (protect the other disc and wheel when
removing opposite disc).
1. Place axle in V-blocks and inspect runout.
Compare to specifications in this chapter. 3. Remove and discard brake disc / tone ring
fasteners q .
11
2. Replace axle if it fails inspection. Do not attempt to

straighten a bent axle.

© Copyright 11.13
4. Remove tone ring w and brake disc e from 2. Check bearings by turning inner race by hand.
wheel.
• Look for signs of discoloration, scoring, galling, or
contamination from moisture or dirt. Replace
bearings if any of the above are present.
• Turn the inner race of the bearings. The bearings
should turn smoothly and quietly. The inner race
should be firm with minimal side to side movement
and no detectable up and down movement.
3. Discard bearings that fail any of the above
inspections.
CAUTION
Do not reuse bearings after removing them from the
wheel. Removal damages the bearings internally.
5. Flip wheel over and repeat procedure to remove 4. Inspect bearing fit into wheel hub. The outer race
opposite side brake disc (no tone ring on right- of the bearing must fit tightly into the bore. You
hand side). should not be able to move it (or remove it) by
hand. Replace the wheel if outer race of a new
6. Installation is performed by reversing the bearing does not fit tightly in the bore.
removal procedure. Use new brake disc
fasteners for installation
7. Torque new brake disc fasteners to specification in
a star pattern.
TORQUE
Brake Disc Fasteners:
22 ft-lbs (30 N·m)
FRONT WHEEL BEARING INSPECTION

NOTICE
Inspect bearings installed in the wheel. Do not
remove to inspect. Bearings cannot be repacked.
Replace both wheel bearings if one or both fail
inspection, or if either bearing was removed.
1. Visually inspect bearing seals q on each side for

wear or damage.

11.14 © Copyright
FRONT WHEEL BEARING REPLACEMENT F R O N T F O R K R E M O VA L ( A L L M O D E L S )

CAUTION WARNING
Do not reuse bearings that have been removed. This procedure requires raising and supporting
the motorcycle so that the front wheel is off the
ground. Precautions should be taken to ensure
NOTICE
the motorcycle is properly stabilized at all times.
This procedure requires the Wheel Bearing Removal Failure to properly support motorcycle may result
/ Installation Kit (PF-51324). Refer to special tool in personal injury or damage to the motorcycle.
manufacturer instructions for proper use of tool.
1. Remove front wheel. See Front Wheel, Removal / CAUTION

Installation page 11.12. Do not twist the brake hose or brake line. Do not
2. Remove brake discs. See Brake Disc Removal / allow calipers to hang from the brake hose. Secure
Installation page 11.13. calipers in such a way to avoid hose damage.
3. Carefully remove both seals using a suitable seal
removal tool and discard. Be careful not to scratch
the seal bore. CAUTION
CALIFORNIA MODELS: Remove the charcoal canister
the swingarm lowers, it can contact the canister hose
1. Remove front fender. See Front Fender Removal

page 3.24.
2. Secure the motorcycle in an upright position with
beneath the engine cases.
4. Refer to special tool manufacturer instructions to

remove bearing from LH side of hub.
5. Remove bearing.
6. Remove spacer.
7. Extract or drive bearing from RH side of hub.
8. Installation: Use the Wheel Bearing Removal /
Installation Kit PF-51324) to install new wheel
bearings. Refer to special tool manufacturer
instructions for proper use of tool.
9. Install new wheel bearing into the RH side of hub NOTE
followed by the inner bearing spacer.
Do not operate the front brake lever with the calipers
11
10. Install new wheel bearing into the LH side of hub. or wheel removed.
11. Install new seals and existing outer bearing
spacers into each side of the wheel hub. 3. Remove front brake calipers and support them so
12. Install the brake discs. See Brake Disc Removal / they do not hang by brake hoses. See Front Caliper
Installation page 11.13. Service page 14.30.
13. Install the front wheel. See Front Wheel, Removal / 4. Remove front wheel. See Front Wheel, Removal /
Installation page 11.12. Installation page 11.12.

© Copyright 11.15
5. Remove fairing assembly. See Outer Fairing 10. Loosen lower triple clamp pinch bolts e for each
Removal, Chieftain / Roadmaster page 3.40. fork tube.
Classic / Vintage / Dark Horse / Springfield:
6. Remove nacelle and headlight bucket.
ALL Models
7. If triple clamp will be removed, remove front brake
line guides from the upper and lower triple clamps.
8. Loosen upper triple clamp pinch bolt q for each
fork tube.
11. Slide fork legs down and remove.
9. If disassembling the fork tube(s), loosen the fork

cap(s) w prior to loosening the lower triple clamp
bolts.

11.16 © Copyright
F R O N T F O R K D I S A S S E M B LY 3. Mount special socket (PV-49464) in spring

compressor. Center it in holding fixture with all
NOTICE
thumb fasteners e .
The following procedure requires the use of Fork
Spring Compressor (PV-49463) and Fork Spring
Compressor Adapter (PV-49464).
NOTICE
Refer to appropriate Front Fork Exploded View.
Clean fork tubes before disassembly.
1. Secure Fork Spring Compressor (PV-49463)

vertically in a vise with drive bolt q UP.
4. Place fork tube in spring compressor tool with

hole in bottom of fork slider over peg on bottom of
tool.
2. Loosen fork cap w approximately 1 turn. Do not 5. Adjust length of spring compressor by turning
remove the cap. drive bolt r as required until fork cap is captive in
socket.
WARNING
Wear eye / face protection. Be sure spring is 6. Rotate tube until cap is unscrewed completely
engaged properly with pegs of tool as you compress from fork tube.
the spring in the following steps.
11

© Copyright 11.17
7. Back off spring compressor and remove special 11. Remove washer u .
socket. Re-adjust length of tool so thumb fasteners
are aligned with first or second coil at top of
spring.
8. Hold fork in center and engage slot of stationary
peg t with spring. Turn other fasteners in and
engage spring in notch.
12. Remove spring from fork tube.

13. Pour fork oil out of tube assembly.
14. Move cartridge shaft through complete stroke
several times to drain cartridge (until damping is
gone).
9. Slowly compress spring by turning drive bolt of NOTICE
compressor until cartridge rod nut is accessible. Fork seal replacement is recommended at oil
DO NOT use air or power tools to rotate drive bolt. change. If you do not intend to replace fork seals
(fork oil change only) STOP HERE and proceed to
Step 14 of Front Fork Assembly. Inner fork tube
removal in the following steps will damage the oil
seal and require seal replacement. For complete fork
disassembly proceed to Cartridge Removal / Step
15.
Cartridge Removal
15. Hold cartridge through top of fork inner tube with
octagonal end of Cartridge Shaft Tool (PV-49452).
Loosen cartridge fastener.
10. Hold nut and remove fork cap y from cartridge

shaft.

11.18 © Copyright
16. Remove cartridge from inner tube. 22. If applicable, remove the lower bushing from the
inner tube.
WARNING
DO NOT disassemble the cartridge. If damaged or
worn, it must be replaced as an assembly.
17. To clean cartridge when removed, submerge oil

holes in clean cartridge fork oil and pump
cartridge shaft.
18. Fully compress the fork tube. Carefully lift dust
seal out of outer fork tube with a small flat
screwdriver. KYB forks have access notch to
remove dust seal.
23. Remove oil lock valve i and bushing o from

bottom of inner tube.
19. Remove seal retaining ring. Use care not to scratch

the surface of the inner fork tube.
24. Protect top surface of fork slider and pry out oil
seal, using care not to scratch the seal bore.
20. Push inner and outer tube together, then pull apart
quickly to produce a slide hammer motion to
11
remove the inner tube.
21. Separate the tubes.

© Copyright 11.19
25. Remove oil seal and backing washer. FRONT FORK INSPECTION
1. Measure fork spring free length and compare to
specifications on .
2. Inspect fork stanchion tube for scoring, heavy

scratches, dents due to rocks or other road debris,
or excessive wear. Replace tube (s) if deep
scratches, pitting, or dents are found.
3. Inspect slider for dents or other indentations due
to rocks or other road debris or damage. If
damage is found on exterior of slider, insert fork
Upper Bushing Removal
tube into slider and move the tube through the
26. To remove upper bushing from fork slider, re- complete travel range. Check for resistance or
install fork tube (with lower bushing attached) into binding in the damaged area. If binding or
fork slider, working the bushing carefully past the resistance is evident, replace the slider.
upper (slider) bushing.
27. Use a VERY LIGHT slide hammer motion to tap
slider bushing out of the slider.
28. Clean tubes and drain completely. Cartridge
removal is not required for seal and bushing
replacement. Cartridge can be cleaned by adding Inspect surface
clean fork oil to slider and pumping the cartridge
rod in the clean oil bath. Discard fork oil used to
flush the cartridge. Inspect surface
4. Inspect oil lock valve for scoring, excessive or

abnormal wear.

11.20 © Copyright
5. Visually inspect the damper rod piston ring. F R O N T F O R K A S S E M B LY

Replace ring if scoring, deep scratches and/or
NOTICE
excessive wear is noted.
Clean all parts prior to assembly.
Stepped side of piston ring
faces damper rod 1. Lubricate and install new upper bushing into fork
slider. Position gap q to left or right side of fork
slider.
CAUTION
Ring is directional. Be sure to install it with stepped
edge toward damper rod and top-out spring as
2. Lubricate and install a new lower bushing w on
shown.
inner fork tube. Install oil lock valve e in bottom
6. Place fork tube in V-blocks and measure runout. of fork tube (tapered side to the tube as shown).
Replace the tube if runout exceeds service limit
listed on .
WARNING
Do not attempt to straighten bent fork tubes. Doing 11
so will weaken the tube and make the motorcycle
unsafe to operate.

© Copyright 11.21
3. Rotate bushing so gap r will be opposite th gap of 6. Use the Fork Seal Tool (PV-49494) (6) to install oil
slider bushing previously installed. seal until seated. Be sure top edge of seal is past
(below) retaining ring groove.
4. Apply a light film of fork oil to outside edge and

inside seal lips of new oil seal. 7. Install a new retaining ring u into groove of fork
tube. Be sure it is completely seated around the
NOTICE entire circumference of the groove.
Install oil seal with markings t facing UP (toward top
of tube and retaining ring).
8. Wipe away any excess grease or oil. Install dust

seal (use opposite end of Fork Seal Tool (PV-
49494) i until fully seated in outer tube.
5. Lubricate the surface of the inner fork tube and
slide backing washer and new oil seal down tube
and into outer fork leg.

11.22 © Copyright
Cartridge Installation Oil Filling / Cartridge Air Bleeding

9. Be sure fastener threads in bottom of cartridge are 14. Tip fork leg at an angle to reduce air bubbles.
clean and not damaged. Slowly add about 350cc of Indian Motorcycle fork
oil
10. Place cartridge assembly into fork slider, and
carefully align bottom of cartridge with recess in 15.
bottom.
NOTICE
11. Install a new cartridge fastener and a new seal The oil quantity slightly exceeds the capacity of the
washer. fork. Final fork oil level must be adjusted correctly as
outlined later in this procedure.
Set fork leg upright.

16. Lift outer tube up to top of travel range.
17. Seal top of tube with your hand and push
downward against air pressure. Hold for 10– 15
seconds. This will help force trapped air from
cartridge and tube.
12. Hold cartridge with the Cartridge Shaft Tool (PV-

49452).
13. Torque cartridge fastener to specification.
18. Mount fork assembly upright in a soft jawed vise

by brake caliper mounts on slider.
19. Screw Damper Rod Holder (PV-49453) o onto
cartridge rod.
20. Bleed cartridge by moving shaft up and down to
TORQUE purge air. Begin with small strokes, increasing
stroke length until all air is removed and damping
Cartridge Fastener: 17 ft-lbs (23 N·m) is smooth and consistent.
11

© Copyright 11.23
21. Slowly compress inner fork tube a and cartridge 25. Install spring with tightly wound coils d down.
rod s until they stop (at bottom of travel) and
remove damper rod holder.
26. Mount tube in spring compressor and adjust

thumb fasteners to catch spring as outlined for
22. Loosen thumb fastener on Fork Oil Level Tool (PV- disassembly.
59000A) and slide stop plate to adjust tube to
length of specified oil level. WARNING
Fork Oil Level (from top of tube): Wear eye / face protection. be sure spring is
Chief: 125 mm (4.92”)Chieftain: 132 mm (5.20") engaged properly with pegs of tool as you compress
the spring in the following steps.
Set level in tube with spring removed, and inner tube
and damper rod (cartridge rod) fully compressed.
27. Attach damper rod holder and hold damper rod
up.
28. Carefully compress spring until fork cap threads
on top of damper rod are visible.
23. Insert fork oil level tool into fork. Be sure fork leg
is standing upright and fork tube is fully
compressed.
24. Draw excess oil out to the specified level. 29. Remove extension tool and hold damper rod up,
clear of spring.
30. Screw jamb nut f fully onto damper rod until
bottomed.

11.24 © Copyright
31. Place backing washer g on top of spring. 37. Slowly compress fork tube assembly with drive nut
until fork cap enters the outer tube, and threads
start to make contact.
32. Place a new o-ring on fork cap and screw cap

FULLY onto damper rod for maximum thread
engagement. 38. Rotate outer tube to start cap. Use care to avoid
thread damage.
33. Hold cap and screw jamb nut up damper rod until
it stops against cap.
34. Hold jamb nut and torque fork cap to specification.
39. After cap thread is started, continue to turn tube

and adjust spring compressor pressure as
required until cap is fully seated against top of
outer tube.
TORQUE
40. Tighten fork cap to outer tube. Torque to
Fork Cap to Jamb Nut: specification.
11 ft-lbs (15 N·m)
TORQUE
35. Slowly release spring pressure and remove fork Fork Cap to Outer Tube:
leg from spring compressor. 16 ft-lbs (22 N·m)
36. Install special socket in compressor as outlined for
disassembly.
11
F R O N T F O R K I N S TA L L AT I O N ( A L L M O D E L S )
NOTE
Clean the fork tubes and the clamping surfaces of the
triple clamps to remove any oil or grease prior to
installation.

© Copyright 11.25
1. Install one fork tube assembly into lower triple 4. Torque the top bolt on the lower triple clamp w .
clamp.
5. REPEAT torque process in steps 3 & 4.

2. Continue to slide tube through lower triple clamp
6. Torque the upper triple clamp bolt e .
and into upper triple clamp. Stop when the top of
the fork cap is flush with the top of the upper triple
clamp.
TORQUE
Lower Triple Clamp Bolts: 18 ft-lbs (24.4 Nm)
3. Torque the bottom bolt on the lower triple clamp q Upper Triple Clamp Bolt: 18 ft-lbs (24.4 Nm)
.
7. Repeat steps 1 through 6 for the other fork tube.

8. Install brake line guides (if removed).
9. Install front wheel. See Front Wheel, Removal /
10. Install brake calipers. See Front Caliper Service
page 14.30.
11. Install front fender. See Front Fender Installation
page 3.26.
12. Install caliper covers. See Caliper Cover, Removal
/ Installation page .

11.26 © Copyright
13. Install fairing. See Outer Fairing Installation - T R I P L E C L A M P R E M O VA L

Chieftain / Roadmaster page 3.44
WARNING
This procedure requires raising and supporting
14. Install headlight bucket and nacelle. the motorcycle so that the front wheel is off the
15. Inspect all bolts for proper torque. Inspect hoses ground. Precautions should be taken to ensure
and wiring for proper routing. the motorcycle is properly stabilized at all times.
Failure to properly support motorcycle may result
16. Lower front end of motorcycle to the ground and in personal injury or damage to the motorcycle.
test front suspension / fork operation.
CAUTION
Do not twist the brake hose or brake line. Do not
allow calipers to hang from the brake hose. Secure
calipers in such a way to avoid hose damage.
CAUTION
CALIFORNIA MODELS: Remove the charcoal canister
the swingarm lowers it can contact the canister hose
1. Secure the motorcycle in an upright position with

beneath the engine cases.
NOTE
Do not operate the front brake lever with the calipers
or wheel removed.
11
2. Remove the front fender. See Front Fender Removal
page 3.24.
3. Remove front wheel. See Front Wheel, Removal /
4. Remove fairing. See Outer Fairing Removal,
Chieftain / Roadmaster page 3.40.

© Copyright 11.27
5. Remove nacelle and headlight bucket. 11. Remove stem adjuster nut w with a suitable
spanner socket.
All Models:
6. Remove the handlebar / riser assembly. See
Handlebar, Removal / Installation (All Models)
page .
7. Remove fork tubes. See Front Fork Removal page
.
8. Remove brake line guides from upper and lower
triple clamp.
9. Remove center nut q and washer on upper triple
clamp.
12. Remove lower triple clamp, with steering stem, and

lower bearing (outer race will remain in head
tube).
13. Inspect bearings and bearing races.
10. Slide upper triple clamp off steering stem.

11.28 © Copyright
F R O N T F O R K L O C K R E M O VA L /
IMPORTANT
Fork lock fasteners must be replaced when fork lock
is removed. Do not reuse fork lock fasteners.
1. Perform steps 1–10 of Triple Clamp Removal

procedure.
2. Remove two fork lock fasteners q and remove fork
lock w.
3. Install NEW fork lock w and Install two NEW

fasteners q. Torque fasteners to specification.
TORQUE
Fork Lock Fasteners:
18 ft-lbs (24 N·m)
11

© Copyright 11.29
T R I P L E C L A M P I N S TA L L AT I O N / S T E E R I N G 4. Screw adjuster nut e (shoulder side down) onto

HEAD BEARING ADJUSTMENT the steering stem until it is finger tight.
1. Inspect both top and bottom bearing races for
pitting, dents, or worn surface. Replace bearings
and races as a set if they are worn or damaged.
2. Be sure lower stem bearing q is seated against
step on lower triple clamp. Apply all purpose
grease to bearing and install lower triple clamp /
stem to frame.
5. Turn triple clamp assembly fully to the right.

6. Torque adjuster nut to specification using suitable
spanner wrench.
TORQUE
Steering Stem Bearing Adjuster Nut: 29 ft-lbs (39.3
Nm)
3. Grease and install upper bearing w onto stem and
push it down until seated in upper bearing race. 7. Place a mark on the frame in alignment with one of
the slots on the adjuster nut.
8. Turn lower triple clamp from lock to lock five
times and return to full right position.
9. Loosen adjuster nut 90 degrees (1/4 turn) so the
reference mark on frame is aligned with the next
one of the four slots on the stem nut.
10. Set upper triple clamp in place on stem. Install
washer r and nut t and tighten top nut until it is
finger tight.
NOTE
Nut will be torqued after fork tubes are installed.

11.30 © Copyright
11. Slide fork tubes through lower triple clamp and

into upper triple clamp. Align top edge of fork cap
with top edge of upper triple clamp and hold in
position.
12. Tighten top triple clamp pinch bolt enough to hold
tubes in place. Leave lower triple clamp pinch
bolts loose.
13. Torque the top steering stem nut to specification.
TORQUE
Top Steering Stem Nut: 72 ft-lbs (97.6 Nm)
NOTE
CHECK STEERING STEM BEARINGS at this time. Pull
firmly on fork tubes with a front-to-rear motion. If
movement can be felt in steering bearings,
disassemble and go back to STEP 10. Tighten
steering stem adjuster nut an additional 5 degrees,
and reassemble following STEPS 10–15. Repeat this
procedure until no play can be felt.
14. Verify fork tube height in upper triple clamp. The

top of the fork cap should be flush with the top of
the upper triple clamp.
15. Torque the upper triple clamp pinch bolts (both
sides) to specification.
TORQUE
Upper Triple Clamp Pinch Bolts: 18 ft-lbs (24.4 Nm)
16. Torque bottom bolts on lower triple clamp to

specification.
17. Torque top bolts on lower triple clamp to
specification.
TORQUE
Lower Triple Clamp Pinch Bolts (ALL): 18 ft-lbs (24.4
Nm)
18. Repeat STEPS 15–17.

19. Install handlebar assembly. See Handlebar,
Removal / Installation page .
20. Install front wheel. See Front Wheel, Removal /
21. Verify all fasteners are installed and properly
torqued.

© Copyright 11.31
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED
Heavy Steering Steering Stem Nut Over Tightened Torque to specification
Damaged Steering Stem Bearings Replace
or Races
Bent Steering Stem Replace
Front Tire Damaged or Worn Replace
Low Tire Pressure Inflate to specification
Pulls to One Side or Wanders Damaged Steering Stem Bearings Replace
or Races
Steering Stem Nut Over Tightened Torque to specification
or Under Tightened
Rear Wheel Not Aligned Correctly Align
Bent Front Axle Replace
Damaged or Excessively Worn Replace
Front Tire / Incorrect Tire
Damaged Wheel Bearings Replace
Damaged Swing Arm Bearings Replace
Loose Swing Arm Pivot Nut Torque to specification
Bent Frame or Swingarm Replace
Handlebars Oscillate (Wobble) Bent Front Axle Replace
Wheel Has Excessive Runout True (Spoked) / Replace (Cast)
Tire Mounted Incorrectly Check Mounting and Balance
Damaged Tire / Worn Tire Replace
Loose Steering Stem Nut Torque to specification
Incorrect Tire Replace
Incorrect Tire Pressure Correct
Noise Coming From Front Worn Fork Bushings Rebuild Forks
Suspension
Low Fork Fluid Determine Cause / Replace Fork
Oil
Loose Fasteners Torque to specification
Loose Steering Stem Bearings Determine Cause / Correct
Front Wheel Oscillates (Wobbles) Bent Front Rim Replace
Damaged Front Wheel Bearings Replace
Damaged or Incorrect Tire Replace
Front Wheel Oscillates (Wobbles) Loose Axle Torque to specification

11.32 © Copyright

Fork Tube Height Unequal Install Correctly
Fork Oil Level Unequal Set Correctly
Fork Spring Free Length Different Replace
Between Right & Left
Wheel Assembly Out-of-Balance Balance
Front Suspension Too Soft Weak Fork Springs Replace
Low Fork Oil Level Determine Cause/Replace Fork Oil
Wrong Weight Fork Oil Replace
Contaminated and/or Deteriorated Replace
Fork Oil
Low Tire Pressure Set Correctly
Front Suspension Too Hard Tire Pressure Too High Set Correctly
Bent Fork Tubes Replace
Wrong Weight Fork Oil Replace
Too Much Fork Oil Set Correctly
Plugged Oil Passages Rebuild Front Forks
Damaged Sliders Replace
Forks Binding Correct
Wheel Turns Hard Damaged Wheel Bearings Replace
Front Axle Bent Replace
Brake Dragging Repair as Necessary
(Hydraulic or Mechanical Problem)
Brake Dragging (Bent Disc) Replace
Improper Assembly After Repairs Correct as Necessary
11

© Copyright 11.33
NOTES

11.34 © Copyright
REAR WHEEL / SUSPENSION
CHAPTER 12
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.3
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.3
TORQUE SPECIFICATIONS - REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.4
ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.6
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.6
REAR SHOCK / PUSHROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.8
REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.9
ROCKER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.10
SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
DRIVE BELT SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.12
DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.12
DRIVE BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.12
DRIVE BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.12
DRIVE SPROCKET SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
DRIVE SPROCKET COVER, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
DRIVE SPROCKET REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
DRIVE SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15
DRIVE SPROCKET INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.16
DRIVEN SPROCKET SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.17
DRIVEN SPROCKET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.17
DRIVEN SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.17
DRIVEN SPROCKET BEARING - REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.18
DRIVEN SPROCKET INSTALLATION (ALL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.20
REAR WHEEL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.21
REAR WHEEL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.21
REAR AXLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.23
REAR WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.23
REAR WHEEL BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.23
WHEEL BEARING REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.25
BRAKE DISC REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.25
SHOCK ABSORBER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.26
SHOCK ABSORBER INSPECTION (ALL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.26
SHOCK ABSORBER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.28
SWINGARM SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.29
SWINGARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.29
12
SWINGARM BUSHING / BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.31
SWINGARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.33
TROUBLESHOOTING, REAR WHEEL / SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.36

© Copyright 12.1
TROUBLESHOOTING, FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.37

12.2 © Copyright
SERVICE NOTES • The rear shock absorber is serviceable.
WARNING • Refer to Maintenance chapter for maintenance of

rear wheel & suspension components, and
This motorcycle was produced with the designated suspension ride height adjustment.
tires as original equipment. The testing to ensure
stability and superior handling was done using the
OEM tires. Using non-OEM tires could result in poor
motorcycle stability and handling, which can lead to SPECIAL TOOLS
a crash resulting in serious injury or death. Use only
SPECIAL TOOL PART NUMBER
the recommended tires inflated to the recommended
tire pressures. Swing-arm Bushing Tool PF-51237
Shock Spanner Wrench PV-46993
IMPORTANT
Bearing Removal / PF-51324
Visual inspection of the cushion drive damper q for Installation Kit
cracks or deformation is required whenever the rear
Platform Jack Commercially Available
wheel is removed. Replace damper if damage is
found.
Tubeless tires are used on certain Indian Motorcycle

models. Operating the motorcycle with damaged rims
creates a safety hazard including air pressure loss,
steering imbalance and/or reduced steering control.
Do not attempt to repair or straighten damaged cast or
spoked rims. Indian Motorcycle Chief Classic and
Vintage models are equipped with spoked tube-type
rims. Small imperfections in the alignment of these
rims can be corrected using an approved wheel truing
stand and spoke wrench (commercially available).
Always use genuine Indian Motorcycle parts or
equivalent so that quality is not compromised. The use
of tire valves and valve cores other than original
equipment replacement Indian Motorcycle parts could
cause tire deflation which may lead to loss of control,
resulting in injury or death. Do not allow any
motorcycle to leave your service area without tire
valve caps securely installed.
12

© Copyright 12.3
T O R Q U E S P E C I F I C AT I O N S - R E A R W H E E L
PART / FASTENER TORQUE
SPECIFICATION
Belt Guard, Lower 96 in-lbs (11.0 Nm)
Brake Disc 22 ft-lbs (29.8 Nm)
Drive Sprocket Cover 84 in-lbs (9.5 Nm)
Drive Sprocket Lock Plate 88.5 in-lbs (10.0 Nm)
Drive Sprocket Nut 180 ft-lbs (244.0 Nm)
Gusset Plate 55 ft-lbs (75.0 Nm)
P-Clamp Fasteners (Brake 84 in-lbs (9.5 Nm)
Line / W.S.S.)
Pushrod Fastener, Upper 55 ft-lbs (75.0 Nm)
Rear Axle Nut
65 ft-lbs (88.0
Nm)
Rear Caliper Mounting 31 ft-lbs (42.0 Nm)
Fasteners
Shock Absorber Fasteners 55 ft-lbs (75.0 Nm)
(Upper & Lower)
Shock Air Line Jamb Nut 20 ft-lbs (27.0 Nm)
(Air Shock)
Swingarm Nut (LH) 65 ft-lbs (88.0 Nm)
Swingarm Shaft, Initial 8 ft-lbs (11.0 Nm)
Torque (Before Outer Nut
Installation)
Swingarm Shaft, Jamb Nut 75 ft-lbs (102.0 Nm)
Wheel Speed Sensor 96 in-lbs (11.0 Nm)

12.4 © Copyright
Axle Runout - .20 mm (.008")
Axial .80 mm (.030 inch) 2.0 mm (.080”)

Rear Wheel Runout
Radial .80 mm (.030 inch) 2.0 mm (.080”)
Classic / Vintage 16” x 5” Spoked –
Rear Wheel Size / Chieftain /
Type Roadmaster / Dark –
16” x 5” Cast
Horse / Springfield
Classic / Vintage / 3.7” (9.4 cm) –
Dark Horse
Rear Wheel Travel Chieftain /
Roadmaster / 4.5” (11.4 cm) –
Springfield
Classic / Vintage / 8.0” (203.2 cm) –
Dark Horse
Shock Spring Free
Length Chieftain /
Roadmaster / 8.0” (203.2 cm) –
Springfield
Classic / Vintage /
Shock Spring Dark Horse
Installed Length Chieftain / Perform Ride Height Adjustment –
(Standard) Roadmaster /
Springfield
Suspension Ride Refer to Maintenance chapter for
All Models –
Height Ride Height Measurement procedure
Classic / Vintage / –
450 lbs / in
Dark Horse
Spring Rate Chieftain /
Roadmaster / 400 lbs / in –
Springfield
Swing Arm Pivot Shaft Runout Not Applicable .20 mm (.008")
LH Ball Bearing Journal: 19.965–
Swing Arm Pivot Shaft O.D. 19.99 mm / RH Needle Bearing –
Journal: 24.95–25.00 mm
Swing Arm Needle Bearing Bore O.D. (RH) 31.946–31.972 mm –
Swing Arm Ball Bearing Bore O.D. (LH) 41.967–41.992 mm –
Wheel bearing O.D. (approx) 51.987–52.00 mm –
Wheel bearing I.D. (approx) 19.998–20.00 mm –
12

© Copyright 12.5
REAR SUSPENSION

12.6 © Copyright
q Retaining Ring -
w Rocker Pivot Shaft -
e Nut, Gusset Plate — M10 x 1.5 (QTY.6) -
r Gusset Plate, Swingarm -
t Upper Pushrod fastener, Rear Suspension 55 ft-lbs (74.5 Nm)
y Shock Absorber Fastener 55 ft-lbs (75Nm)
u Rocker Arm Assembly -
i Shock -
o Spherical Bearing -
a Nut, Swingarm — M18 x 1.5 (QTY.1) 65 ft-lbs (88 Nm)
s Spacer, Pivot (Left-Hand Outer) -

d Spacer, Pivot (Left-Hand) -
f Retaining Ring -
g Ball Bearing — M42 x 20 x 12 (QTY.2) -
h Pushrod -
j Swingarm -
k Gusset Plate (Right-Hand), Swingarm -
l Seal -
1( Bearing, Needle -
2) Suspension Pivot -
2! Nut, Jamb — M27 x 1.5 (QTY.1) 75 ft-lbs (102 Nm)
2@ Fastener — M10 x 1.5 x 50 (QTY.4) 55 ft-lbs (75Nm)

2# Belt Guard, Lower -
2$ Sleeve (QTY.2) -
2% Fastener — M6 x 1.0 x 20 (QTY.2) 96 in-lbs (11 Nm)
2^ Nut — M18 x 1.5 (QTY.1) 65 ft-lbs (88 Nm)
2& Axle Adjuster (RH) -

2* Nut — M8 x 1.25 (QTY.2) -
2( Axle Adjuster (QTY.2) -
3) Wheel Spacer (Right-Hand) -
3! Axle, Rear -
12

© Copyright 12.7
REAR SHOCK / PUSHROD

q Retaining Ring -
w Pivot Shaft, Rocker -
e Shock Absorber Fastener 55 ft-lbs (75Nm)

r Rocker Arm -
t Upper Pushrod fastener, Rear Suspension 55 ft-lbs (74.5 Nm)

y Nut — (QTY.6) -
u Gusset Plate, Swingarm -
i Spherical Bearing -
o Pushrod -
a Gusset Plate, Swingarm -
s Shock Assembly -
d Gusset Plate, Fasteners — (QTY.4) 55 ft-lbs (75Nm)

12.8 © Copyright
REAR WHEEL

q Belt, Drive — 152T / 24 mm -
w Bearing, Cushion Drive -
e Spacer, Inner -
r Sprocket — 66T -
t Damper, Cushion Drive Visual inspection for cracks or

deformation is required whenever the
rear wheel is removed. Replace if
damage is found.
y Spacer, Wheel -
u Bearing, Wheel (RH) — 20 mm X 52 mm X 15 mm -
i Spacer, Bearing — 130 mm -
o Rim -
a Seal -
12

© Copyright 12.9
R O C K E R A S S E M B LY
q Bearing, Needle -
w Bearing, Thrust -
e Spherical Bearing -
r Seal -
t Rocker -

12.10 © Copyright
SWINGARM

q Nut, Swingarm — M18 x 1.5 (QTY.1) 65 ft-lbs (88 N·m)
w Spacer, Pivot (LH Outer) -
e Spacer, Pivot (LH) -
r Retaining Ring -
t Ball Bearing — M42 x 20 x 12 (QTY.2) -
y Swingarm -
u Seal -
i Bearing, Needle -
o Suspension Pivot -
a Nut, Jamb — M27 x 1.5 (QTY.1) 75 ft-lbs (102 N·m)

s Fastener, Belt Guard — M6 x 1.0 x 20 (QTY.2) 88 in/lbs (10 Nm)
d Sleeve -
f Guard, Lower Belt -
g Axle, Rear -
h Nut, Axle Adjuster -
j Axle Adjuster -
k Spacer, RH -
l Adjuster Plate, LH - 12
1( Nut, Axle — M18 x 1.5 (QTY.1) 1. Torque to 15 ft-lbs (20 N·m)
2. Torque to 65 ft-lbs (88 N·m)

© Copyright 12.11
D R I V E B E LT S E R V I C E
D R I V E B E LT I N S P E C T I O N D R I V E B E LT I N S TA L L AT I O N
1. Inspect belt tension and adjust if necessary. See 1. Inspect sprockets and verify sprocket fasteners
Drive Belt Inspection page 2.38. are tight.
2. If one or more component is damaged, replace 2. Install drive belt with the Indian Motorcycle script
belt and both sprockets as a set if the drive system situated so that it reads correctly when viewed
has been in service for 5000 miles or more (8000 from the RH side of the motorcycle.
Km).
3. Install the drive sprocket cover. See Drive
Sprocket Cover, Removal / Installation page 12.13.
D R I V E B E LT R E M O VA L 4. Install the exhaust system. See Head Pipe
NOTICE Installation page 5.18.
If belt is to be reinstalled, mark direction of rotation 5. Install the swingarm assembly. See Swingarm
on the outer surface of belt. Reinstall belt in same Installation page 12.33.
direction as it was removed. 6. Install the rear wheel. See Rear Wheel Removal /
WARNING 7. Set drive belt alignment and tension. See Drive
Belt Adjustment page 2.42.
A misaligned rear axle can cause drive line noise and
damage the drive belt, which could cause belt failure
and loss of control of the motorcycle.
WARNING
Care should be taken to be sure the motorcycle will
not tip or fall while elevated. Severe personal injury
or death may occur if the motorcycle tips or falls.
1. Remove rear wheel. See Rear Wheel Removal /

2. Remove swingarm assembly. See Swingarm
Removal page 12.29.
3. Remove exhaust assembly. See Muffler Removal
page 5.14.
4. Remove drive sprocket cover. See Drive Sprocket
5. Remove belt from drive sprocket.

12.12 © Copyright
DRIVE SPROCKET SERVICE

D R I V E S P R O C K E T C O V E R , R E M O VA L / D R I V E S P R O C K E T R E M O VA L
I N S TA L L AT I O N This procedure requires use of the Clutch Shaft
1. Remove the rear muffler and head pipe assembly. Holding Tool (PF-51232).
See Head Pipe Removal page 5.17. 1. Place motorcycle in an upright position with the
2. Using a 5mm hex wrench, remove the two short front wheel clamped in a wheel vise.
fasteners q and two long fasteners w securing the 2. Remove exhaust system. See Muffler Removal
cover to the engine and remove cover. page 5.14
3. Remove the drive sprocket cover. See Drive
Sprocket Cover, Removal / Installation page 12.13.
Removal page 9.8.
6. Remove clutch assembly. See Clutch Removal
page 9.15.
7. Install the Clutch Shaft Holding Tool (PF-51232).
8. Loosen rear axle nut q so that wheel assembly can
be moved forward to slacken drive belt.
NOTICE
Note the position of the oxygen sensor harness for
use during installation.
3. To install the drive sprocket cover, reverse the

removal procedure.
4. Torque drive sprocket cover fasteners to
specification.
TORQUE
Drive Sprocket Cover Fasteners (All):
88 in-lbs (10 N·m)
9. Loosen both axle adjuster nuts evenly to move
wheel forward until belt is loose.
10. Pull belt off drive sprocket.
12

© Copyright 12.13
11. Remove two locking plate fasteners w and locking

plate e .
12. Remove drive sprocket retaining nut r and drive

sprocket t .
13. Remove spacer y , and O-ring u from output

shaft.

12.14 © Copyright
DRIVE SPROCKET INSPECTION 5. Sprockets and belt normally exhibit a polished

1. Visually inspect sprocket teeth q for excessive appearance due to normal operation. Belt
wear and damage. replacement is not required unless
uncharacteristic damage is noted, or if the mileage
service interval is reached. Belt or sprocket
damage is usually due to debris trapped between
belt and sprocket, or from improper maintenance
and adjustment.
2. Inspect splines w for a tight fit on output shaft

splines.
3. Inspect the back surface of sprocket hub e where

it contacts the seal sleeve. Replace if worn or if
surface is rough.
4. Inspect the machined sealing surface of the spacer
sleeve r . Replace the spacer sleeve if it is
grooved or otherwise damaged.
12

© Copyright 12.15
D R I V E S P R O C K E T I N S TA L L AT I O N 8. Install lock plate e and tighten fasteners r until

lightly seated on plate.
NOTICE
If replacing the output shaft seal, it will be necessary
to use the Output Shaft Seal Tool (PF-51243) for
proper installation.
1. Place new output shaft seal over the output shaft

and drive into position using the Output Shaft Seal
Tool (PF-51243).
2. Apply grease to a new O-ring q and install on
output shaft.
3. Install seal sleeve w with the chamfer on inside
diameter of sleeve facing in, toward O-ring.
NOTICE
The lock plate can be installed in many positions and
either side of the plate can be used. If the plate still
does not align, tighten sprocket nut slightly and try to
fit the lock plate again.
9. Rotate the plate CLOCKWISE until it stops and

hold it firmly against the nut.
10. Torque lock plate fasteners to specification.
TORQUE
4. Clean shaft threads and sprocket nut to remove all Lock Plate Fasteners:
previous thread locking agent. 88 in-lbs (10 N·m)
5. Apply a light film of anti-seize compound to
11. Remove the clutch shaft holding tool and install the
splines of shaft. Place belt onto front sprocket,
clutch assembly. See Clutch Installation page 9.20.
place sprocket over splines of output shaft.
6. Apply Loctite™ 262 to threads of shaft and nut.
7. Install drive sprocket nut and torque to
13. Add engine oil to correct level. See Engine Oil
specification.
Level in the Maintenance Chapter.
NOTICE 14. Install the drive sprocket cover. See Drive
Install Clutch Shaft Holding Tool (PF-51232) on clutch Sprocket Cover, Removal / Installation page 12.13.
shaft prior to tightening sprocket nut. 15. Install the exhaust system. See Head Pipe
TORQUE 16. Adjust belt tension and wheel alignment. See
Drive Sprocket Nut: Drive Belt Adjustment page 2.42.
180 ft-lbs (244 N·m)

12.16 © Copyright
DRIVEN SPROCKET SERVICE

D R I V E N S P R O C K E T R E M O VA L DRIVEN SPROCKET INSPECTION
1. Visually inspect sprocket teeth q for excessive
CAUTION wear and damage from foreign material or road
Protect brake disc surface while working on wheel. debris.

2. Remove the RH wheel spacer q from the driven
sprocket roller bearing.
2. Inspect the back side of the sprocket where it

engages the damper w for wear, galling or
roughness. Surface must be smooth, with no burrs
or surface irregularities.
3. Lift the driven sprocket assembly w off of the drive

damper e .
12

© Copyright 12.17
3. Visually inspect the cushion drive damper e for DRIVEN SPROCKET BEARING -
cracks or deformation. Replace damper if damage REPLACEMENT
is found.
BEARING REMOVAL
1. Remove the driven sprocket. See Driven Sprocket
Removal page 12.17.
2. Remove the cushion drive damper q from the
driven sprocket and set aside.
NOTICE
Mark the cushion drive damper and driven sprocket
so the damper can be reinstalled in the same position
from which it was removed.
NOTICE
If the drive system has been in service for 5000 miles
or more, replace both front and rear sprockets along
with the belt if any one item is damaged or worn
beyond a normal polished appearance.
3. Place the driven sprocket face down on a suitable

press leaving enough space for the bearing to be
pressed through.
CAUTION
The painted surface of the driven sprocket should be
resting on a protective surface such as wood or shop
rags to ensure the finished surface is not damaged
while pressing the bearing out.

12.18 © Copyright
4. Locate an arbor that is roughly the same size as the 9. Locate an arbor that is roughly the same size as the
O.D. of the inner sprocket spacer w and press O.D. of the outer bearing race and press the
straight down on the inner spacer to remove the bearing r into position until fully seated.
bearing e.
NOTICE
Once seated, the bearing will be approximately .019
in (0.5 mm) proud against the machined face of the
driven sprocket.
BEARING INSTALLATION
5. Turn the driven sprocket over on the press, so the
face is pointing up toward the press arbor.
CAUTION
10. Verify that the inner race of the bearing rotates
The cushion drive damper fingers should be resting
freely and does not bind.
on a solid, flat surface to prevent warping or damage
as the new bearing is being pressed into the driven 11. Reinstall the cushion drive damper in the same
sprocket. position from which it was removed.
12. Install the driven sprocket assembly. See Driven
6. Verify that the inner spacer is in place in the driven Sprocket Installation (All Models) page 12.20.
sprocket prior to pressing in the new bearing.
7. Apply a thin coat of all-purpose grease to the outer
race of the new driven sprocket bearing.
8. Place the new bearing into the bore on the driven
sprocket so it is resting flat.
12

© Copyright 12.19
D R I V E N S P R O C K E T I N S TA L L AT I O N ( A L L
MODELS)
1. Install cushion damper q into wheel hub.
2. Install sprocket assembly w onto wheel hub

making sure the cushion damper is properly
engaged.
3. Install the RH wheel spacer e into the sprocket

roller bearing.

12.20 © Copyright
REAR WHEEL SERVICE

R E A R W H E E L R E M O VA L / I N S TA L L AT I O N 6. Remove two caliper mounting fasteners q and
remove caliper.
WARNING
Rear wheel removal involves supporting the machine
with the rear end elevated. Take precautions so that
the motorcycle is securely supported when the rear
tire is off the ground. Severe personal injury or death
can occur if the motorcycle tips or falls.
WARNING
Make sure the exhaust system has cooled to room
temperature before elevating the motorcycle. The
drive belt may be damaged if it comes into contact
with HOT exhaust components.
WARNING
CAUTION
If working on a motorcycle equipped with a charcoal
canister (EVAP), remove the canister prior to Do not hang rear brake caliper brake line or twist the
elevating the rear of the motorcycle to prevent brake line or damage may result.
damage to the canister hose fittings.
NOTICE
1. Place the motorcycle in an upright position on a lift
table with the front wheel clamped in a wheel vise. Do not apply rear brake pedal after the brake caliper
has been removed.
7. Remove rear ABS wheel speed sensor mounting

fastener w , sensor e , and shims r , if
applicable.
2. If equipped, remove the charcoal canister. See

Evaporative Emission Control System (CA Models)
page 2.32.
4. Remove upper left side panel. See Side Cover
5. Position a platform jack beneath the engine cases NOTICE
and raise until the rear tire is barely in contact with
the ground. Move sensor aside so that it is not damaged.
12

© Copyright 12.21
8. Remove the upper shock pivot pin retaining ring 11. Loosen right and left axle adjusters u .
t.
12. Remove rear axle nut i and washer o from left

9. Thread a lower side panel fastener into the side of swingarm.
threaded opening on the pivot pin y and pull on
exposed fastener to withdraw pin from bore.
13. Remove axle a from right side of swingarm.
10. Raise the rear of the motorcycle until rear axle nut
is accessible below the left muffler assembly.
14. Push wheel forward and slide drive belt to the

right side off of the rear sprocket.

12.22 © Copyright
15. Remove rear wheel assembly by sliding it to the REAR WHEEL INSPECTION
rear of the motorcycle.
IMPORTANT
Visual inspection of the cushion drive damper q for
cracks or deformation is required whenever the rear
wheel is removed. Replace damper if damage is
found.

removal procedure.
17. Torque fasteners to specification.
TORQUE
Axle Nut: 1. Torque to 15 ft-lbs (20 N·m)2. Torque to
65 ft-lbs (88 N·m)
Wheel Speed Sensor Fastener: 96 in-lbs (11 N·m)
Rear Caliper Mounting Fasteners: 31 ft-lbs (42.0 Nm)
Set drive belt tension and alignment. See Drive

Belt Tension page 2.40 and Drive Belt Adjustment
NOTICE
page 2.42.
Wheel bearings must be in good condition.
REAR AXLE INSPECTION 1. Set up a dial indicator to measure axial and radial
1. Install rear axle in V-blocks and measure runout runout of the wheel and compare to service limit.
and compare to service limit. See Service See Visual Inspection & Runout page 13.14.
2. Visually inspect wheel for cracks or other damage.
2. Axle diameter should be measured on bearing
surfaces. 3. Replace wheel if it fails visual or measured
inspection.
REAR WHEEL BEARING INSPECTION

NOTICE
If possible, also inspect wheel bearings before
removing the wheel from the vehicle. Do not remove
bearings from wheel to inspect. Bearings cannot be
repacked. Replace both bearings if one or both fail
inspection, or if either bearing was removed.
1. Visually inspect integral bearing seal for damage.

2. Inspect bearing fit in wheel hub. The outer race of
the bearing must fit tightly into the bore. You
should not be able to move outer race by hand.
12

© Copyright 12.23
3. Slide axle into wheel and check for smooth

rotation and tight fit.
NOTICE
Due to extremely close tolerances, the bearings must
be inspected visually, and by feel. Look for signs of
discoloration, scoring, galling, or contamination from
moisture or dirt. Replace bearings if any of the above
are present. Turn the inner race of the bearings. The
bearings should turn smoothly and quietly. The inner
race should be firm with minimal side to side
movement and no detectable up and down
movement.

12.24 © Copyright
WHEEL BEARING REPLACEMENT B R A K E D I S C R E M O VA L / I N S TA L L AT I O N

1. Remove the rear wheel. See Rear Wheel Removal /
CAUTION Installation page 12.21.
Do not reuse bearings that have been removed. 2. Remove the driven sprocket and cushion damper.
See Driven Sprocket Removal page 12.17.
NOTICE 3. Position wheel with brake disc facing up.
This procedure requires the Wheel Bearing Removal 4. Remove and discard ABS tone ring / brake disc
/ Installation Kit (PF-51324). Refer to special tool fasteners q .
manufacturer instructions for proper use of tool.
5. Remove the ABS tone ring w and brake disc e .
2. Remove driven sprocket. See Driven Sprocket
Removal page 12.17.
3. Remove brake disc. See Brake Disc Removal /
4. Carefully pry seal q out of LH side of hub.

removal procedure.
7. Torque brake disc fasteners to specification in a
star pattern.
TORQUE
Brake Disc Fasteners:
22 ft-lbs (30 N·m)
5. Refer to special tool manufacturer instructions to
remove bearing from brake disc side of hub.
6. Remove bearing.
7. Remove spacer.
8. Extract or drive bearing from sprocket side.
9. Installation: Use the Wheel Bearing Removal /
Installation Kit PF-51324) to install new wheel
bearings. Refer to special tool manufacturer
instructions for proper use of tool.
10. Install new seal into the LH side of hub.
11. Install the brake disc. See Brake Disc Removal /
12. Install driven sprocket. See Driven Sprocket
13. Install the rear wheel. See Rear Wheel Removal /

© Copyright 12.25
S H O C K A B S O R B E R R E M O VA L SHOCK ABSORBER INSPECTION (ALL

WARNING
MODELS)
Chief Classic / Chief Vintage / Chief Dark Horse
Shock absorber removal involves supporting the
machine with the rear end elevated. Take 1. Measure spring installed height and record so ride
precautions so that the motorcycle is securely height adjustment can be returned to rider’s
supported when the rear tire is off the ground. Severe preference.
personal injury or death can occur if the motorcycle
tips or falls.
1. Remove the swingarm / shock absorber assembly.

See Swingarm Removal page 12.29.
2. With the swingarm assembly resting on a sturdy
work surface, remove the lower shock fastener q
and upper shock fastener w .
2. Lubricate spring collars q and loosen completely

to relieve spring tension.
3. Remove shock absorber from swingarm assembly.
3. Remove lower spring keeper w and slide spring

off of shock.

12.26 © Copyright
4. Thoroughly clean the shock spring. 11. Compress spring enough to raise the lower keeper
5. Inspect shock for signs of oil seepage around the t and remove the circlip y .
shaft seal. If leakage is suspected rebuild the shock
absorber assembly.
6. Inspect eyelets e r for cracks, damage or loose
fitting eyelet. Rebuild shock if either eyelet is
cracked.
12. Remove the lower keeper and slide spring off of

shock.
13. Thoroughly clean the shock spring.
14. Inspect shock for signs of oil seepage around the
shaft seal. If leakage is suspected rebuild the shock
7. Inspect damper rod for corrosion, pitting, or absorber assembly.
damage. Rebuild shock if any of the above is
evident. 15. Inspect eyelets for cracks or damage. Rebuild
shock if either eyelet is cracked.
8. With shock upright, move damper rod through
entire travel range. Damper rod should move 16. Inspect damper rod for corrosion, pitting, or
smoothly with consistent damping through the damage. Rebuild shock if any of the above is
entire travel range, and return to the fully extended evident.
position when released. Rebuild shock if damping
17. Inspect shock spring for cracks or distortion.
is inconsistent, or if gas leakage has occurred and
Measure free length and compare to specification.
the damper rod does not fully extend when
See Service Specifications page 12.5.
released.
9. Inspect shock spring for cracks or distortion.
Measure free length and compare to specification.
See Service Specifications page 12.5.
Chieftain / Chieftain Dark Horse / Roadmaster
/ Springfield
10. Install the shock / spring assembly in a suitable
spring compressor.
12

© Copyright 12.27
S H O C K A B S O R B E R I N S TA L L AT I O N
1. Grease all pivot points.
2. Lift shock into position and install top shock
fastener q from right to left, and install nut finger
tight.
3. Install the lower shock fastener w from right to

left, and install nut finger tight.
4. Torque upper and lower shock fasteners to

specification.
TORQUE
Shock Fasteners (2017–2019):
55 ft-lbs (75 N·m)
TORQUE
Shock Fasteners (2020+):
96 ft-lbs (130 N·m)
5. Install the swingarm / shock absorber assembly.

See Swingarm Installation page 12.33.
6. Set suspension ride height / preload to
accommodate rider /cargo weight. See “REAR
SHOCK PRELOAD INSPECTION”.

12.28 © Copyright
SWINGARM SERVICE
S W I N G A R M R E M O VA L 7. Remove rear wheel assembly. See Rear Wheel
WARNING
8. Remove the rear brake hose rear p-clamp q and
Swingarm removal involves supporting the machine front p-clamp w fasteners located on the left inner
with the rear end elevated. Take precautions so that surface of the swingarm.
the motorcycle is securely supported when the rear
tire is off the ground. Severe personal injury or death 9. Remove the rear ABS wheel speed sensor harness
can occur if the motorcycle tips or falls. p-clamp fastener e from the front left side of the
swingarm.
WARNING
Make sure the exhaust system has cooled to room
temperature before elevating the motorcycle. The
drive belt may be damaged if it comes into contact
with HOT exhaust components.
WARNING
If working on a motorcycle equipped with a charcoal
canister (EVAP), remove the canister prior to
elevating the rear of the motorcycle to prevent
damage to the canister hose fittings.
1. Place the motorcycle in an upright position on a lift

10. Disconnect the rear ABS wheel speed sensor
table with the front wheel clamped in a wheel vise.
connector located at the front of swingarm.
2. Position a platform jack beneath the engine cases
and raise until it contacts the engine. 11. Remove the plastic darts r securing the rear wheel
debris flap t to the forward upper edge of the rear
fender.
12. Disconnect the tip over sensor connector y
located on the rear wheel debris flap and remove
debris flap t .
3. If equipped, remove the charcoal canister. See

Evaporative Emission Control System (CA Models)
page 2.32.
4. Remove saddlebags, if equipped. Refer to Owner’s
Manual.
5. Remove upper and lower side panels. See Side
Cover (Upper), Removal / Installation page 3.15
and Side Cover (Lower), Removal / Installation 12
page 3.15.
6. Remove the seat. See Seat, Removal / Installation -

© Copyright 12.29
13. Remove swingarm nut u and outer pivot spacer i 16. CHIEFTAIN / CHIEFTAIN DARK HORSE /
from the left side of the swingarm pivot shaft. ROADMASTER / SPRINGFIELD ONLY:
Disconnect the shock absorber air line fitting from
the left frame section.
17. Support and remove the swingarm assembly
towards the rear of the motorcycle.
14. Remove the pivot Jam nut o located on the right

side of the swingarm pivot shaft.
15. Use an 8 mm hex wrench to thread the swingarm

shaft a out of the right side of the frame.

12.30 © Copyright
SWINGARM BUSHING / BEARING 5. Working from the RH side of the swingarm, gently
REPLACEMENT pry the seal t out of the bearing bore.
NOTICE
Disassembly and assembly of the swingarm requires
Swingarm Bushing Tool (PF-51237).
REMOVAL
1. Remove swingarm assembly from motorcycle. See
Swingarm Removal page 12.29.
2. Remove shock absorber assembly from swingarm.
See Shock Absorber Removal page 12.26.
3. Remove the two fasteners q and lower belt guard
w.
6. Assemble the Swingarm Bushing Tool (PF-51237):

1. Thread nut y on to threaded rod u
approximately 1/2 way.
2. Slide bearing i on to threaded rod followed
by washer o and arbor a .
3. Drop spreader ball s into adapter d and
thread rod into adapter until the end lightly
contacts the spreader ball.
4. Remove the pivot spacer e from the LH side of the

swingarm followed by internal snap-ring r .
12

© Copyright 12.31
7. Lay the press plate f over the needle bearing and 11. Hold the threaded rod in place and turn the nut in
install the Swingarm Bushing Tool (PF-51237) until the needle bearing is drawn from the bore.
through the needle bearing as shown.
12. With the needle bearing removed, gently pry the

8. Raise the arbor up high enough to hold the inner seal g out of the needle bearing bore.
adapter in place with an open ended wrench.
9. Turn the top of the threaded rod in until the
adapter fingers are spread enough to grab the
inner diameter of the needle bearing.
13. Insert a suitable bearing driver or drift through the

RH side of the swingarm and drive the two
bearings h out through the LH side.
10. Lower the arbor until its seated on the press plate
and thread the nut down onto the bearing.
14. Inspect bearing bores for any galling or damage.

12.32 © Copyright
INSTALLATION S W I N G A R M I N S TA L L AT I O N
15. Working on the LH side of the swingarm, press or Drive belt must be installed on the drive sprocket
drive new bearings into the bearing bore using a prior to installing the swingarm.
suitable bearing driver.
1. Clean inside of the swingarm shaft bores in both
16. Install internal snap-ring and spacer removed in sides of the frame midcastings.
STEP 4 of this procedure.
2. Grease swingarm pivot shaft.
17. Working on the RH side of the swingarm, press a
new inner seal into the bearing bore until seated 3. If previously removed, install the shock absorber
on the shoulder. and pushrod assembly. See Shock Absorber
18. Using the bearing driver j provided in Swingarm
Bushing Tool (PF-51237), drive a new needle 4. Apply a thin film of grease to the LH swingarm
bearing into the RH side of the swingarm until fully spacer q and press into position in the LH bearing
seated. bore.
NOTE
Grease should be applied to the left side spacer so it
stays in position when swingarm is installed.
5. Lift the swingarm / shock absorber assembly into

position in the frame. Make sure the LH spacer
stays in position.
19. Press a new outer seal into the bearing bore until
seated.
20. Install lower belt guard and torque fasteners to
specification.
TORQUE
Lower Belt Guard Fasteners:
96 in-lbs (10.8 Nm)
6. CHIEFTAIN / CHIEFTAIN DARK HORSE /
21. Install shock absorber assembly. See Shock ROADMASTER / SPRINGFIELD ONLY:
Absorber Installation page 12.28.
Install the shock absorber air line into the LH frame
22. Install swingarm assembly. See Swingarm section and torque nut to specification.
TORQUE
Air Line Jam Nut:
20 ft-lbs (27 N·m)
12

© Copyright 12.33
7. Use an 8 mm hex wrench to thread the swingarm 9. Working on the LH side of the motorcycle, install
shaft w into the right side of the frame and torque the outer pivot spacer r and swingarm nut t and
to specification.. torque to specification.
TORQUE NOTICE
Swingarm Shaft: The swingarm nut cannot be reused once
8 ft-lbs (11 N·m) removed from the swingarm shaft. Apply AP
grease to the shoulder of the new nut prior to
installation.
8. Install the swingarm shaft jam nut e onto the end of
the swingarm shaft on the RH side. Torque jam nut
to specification. TORQUE
Swingarm Nut:
65 ft-lbs (88 N·m)
10. Install the debris flap y and three plastic dart clips
u and reconnect the tip over sensor i .
TORQUE
Swingarm Shaft Jam Nut:
75 ft-lbs (102 N·m)
11. Connect the ABS wheel speed sensor located at the

front of the swingarm.
12. Route the ABS wheel speed sensor harness as
shown and install the p-clamp fastener o . Torque
to specification.

12.34 © Copyright
13. Route the rear brake line as shown and install the 21. Adjust ride height. See “REAR SHOCK PRELOAD
front p-clamp a and rear p-clamp s . Torque INSPECTION”.
TORQUE
P-Clamp Fasteners:
84 in-lbs (9.5 Nm)
14. Install the rear wheel. See Rear Wheel Removal /

15. Make sure that the following applies:
• The rear wheel turns freely, without any interference
between the belt guard, the tire, and the swingarm.
• Brake line is properly routed and secured.
• The left and right axle adjusters are aligned
properly (wheel is in alignment).
• The rear brake functions properly.
• All fasteners have been tightened correctly.
• There is adequate clearance between swingarm and
exhaust mufflers and mounting.
• The swingarm is not loose, it doesn’t wobble from
side to side, and it doesn’t move up and down more
than 1/32 of an inch when pushed and pulled firmly.
16. Install the seat.

17. Install the upper and lower side panels. See Side
Cover (Upper), Removal / Installation page 3.15.
18. Install saddlebags, if equipped. Refer to Owner’s
Manual.
19. If equipped, install the charcoal canister. See
Evaporative Emission Control System (CA Models) 12
page 2.32.
20. Test ride motorcycle to be sure rear suspension
operates smoothly without binding or abnormal
noises.

© Copyright 12.35
TROUBLESHOOTING
TROUBLESHOOTING, REAR WHEEL /
SUSPENSION
Rear Wheel Feels “Loose” Loose fasteners Torque to specification
or Wobbles
Distorted (bent) rear wheel Replace wheel
Worn or damaged wheel bearings Replace wheel bearings
Worn or damaged swing arm Replace swing arm bushings
bushings.
Damaged or incorrect rear tire Replace rear tire
Unbalanced rear wheel assembly Balance tire/wheel
Low tire pressure Inflate to specification
Loose swing arm, axle or suspension Torque to specification
fasteners
Pushrod or shock bearing failure Replace pushrod or shock bearings
Rear Suspension Too Hard Incorrect preload adjustment Adjust to rider & load
Damaged shock absorber Replace / Rebuild shock
Damaged or corroded suspension Correct as necessary
mount bushing
Damaged or corroded swingarm Replace
bushings
High tire pressure Deflate to specification
Drive belt adjustment too tight Adjust drive belt tension
Rear Suspension Too Soft Incorrect preload adjustment Adjust to rider & load
Damaged shock absorber Rebuild or replace shock
Weak shock spring Replace shock spring
Excessive load placed on motorcycle Reduce load weight
Rear Suspension Noisy Loose fasteners Torque to specification
Worn wheel bearings Replace
Worn swing arm bushings Replace
Damaged shock absorber Replace as necessary
Worn pushrod or shock bearings Replace pushrod or shock bearings
Wheel Drags (Turns Hard) Incorrect drive belt adjustment Adjust drive belt tension
Brake problem Diagnose and Service
Loose fasteners Torque to specification
Bent rear axle Replace
Damaged wheel bearings Replace
Tire contact with object or chassis Determine point of contact and correct

12.36 © Copyright
TROUBLESHOOTING, FINAL DRIVE

PROBLEM POSSIBLE CAUSE POSSIBLE REPAIR NEEDED
Belt Shows Excessive Wear Out-of-Alignment Align rear wheel
On One Side
Belt Squeal Out-of-Alignment Align rear wheel
Belt Whine / Noise Out-of-Alignment Align rear wheel
Belt Damage Inspect Belt
Incorrect Belt Tension Adjust Tension
Broken Sprocket Teeth Foreign material damage / Loose drive Replace parts or repair as necessary
belt or sprocket
Broken or Torn Cogs on Belt Foreign material damage / Loose drive Replace parts as necessary
belt or sprocket
Belt Jumps Sprocket Teeth Worn, damaged or out of adjustment Replace parts as necessary
belt or sprockets
Belt Loose Adjust Belt
Excessive Wear, Binding Belt Tight Adjust Belt
Suspension
Broken Belt Belt weakened by foreign material Replace Belt, Replace Sprockets
damage. Belt run excessively tight or
loose.
12

© Copyright 12.37
NOTES

12.38 © Copyright
TIRES
CHAPTER 13
TIRES
13
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.2
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.2
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.5
TIRE WEAR PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.5
OZONE CRACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.5
FRONT TIRE CUPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.5
TIRE PRESSURE MONITORING SYSTEM (TPMS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.6
TPMS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.6
TPMS SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.6
TPMS ACTIVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.7
TIRE CHANGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.9
TIRE CHANGING, GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.9
TIRE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
TIRE REMOVAL - (CHIEFTAIN / ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
TIRE REMOVAL - (CLASSIC / VINTAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.11
TIRE REMOVAL - (DARK HORSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.12
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.14
VISUAL INSPECTION & RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.14
TIRE REPAIR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.14
VALVE STEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.15
VALVE STEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.15
VALVE STEM INSTALLATION - RUBBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.15
VALVE STEM INSTALLATION - METAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.15
TIRE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.16
TIRE INSTALLATION - (CHIEFTAIN / ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.16
TIRE INSTALLATION - (CLASSIC / VINTAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.18
TIRE INSTALLATION - (DARK HORSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.20
TIRE BALANCING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.22
TIRE BALANCING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.22
SPOKED WHEEL SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.23
WHEEL TRUING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.23
FINAL TIGHTENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.23
WHEEL LACING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.24

© Copyright 13.1
TIRES
WARNING All repairs must be made from inside the tire.
If a consumer wishes to replace the Original
Equipment Manufacturer (OEM) tires with another
brand of tire, Indian Motorcycle recommends WARNING
contacting the tech-line department of the tire No form of temporary repair should ever be
manufacturer being considered to ensure attempted. Secondary damage caused by a
compatibility. Indian Motorcycle makes no other penetrating object may not be detected and tire or
recommendation other than the OEM tires. Tires tube deflation may occur at a later date.
other than OEM may or may not adversely affect the
handling characteristics of the motorcycle or may not
have adequate clearance between tire and various WARNING
parts of the motorcycle.
It is dangerous to ride with a worn tire. When a
tire reaches the minimum tread depth listed
WARNING below, replace the tire immediately.
Indian Motorcycles are produced using the

designated tires listed as original equipment. This CAUTION
includes field testing to ensure stability and superior
handling. The use of tires other than original Two of the biggest factors contributing to premature
equipment may cause instability which can lead to a tire wear are overloading and under-inflation. Do not
crash resulting in serious injury or death. Use only deviate from the specifications for loading or
the recommended tires inflated to the recommended inflation.
tire pressures. Operating the motorcycle with
damaged rims creates a safety hazard including air
pressure loss, steering imbalance and/or reduced
steering control. Do not attempt to repair or SPECIAL TOOLS
straighten damaged rims. TOOL DESCRIPTION PART NUMBER
TPMS Activation Tool PF-51288
WARNING Tire Changing Machine Commercially Available
Do not attempt to repair tires that have:
• Punctures with a diameter of greater than 6mm
(0.240").
• Cuts with a length of greater than 6mm (0.240").
• Any punctures or cuts on the sidewall of the tire.
• Tread depth of less than 1.6mm (.063") for the front
tire.
• Tread depth of less than 1.6mm (.063") for the rear
tire.
• Ply separation.
• Tread separation.
• Severe tread cupping.
• Cuts, gouges or scratches on the sealing surface of
the bead.
• Flat spots on the tread.
• Bubbles, separation or any unusual damage to the
inner liner of the tire.
• Chemical sealants or balance additives added to
the tire.

13.2 © Copyright
TIRES
Refer to Steering / Suspension chapter for front and rear wheel specifications.
Tire Pressure Table (Cold)
NOTICE 13
Also refer to Manufacturing Information label.
CHIEF CLASSIC
FRONT: Dunlop American Elite (130/90 B16) 36 PSI(248 kPa)
REAR: Dunlop American Elite (180/65 B16) 40 PSI (276 kPa)
CHIEF VINTAGE
FRONT: Dunlop American Elite (130/90 B16) 36 PSI (248 kPa)
CHIEF DARK HORSE

FRONT: Dunlop Elite 3 (130/90 B16) 36 PSI (248 kPa)
SPRINGFIELD
CHIEFTAIN DARK HORSE

CHIEFTAIN
CHIEFTAIN LIMITED / ELITE

FRONT: Dunlop American Elite - 130/60B19 36 PSI (248 kPa)
REAR: Dunlop Elite 3 - 180/60R16 41 PSI (282 kPa)
ROADMASTER
ROADMASTER CLASSIC
Minimum Tread Depth (ALL MODELS)
Front Tire Minimum Tread Depth .063 in (1.6 mm)

Rear Tire Minimum Tread Depth .063 in (1.6 mm)

© Copyright 13.3
TIRES

13.4 © Copyright
TIRES
TIRE INSPECTION
T I R E W E A R PAT T E R N S
TIRE WEAR PATTERNS
SYMPTOM CAUSE
Riding on Crowned
13
Wear on Left Side
Roads
Edges Worn Underinflation or

Excessive Loads
Excess Wear in the Over-inflation or Tire
Middle of Tire Abuse
Underinflation,
Cracks in Tread Grooves Excessive Loads,
Suspension Bottoming
Tread Block Cupping

(Usually Front Tire -See Normal Braking Wear
Below)
OZONE CRACKING
Ozone cracking usually shows up on the sidewalls of
tires and is caused by sunlight, electric motor
emissions, smog, or other environmental factors.
Ozone cracking does not pose a problem unless the
cracks reach the cords. If this occurs, moisture may
penetrate the carcass of the tire causing cord
separation. Tires showing signs of severe ozone
cracking (cords visible at the bottom of the cracks)
must be replaced.
FRONT TIRE CUPPING

Front of tread block worn more than rear of tread
block:
• The cupping of front tires is somewhat normal.

• Rear tires are subjected to forces in both directions.
The forces of braking and acceleration result in even
tire wear.
• Front tires are subjected only to the forces of
braking. When the brakes are applied, tire
deflection is increased and wear occurs in only one
direction.
• Incorrect tire pressure is the number one cause of
excessive tire cupping. Too little tire pressure
causes the tire to over-deflect which increases the
amount of scrubbing and causes more tire cupping.
• Binding or improperly assembled front forks can
also contribute to excessive tire cupping. If the front
forks do not react as they should the tire acts as the
sole suspension component and tread deflection
increases.

© Copyright 13.5
TIRES
TIRE PRESSURE MONITORING SYSTEM (TPMS)

TPMS OVERVIEW TPMS SENSOR REPLACEMENT
The Chieftain and Roadmaster models are equipped 1. Remove tire from rim. See Tire Removal, Chieftain
with an electronic tire pressure monitoring system / Roadmaster page 13.10.
(TPMS). The TPMS provides real-time tire pressure 2. Remove fastener q and sensor w.
information to the operator of the vehicle and displays
it via MFD and a low pressure warning light.
On models equipped with a TPMS, the sensors q

are located 180° from the valve stem w. Use
caution when servicing tires.
To avoid damaging a sensor, break the bead at the
valve stem, then at 90° and 270° from the valve stem as
required.
3. Reverse the removal procedure for installation.

Torque fastener to specification.
TORQUE
TPMS Sensor Fastener:
44 in-lbs (5 N·m)
4. Install tire. See Tire Installation - (Chieftain /

Roadmaster) page 13.16.
With TPMS, the pressure of each tire can be viewed in 5. Perform the TPMS sensor activation procedure.
the MFD. If the display shows dashes (—) instead of a
pressure value while traveling above 15 MPH (24 km/
h), the system may not be functioning properly. See
your dealer for service.
The TPMS warning indicator will illuminate if low tire
pressure is detected. Always correct low tire pressure
promptly. Always inspect tire pressure and condition
before each ride.
The TPMS display may indicate an increase in tire
pressure while riding, a normal occurrence as tires
warm up. Riding into colder conditions may result in a
drop in tire pressure as tires cool down. Regardless of
conditions, low tire pressures should always be
corrected promptly.

13.6 © Copyright
TIRES
T P M S A C T I VAT I O N 2. Press and hold RH and LH mode buttons

TPMS sensor activation is required any time the follow- simultaneously until the SETUP screen is displayed
ing occur: on the MFD.
• TPMS sensor has been replaced.
• Vehicle Control Module (VCM) has been reflashed.
• Vehicle Control Module (VCM) has been replaced. 13
TPMS activation or “Wake Up” requires the use of
the TPMS Activation tool (PF-51288).
NOTE
The TPMS sensor is located 180° from the valve stem
(1). Locate the position of the front and rear valve
stems and place a piece of tape on the tire on the
opposite side (180°). Both pieces of tape (front and
rear tires) should be visible so the TPMS Activation
tool can be held within 3 in (7.6 cm) of the tire where
the sensor is located. 3. Press the RH mode button until TPMS is highligted.
NOTE
The TPMS Activation tool should be held close to the
sidewall of the tire when activating the sensors. If
the Activation tool is held over the aluminum rim, the
sensor signal may not be received.

motorcycle electrical system.

© Copyright 13.7
TIRES
4. 6. With the Activation tool powered up and

“Searching” for the TPMS sensor, hold the device
NOTE
no more than 3 in (7.6 cm) from the sidewall where
Once TPMS setup has been initiated on the the tape was placed on the front tire. You should
motorcycle, there is approximately 30 seconds to hear a short audible “beep” acknowledging
complete the activation procedure before the sensor activation. The MFD will switch to the rear
system times out and must be restarted. Make wheel.
sure the TPMS Activation tool is close at hand and
powered up before initiating setup.
Press the LH mode button to begin the activation

process. The following screen should appear.
7. Move to the rear wheel and hold the Activation

tool no more than 3 in (7.6 cm) from the sidewall
where the tape was placed previously. You should
hear a short audible “beep” acknowledging
sensor activation. The MFD will display the
following screen indicating successful activation of
5. After a few seconds the following screen will both TPMS sensors.
appear, indicating that the TPMS sensors are ready
to be activated with the Activation tool.

13.8 © Copyright
TIRES
TIRE CHANGING
T I R E C H A N G I N G , G E N E R A L I N F O R M AT I O N
There are three generally acceptable methods to
dismount and mount a motorcycle tire to its rim. For
each of the three methods, there are countless
variations.
13
The three general methods are:
• Pneumatic or electrically operated tire machine

• Manually operated tire machine
• Manual manipulation of tire irons
Indian Motorcycle permits and recommends all three

of the general methods, but realizes that careless or
improper work habits can damage both the tire and
rim no matter which method is used. With any of the
methods, care must still be taken to avoid damaging
the rim, tire, inner tube (if applicable), brake disk, or
sprocket.
The pneumatic or electrically operated tire machine is
preferred because it is the most efficient method to
dismount and mount tires.
The manually operated tire machine is the next
preferred method. It can be just as efficient as a power
assisted tire machine but with some of the machines it
may be necessary to remove the belt driven sprocket
in order to gain sufficient clearance for tire removal.
Manual manipulation is the least preferred method
since it will generally not deliver the same efficiency
as the other methods and greater care needs to be
taken when performed. Care must be taken when
using tire irons to not damage or stress the tire bead,
Also, the opposite bead needs to be in drop center of
wheel during mounting and dismounting of the tire.
Be very careful not to damage the rim, tire, inner tube,
brake disk, TPMS sensor or sprocket regardless of
which method is used.
CAUTION
On models equipped with a Tire Pressure Monitoring
System (TPMS) break beads at the valve stem, then at
90° and 270° from the valve stem as required. If the
bead is broken 180° from the valve stem (sensor
location) the TPMS sensor may be damaged and
require replacement. See TPMS Overview page 13.6.

© Copyright 13.9
TIRES
T I R E R E M O VA L
T I R E R E M O VA L - ( C H I E F TA I N / 3.
ROADMASTER) CAUTION
NOTICE The TPMS sensor is located 180° from the valve stem.
This procedure is written assuming that a If the bead is broken 180° from the valve stem the
pneumatic, electric, or manually operated rim- TPMS sensor may be damaged and require
clamp type tire machine is being used. replacement.
1. Remove wheel / tire assembly from motorcycle.

See Steering / Suspension chapter for front and Mount the wheel assembly onto a tire bead
rear wheel removal procedures. breaker and break the bead starting at the valve
stem, then again at 90° and again at 270° from the
2. Remove valve core q from valve stem and let all valve stem as necessary.
air escape.
4. Flip the wheel assembly over and repeat STEP 3 on

the other side.
IMPORTANT
Take great care not to bend or otherwise damage the
brake disc and/or belt driven sprocket. If the bead
breaker being used interferes with either the brake
disk and/or belt driven sprocket, remove the disc or
sprocket as required.
5. Push tire down and lubricate tire bead with tire

lubricant on both sides of the tire.
6.
NOTICE
Refer to manufacturer’s instructions for proper
tire changer operation.
Mount the tire and wheel assembly on the tire

machine per the manufacturers instructions.

13.10 © Copyright
TIRES
7. Carefully work around the circumference of the T I R E R E M O VA L - ( C L A S S I C / V I N TA G E )

upper bead w with the tire lever until it is
completely off of the rim. NOTICE
This procedure is written assuming that a
pneumatic, electric, or manually operated rim-
clamp type tire machine is being used.
13
See Steering / Suspension chapter for front and
rear wheel removal procedures.
2. Remove valve core q from valve stem and let all
air escape.
8. Paying attention to the location of the TPMS sensor

e, lift the lower tire bead up until the tire lever can
be positioned and the tire completely removed.
3. Mount the wheel assembly onto a tire bead

breaker and break the bead starting at the valve
stem and continue around the circumference of the
rim as necessary.
4. Flip the wheel assembly over and repeat STEP 3 on
the other side.
IMPORTANT
Take great care not to bend or otherwise damage the
9. Work around the circumference of the rim until the brake disc and/or belt driven sprocket. If the bead
tire can be lifted free of the rim. breaker being used interferes with either the brake
5.
NOTICE


© Copyright 13.11
TIRES
6. Carefully work around the circumference of the T I R E R E M O VA L - ( D A R K H O R S E )

completely off of the rim. NOTICE

See Steering / Suspension chapter for front and
rear wheel removal procedures.
2. Remove valve core q from valve stem and let all
air escape.
7. Lift the lower tire bead up until the inner tube can
be withdrawn from the tire. Remove inner tube e .
3. Mount the wheel assembly onto a tire bead breaker

and break the bead starting at the valve stem and
continue around the circumference of the rim as
necessary.
8. Lift the lower tire bead up until the tire lever can 4. Flip the wheel assembly over and repeat STEP 3 on
be positioned and the tire completely removed. the other side.
9. Work around the circumference of the rim until the IMPORTANT
tire can be lifted free of the rim. Take great care not to bend or otherwise damage the
brake disc and/or belt driven sprocket. If the bead
breaker being used interferes with either the brake
5.
NOTICE


13.12 © Copyright
TIRES
6. Carefully work around the circumference of the

completely off of the rim.
13
7. Lift the lower tire bead up until the tire lever can be
positioned and the tire completely removed.
8. Work around the circumference of the rim until the
tire can be lifted free of the rim.

© Copyright 13.13
TIRES
WHEEL INSPECTION
VISUAL INSPECTION & RUNOUT T I R E R E PA I R P R E C A U T I O N S
1. Clean the rim of all rubber particles and
corrosion. WARNING
2. Inspect wheel for cracks and/or distortion. Only permanent plug-patch repairs of small tread
area punctures from inside the dismounted tire are
3. Inspect bead seating area for scratches, distortion, recommended. Never perform an exterior repair and
or damage that could prevent proper sealing. never use an inner tube as a substitute for a proper
4. Measure wheel for radial runout (1). repair. Speed should not exceed 50 MPH for the first
24 hours after repair and the repaired tire should
5. Measure wheel for axial runout (2). never be used over 80 MPH. Inspect inflation
pressure after tire cools for at least three hours
following initial operation.
NOTICE
Measure runout on tire bead sealing surface of
wheel. Be sure surface is clean.
6. Compare measurements of axial and radial runout

to specifications. See Service Specifications page
12.5. Replace wheel if any measurement exceeds
Service Limit.
7. Clean the sealing surfaces of the rim thoroughly.
Use a soft brush (nylon) soap and water if
necessary.
WARNING
Do not scratch or damage sealing surfaces of rim.
Loss of air pressure can cause a loss of control and an
accident, resulting in serious injury or death.

13.14 © Copyright
TIRES
VA LV E S T E M
VA LV E S T E M I N S P E C T I O N 2. Remove valve stem nut q , valve stem w and o-
1. Remove the valve stem cap and spray the valve ring e .
stem down with a mild soap and water solution.
2. Observe the area around the base of the valve
stem and valve core area. If any bubbles form over
a 1–2 minute period, the valve stem or inner tube
13
should be replaced.
3. Inspect valve stem for cracks or visible damage
and replace if necessary.
NOTICE
Tubeless: Valve stem replacement is recommended
when tire is being replaced.
Tube Type: Inner tube replacement is
recommended when tire is being replaced.
3. Clean gasket or o-ring sealing surface of rim.

VA LV E S T E M I N S TA L L AT I O N - R U B B E R
1. Remove tire from wheel and cut valve stem with a 4. Place new valve stem (with seal washer or O-ring
diagonal cutter to remove. installed) through hole in rim and position it so the
stem is perpendicular from wheel center and,
2. Clean tire valve hole and sealing area thoroughly. valve opening facing away from surface containing
3. Lubricate tire valve and hole with P-80 rubber direction indicator.
lubricant or equivalent.
4. Place tire valve into hole and fastener a tire valve
installation tool (commercially available) onto
valve.
5. Place a small wood block against the rim to
improve leverage point and keep the pulling angle
as straight as possible. (Fig. 9)
6. Pull the valve until fully seated and remove tool.
VA LV E S T E M I N S TA L L AT I O N - M E TA L
IMPORTANT
The Chieftain, Roadmaster and Dark Horse models
use directional tires and wheels. Pay close attention
to markings to ensure proper tire and valve stem
orientation. 5. Hold stem and tighten nut to specification.
TORQUE
1. Remove tire from wheel as outlined in this chapter.
Valve Stem Nut:
44 in-lbs (5.0 Nm)
6. Install tire as outlined in this chapter.

© Copyright 13.15
TIRES
T I R E I N S TA L L AT I O N
T I R E I N S TA L L AT I O N - ( C H I E F TA I N / 2.
ROADMASTER) NOTICE
NOTICE Refer to manufacturer’s instructions for proper
clamp type tire machine is being used. Mount the tire and wheel assembly on the tire
NOTICE 3. Orient tire correctly as to the balance dot and
Balance Dots directional arrows.
Dunlop tires have a yellow dot on the sidewall which 4.
corresponds to the lightest part of the tire. This dot is
meant to line-up with the tire valve which often is the CAUTION
heaviest part of the rim (although this is not always
the case). Use care not to damage the TPMS sensor while
installing the tire bead over the edge of the rim.
Indian Motorcycle does not recommend the use of
liquid balancer/sealers. These are a form of
temporary repair which may adversely affect ply
Push tire on to rim until one bead is installed. It
material and mask secondary damage caused by the
shouldn’t be necessary to use tire irons to put one
penetrating object. Reliance upon sealants can result
side of the tire onto the rim. Remember to keep
in sudden tire failure and accident.
bead(s) in the drop center of the wheel whenever
Directional Arrows possible.
Tires q and rims w have directional arrows that must
be observed when installing tires to rims.
NOTICE
The wheel assemblies must be free of foreign debris Confirm tire is positioned correctly by observing
that would affect balancing. directional arrows.
Carefully inspect the wheel bearings, seals and axle
for damage or corrosion. 5. Lubricate the tire bead.
1. Lubricate both tire beads with rubber lubricant. 6. With your hands, push as much of the remaining
tire bead as possible into the rim, pinching both
CAUTION upper and lower beads into the drop center.
Never apply grease, oil, gasoline, spray type 7. When no more of tire can be installed by hand,
lubricants or anything other than rubber lubricant or press down on portion of tire in front of you with
a neutral soap and water solution to the tire bead. your knee to keep the top bead in the drop center.
Doing so can damage the tire.

13.16 © Copyright
TIRES
8. Install the tire lever and work around the 18. Balance tire / wheel assembly.
remaining circumference of the wheel until the
bead is fully installed onto the rim. WARNING
NOTICE FOR REPAIRED TIRES: Speed should not exceed
50 MPH for the first 24 hours after repair and
Be sure both beads are forced as far as possible into repaired tire should never be used over 80 MPH.
the drop center of the rim. Inspect inflation pressure after tire cools for at least 13
three hours following run-in.
9. Install valve core if it was removed. FOR NEW TIRES: Replacement of OEM tires or
10. Line up balance dot. replacement with differently constructed tires will
not immediately produce improved reactions the
11. Confirm that the directional arrows are pointing in same as the original tires when new. When new tires
the correct direction. are installed, they should not be subjected to
12. Bounce tire on the floor several times while maximum power or hard cornering until a reasonable
rotating tire. This will expand tire bead outward “scrub” period of approximately 100 miles has been
slightly which will make tire inflation easier. covered. This will permit the rider to become
accustomed to “feel” of new tires or tire
13. Inflate tire observing the precautions listed below. combination, and achieve optimum road grip.
Tire Inflation & Precautions Inspect and adjust tire inflation pressure after tire
cools down for at least three hours following “run-
• Wear approved eye protection in”.
• Lubricate the tire beads with a tire mounting
lubricant before inflation.
• Lock assembly on mounting machine or place in
safety cage before inflating to seat beads
• Use extension gauge and hose with slip-on air
chuck.
• Stand back with no part of your body within the
perimeter of the assembled tire and rim.
• Inflate with core in valve stem
• Never inflate above 42 psi to seat beads
• If beads do not seat by 42 psi. Deflate and repeat
procedures. Never use a volatile substance or
rubber “donut” to aid bead seating.
14. Inspect the line molded onto the tire side walls. It
must be the same distance from the rim all the way
around the tire. If the distance varies it indicates
that tire is not seated properly.
15. If tire is not seated correctly, deflate and unseat
the tire, lubricate the tire beads and repeat
inflation procedure.
16. Install wheel assembly onto balance stand and
spin. Observe the wheel assembly while it is
spinning to make sure the tire is seated properly.
17. Adjust tire pressures to specifications.

© Copyright 13.17
TIRES
T I R E I N S TA L L AT I O N - ( C L A S S I C / V I N TA G E ) 3.
NOTICE NOTICE
This procedure is written assuming that a Refer to manufacturer’s instructions for proper
pneumatic, electric, or manually operated rim- tire changer operation.
NOTICE machine per the manufacturers instructions.
Balance Dots 4. Orient tire correctly as to the balance dot and
Dunlop tires have a yellow dot on the sidewall which directional indicators.
corresponds to the lightest part of the tire. This dot is
5. Push tire on to rim until one bead is installed. It
meant to line-up with the tire valve which often is the
shouldn’t be necessary to use tire irons to put one
heaviest part of the rim (although this is not always
side of the tire onto the rim. Remember to keep
the case).
bead(s) in the drop center of the wheel whenever
Indian Motorcycle does not recommend the use of possible.
Directional Arrows
Tires and rims have directional indicators that must
Rims:The valve stem q should exit the rim on the
riders RH side when installed on the motorcycle.
Tires:The tires w have directional arrows located on
the side wall.
NOTICE
Confirm tire is positioned correctly by observing
directional arrow.
6. Thread valve stem base nut completely on to valve

stem.
7. Apply baby powder to new (deflated) tube and
install by inserting valve stem through the rim
band and rim.
The wheel assemblies must be free of foreign debris

that would affect balancing.
Carefully inspect the wheel bearings, seals and axle
for damage or corrosion.
1. Make sure that the edges of the rim, where the

beads rest, are clean and free of debris.
2. Lubricate both tire beads with rubber lubricant.
CAUTION
Never apply grease, oil, gasoline, spray type
lubricants or anything other than rubber lubricant or
a neutral soap and water solution to the tire bead.
Doing so can damage the tire.

13.18 © Copyright
TIRES
8. Install the tube e into the tire starting at the valve 15. Inflate tire observing the precautions listed below.
stem and working around until the entire tube is Tire Inflation & Precautions
laying inside the tire in a natural position.
• Wear approved eye protection
• Lubricate the tire beads with a tire mounting
lubricant before inflation.
13
• Lock assembly on mounting machine or place in
safety cage before inflating to seat beads
• Use extension gauge and hose with slip-on air
chuck.
• Stand back with no part of your body within the
9. Arrange the tube, if necessary, to remove kinks or procedures. Never use a volatile substance or
bends, making sure that the valve stem projects rubber “donut” to aid bead seating.
straight out and forms a 90 degree angle with the
rim. 16. Inspect the line molded onto the tire side walls. It
10. Thread the valve stem lock nut until it fully draws around the tire. If the distance varies it indicates
the valve stem through the rim and torque to that tire is not seated properly.
specification.
17. If tire is not seated correctly, deflate and unseat
TORQUE the tire, lubricate the tire beads and repeat
inflation procedure.
Valve Stem Lock Nut:
13 in-lbs (1.6 Nm) 18. Install wheel assembly onto balance stand and
11. For tube type tires, also observe the following: spinning to make sure the tire is seated properly.
CAUTION
20. Balance tire / wheel assembly.
Make sure your tire irons are smooth and free of
scratches or any sharp edges. Polish them if WARNING
necessary. Do not slide the tire iron in any more than
is necessary. When installing tube type tires, avoid FOR REPAIRED TIRES: Speed should not exceed
lifting the tire iron past vertical to minimize the 50 MPH for the first 24 hours after repair and
chance of pinching the tube. repaired tire should never be used over 80 MPH.
Inspect inflation pressure after tire cools for at least
three hours following run-in.
12. Install valve core if it was removed.
FOR NEW TIRES: Replacement of OEM tires or
13. Line up balance dot. replacement with differently constructed tires will
14. Confirm that the directional arrows are pointing in same as the original tires when new. When new tires
the correct direction. are installed, they should not be subjected to
maximum power or hard cornering until a reasonable
“scrub” period of approximately 100 miles has been
covered. This will permit the rider to become
accustomed to “feel” of new tires or tire
combination, and achieve optimum road grip.
Inspect and adjust tire inflation pressure after tire
in”.

© Copyright 13.19
TIRES
T I R E I N S TA L L AT I O N - ( D A R K H O R S E ) 2.
NOTICE NOTICE
This procedure is written assuming that a Refer to manufacturer’s instructions for proper
pneumatic, electric, or manually operated rim- tire changer operation.
NOTICE
3. Orient tire correctly as to the balance dot and
Balance Dots directional arrows.
Dunlop tires have a yellow dot on the sidewall which
corresponds to the lightest part of the tire. This dot is 4. Push tire on to rim until one bead is installed. It
meant to line-up with the tire valve which often is the shouldn’t be necessary to use tire irons to put one
heaviest part of the rim (although this is not always side of the tire onto the rim. Remember to keep
the case). bead(s) in the drop center of the wheel whenever
Indian Motorcycle does not recommend the use of possible.
Directional Arrows
Tires q and rims w have directional arrows that must
NOTICE
Confirm tire is positioned correctly by observing
directional arrows.
5. Lubricate the tire bead.

6. With your hands, push as much of the remaining
The wheel assemblies must be free of foreign debris tire bead as possible into the rim, pinching both
that would affect balancing. upper and lower beads into the drop center.
Carefully inspect the wheel bearings, seals and axle 7. When no more of tire can be installed by hand,
for damage or corrosion. press down on portion of tire in front of you with
your knee to keep the top bead in the drop center.
1. Lubricate both tire beads with rubber lubricant. 8. Install the tire lever and work around the remaining
circumference of the wheel until the bead is fully
CAUTION installed onto the rim.
Never apply grease, oil, gasoline, spray type NOTICE
lubricants or anything other than rubber lubricant or
a neutral soap and water solution to the tire bead. Be sure both beads are forced as far as possible into
Doing so can damage the tire. the drop center of the rim.
9. Install valve core if it was removed.

10. Line up balance dot.

13.20 © Copyright
TIRES
11. Confirm that the directional arrows are pointing in 18. Balance tire / wheel assembly.
the correct direction.
12. Bounce tire on the floor several times while rotating WARNING
tire. This will expand tire bead outward slightly FOR REPAIRED TIRES: Speed should not exceed
which will make tire inflation easier. 50 MPH for the first 24 hours after repair and
repaired tire should never be used over 80 MPH.
13. Inflate tire observing the precautions listed below.
Inspect inflation pressure after tire cools for at least 13
IMPORTANT three hours following run-in.
FOR NEW TIRES: Replacement of OEM tires or
Tire Inflation & Precautions replacement with differently constructed tires will
• Wear approved eye protection same as the original tires when new. When new tires
• Lubricate the tire beads with a tire mounting are installed, they should not be subjected to
lubricant before inflation. maximum power or hard cornering until a reasonable
“scrub” period of approximately 100 miles has been
• Lock assembly on mounting machine or place in covered. This will permit the rider to become
safety cage before inflating to seat beads accustomed to “feel” of new tires or tire
• Use extension gauge and hose with slip-on air combination, and achieve optimum road grip.
chuck. Inspect and adjust tire inflation pressure after tire
• Stand back with no part of your body within the in”.
procedures. Never use a volatile substance or
rubber “donut” to aid bead seating.
14. Inspect the line molded onto the tire side walls. It
around the tire. If the distance varies it indicates
that tire is not seated properly.
15. If tire is not seated correctly, deflate and unseat the
tire, lubricate the tire beads and repeat inflation
procedure.
16. Install wheel assembly onto balance stand and
spinning to make sure the tire is seated properly.

© Copyright 13.21
TIRES
TIRE BALANCING
TIRE BALANCING
WARNING
It is essential that the wheel assembly be balanced
before use and rebalanced each time the tire is
removed. Wheel balance affects stability, handling
and overall safety of the motorcycle.
All Dunlop street tires should be installed with the

yellow balance dot at the tire valve.
The use of liquid balancer/sealer is not
recommended.
This procedure will outline balancing wheel assembly
in a gravity balance stand. If a pendulum or spin type
balancer is being used, reference the manufacturer’s
instructions that came with the equipment.
1. Mount wheel assembly in a commercially
available balance stand.
2. Remove all balance weights. Clean tire and rim
thoroughly.
NOTICE
While it is possible to balance a wheel assembly with
axle and grease-free wheel bearings as the pivot
point, it is not recommended. Use an inspection
stand that has knife edge bearings and its own axle.
3. Spin the wheel assembly. Allow it to stop on its

own and mark the highest (lightest) part of the
wheel.
4. Repeat the spinning process to verify the heaviest
part of the wheel.
5. Place balance weights at the lightest portion of
wheel in small increments.
6. After each addition of weight, spin the wheel
assembly and allow it to stop by itself.
7. When correct amount of weight has been added to
wheel, it will no longer stop in the same location
and the wheel assembly is balanced.
CAUTION
Do not add more than 85 grams (3.0 oz.) of weight to
the front or rear wheel.
If more than the recommended weight is

necessary to balance the wheel, dismount the tire
and rotate it 90o without regard to the yellow
balance dot, and re-balance the wheel / tire.
Adhesive Weight P/N 1520253
8. Install wheel / tire assembly onto motorcycle. See
Steering / Suspension chapter for front and rear
wheel installation procedures.

13.22 © Copyright
TIRES
SPOKED WHEEL SERVICE

WHEEL TRUING 3. Adjust axial runout.
1. Measure axial and radial runout.
NOTICE
It’s important to work slowly and make adjustments in
small increments. Alternate between radial and axial
adjustments until runout is within specification. 13
FINAL TIGHTENING
1. Using tape, divide wheel into four quadrants to
perform final spoke torque sequence. Tighten
each spoke equally. (Tightening Sequence
1,3,2,4)
TORQUE
Final Spoke Torque:
69 in-lbs (8 Nm)
2. Maintain proper runout adjustment during final

tightening of spokes.
NOTICE
Axial runout is side to side movement (wobble) of the
rim. Radial runout is the up and down movement
(hop) of the rim.
2. First, adjust radial runout by loosening spokes

around any high spots, rotate wheel 1/2 turn and
tighten spokes directly opposite the high spot.

© Copyright 13.23
TIRES
WHEEL LACING 3. Using the index marks from step one, insert all
inside spokes skipping one hole between each.
NOTICE
If an assembled wheel is available, it can be
referenced for proper spoke pattern.
NOTICE
Using tape or a grease pen, mark one side of the hub
and rim for reference during reassembly. These
parts must be assembled the same way they came
apart.
1. Before disassembly, select a “starting spoke” and

make index marks at its anchor points on the hub
and rim. This will help ensure the spokes are
installed and grouped correctly upon assembly.
NOTICE
Install inside spokes on the opposite flange one hole
to the right or left.
4. Lay rim in position around the hub assembly

making sure the valve stem hole and spoke index
marks are correctly located.
2. Organize 20 inside spokes and nipples on a clean

work surface. Lubricate spoke threads and rim
nipple-holes with a light oil.
5. Thread the “starting spoke” into the

corresponding nipple and continue to thread
inside spokes until they are all finger tight.
6. Install outside spokes and screw on nipples. Work
your way around the wheel, installing spokes on
alternate sides of wheel. Continue until all spokes
and nipples are installed. Tighten nipples equally
by hand.
7. With all nipples installed, evenly snug all nipples
using a spoke wrench. Equally tighten around the
wheel until one thread shows above each nipple.
8. Place wheel assembly onto a truing stand for rim
offset adjustment, final spoke tightening and
wheel truing of wheel.

13.24 © Copyright
TIRES
TROUBLESHOOTING
Rear Wheel (Wobbles) Bent rim Replace
Worn or damaged wheel bearings Replace as a set
Worn or damaged swing arm Replace as a set 13
bushings.
Damaged or incorrect tire Replace rear tire
Wheel assembly out-of-balance Balance wheel
Loose swing arm, axle or Torque to specification
suspension fasteners.
Handlebars Oscillate (Wobble) Bent front axle Replace
Tire mounted incorrectly Inspect and re-mount tire
Damaged tire Replace
Loose steering stem nut Adjust to specification
Incorrect tire Replace
Incorrect tire pressure Inflate to specification
Front Wheel Oscillates (Wobbles) Bent rim Replace
Damaged or incorrect tire Replace
Loose axle or axle pinch fasteners Torque to specification
Right and left fork not installed at Repair
same height
Fork oil level incorrect Fill to specification
Fork spring free length different Replace spring that does not meet
between right & left specification
Wheel assembly out-of-balance Balance wheel

© Copyright 13.25
TIRES
NOTES

13.26 © Copyright
BRAKES
CHAPTER 14
BRAKES
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.3
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.3 14
ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.5
FRONT BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.5
REAR BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.6
BRAKE LINE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.7
FRONT MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.8
REAR MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.9
FRONT BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.10
REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.11
ABS MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.12
WHEEL SPEED SENSOR, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.13
WHEEL SPEED SENSOR, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.14
ANTI-LOCK BRAKES SYSTEM (ABS) SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.15
ABS SYSTEM SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.15
ABS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.15
ABS SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.16
ABS OVERVIEW OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.16
ABS TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.16
ABS AND LOW BATTERY VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17
WHEEL SPEED SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.18
WHEEL SPEED SENSOR AIR GAP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.19
ABS MODULE REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.19
ABS BRAKE SYSTEM BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.21
BRAKE FLUID REPLACEMENT & BLEEDING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.21
ABS BRAKE VACUUM BLEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.21
ABS FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.22
ABS REAR BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.22
ABS FRONT BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.23
BRAKE LEVER RESERVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.24
BRAKE SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.25
FRONT BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.25
REAR BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.26
BRAKE DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.27
FRONT MASTER CYLINDER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.28
FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.30
FRONT CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.32
REAR MASTER CYLINDER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.33

© Copyright 14.1
BRAKES
REAR CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.34

REAR CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.36
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.37

14.2 © Copyright
BRAKES
Use only genuine Indian Motorcycle replacement
parts when servicing the brake system. Clean all The brake system uses ethylene-glycol based fluid
system components prior to disassembly, including (DOT 4). Do not use or mix with different types of
the fluid reservoir cover(s) to reduce the chance of fluid such as silicone-based (DOT 5) or any
debris entering the system during repair or petroleum-based fluid.
maintenance work. Start with a clean work area away Do not let water or moisture enter the master
from dust, water or other contamination. Cleanliness is cylinder when refilling. Water significantly lowers the
very important for proper brake system maintenance boiling point of the fluid and can result in poor
braking.
and repair. Follow procedure outlined in this manual
carefully, including fastener torques and the Do not use brake fluid taken from old, used or 14
application of special lubricant in required areas. unsealed containers. Never reuse brake fluid.
Special lubricants are included with service kits. Keep brake fluid containers completely sealed and
out of reach of children.
WARNING Brake hoses should be replaced whenever the
exterior shows signs of deterioration or damage.
Contaminated brake discs or pads greatly reduce the Brake hoses should be replaced every four (4) years
amount of stopping force available & increase regardless of their exterior condition.
stopping distance. Brake discs can be cleaned using Bleed the brake system any time it is disassembled
a commercially available brake disc cleaner. Follow or when the brake action is spongy.
the manufacturer instructions printed on the Always inspect the operation of the brakes before
container. NEVER attempt to clean contaminated riding the motorcycle.
brake pads. Always replace pads as a set. Replace sealing washers whenever brake lines are
removed.
Always remove the master cylinder fluid reservoir
cover and inspect the fluid level when brake pads are
replaced.
NOTICE
Brake fluid and some types of brake cleaners will
damage paint, plastics and some rubber compounds.
Cover or remove plastic and painted parts before
working on the brake system. If brake fluid is spilled
on cosmetic surfaces, immediately rinse the area
with a mild solution of soap and water until all traces
of brake fluid are removed. Make sure the master
cylinder reservoir being worked on is level and
clean before removing the cap.
SPECIAL TOOLS
ABS Tool (Lever Reserve) PV-50104
Vacuum Brake Bleeder Commercially Available

© Copyright 14.3
BRAKES
T O R Q U E S P E C I F I C AT I O N S TORQUE
PART / FASTENER
SPECIFICATION
TORQUE
PART / FASTENER
SPECIFICATION Caliper Fastener, Rear 31 ft-lbs (42.0 Nm)
Banjo Fastener, Front 18 ft-lbs (24.4 Nm) Caliper Slide Fastener, Rear 20 ft-lbs (27.0 Nm)
(Caliper, M/C)
Caliper Stud, Front 35 ft-lbs (47.5 Nm)
Banjo Fastener, Rear (Caliper, 18 ft-lbs (24.4 Nm)
M/C) Master Cylinder Cover, Front 13 in-lbs (1.5 Nm)
Bleeder Fastener (All) 48 in-lbs (5.4 Nm) Master Cylinder Cover, Rear 13 in-lbs (1.5 Nm)
Brake Disc, Front 22 ft-lbs (29.8 Nm) Master Cylinder Nut, Rear 35 ft-lbs (47.5 Nm)
Brake Lever Clamp 70 in-lbs (7.9 Nm) 120 in-lbs (13.5

Pad Retaining Pin (All)
Nm)
Brake Pressure Swithes 18 ft-lbs (24.4 Nm)
Wheel Speed Sensor (Both) 8 ft-lbs (10.8 Nm)
Caliper Body, Front 20 ft-lbs (27.0 Nm)
Replace every 24 months or 10,000 miles (16,000
Specified Brake Fluid DOT 4 km)
Brake Disc Thickness, Front 5 mm 4.5 mm (.177") (Min)
Brake Disc Thickness, Rear 7 mm 6.5 mm (.256") (Min)
Brake Disc Runout - .30 mm (.012") (Max)

Brake Pad Wear Limit (Front & Rear) - When wear limit groove is no longer visible
Brake Pedal Free Play (Pedal
No Adjustment -
Clearance)
Brake Lever Freeplay (Front) No Adjustment -

14.4 © Copyright
BRAKES
FRONT BRAKE SYSTEM
14
q Fastener, Front Disc — M8 x 25 (QTY.12) 22 ft-lbs (30 N·m)
w Stud, Front Caliper 35 ft-lbs (48 N·m)
e Washer, Copper Sealing -
r Fastener, Banjo — 10 x 1.25 18 ft-lbs (24 N·m)
t Fastener, Banjo — 10 x 1.25 18 ft-lbs (24 N·m)
y Washer, Copper Sealing -
u Snap Ring, External -
i Pivot Pin, Brake Lever -
o Rubber Diaphragm -
a Cover, Front Master Cylinder -
s Fastener, Front Master Cylinder Cover 14 in-lbs (2 N·m)
d Fastener, Brake Lever Clamp 70 in-lbs (8 N·m)

IMPORTANT
Torque the Brake Lever Clamp
upper fastener first and the
bottom fastener second.

© Copyright 14.5
BRAKES
REAR BRAKE SYSTEM
q Valve, Bleeder 48 in-lbs (5 N·m)
w Fastener, Caliper — 10 x 1.25 x 25 31 ft-lbs (42 N·m)

(QTY.2)
e Fastener, Banjo — 10 x 1.25 18 ft-lbs (24 N·m)
r Washer, Copper Sealing -
t Fastener, Pedal Pad — -
y Pedal Pad -
u Nut, Master Cylinder (QTY.1) 35 ft-lbs (47.5 Nm)
i Washer, Copper Sealing -
o Fastener, Banjo — 10 x 1.25 18 ft-lbs (24 N·m)
a Rubber Diaphragm -
s Cover, Rear Master Cylinder -
d Fastener, Rear Master Cylinder 7 in-lbs (1 N·m)

Cover

14.6 © Copyright
BRAKES
BRAKE LINE ROUTING
14
q Brake Line, Rear (Rear Caliper to ABS Module) -
w Fastener, P-Clamp — (QTY.3) 88 in-lbs (10 N·m)
e Fastener, Bracket — (QTY.6) 84 in-lbs (9 N·m)
r Brake Line, Front (ABS Module to Front Calipers) -
t Brake Line, Front (Front Master Cylinder to ABS Module) -
y Brake Pressure Switches 18 ft-lbs (24 N·m)
u Retaining Strap -
i Routing Clip -

© Copyright 14.7
BRAKES
FRONT MASTER CYLINDER
q Lever, Brake -
w Adjuster, Brake Lever -
e Pivot Pin, Brake Lever -
r Fastener, Front Master Cylinder Cover 14 in-lbs (2 N·m)
t Cover, Front Master Cylinder -
y Rubber Diaphragm -
u Fastener, Brake Lever Clamp 70 in-lbs (8 N·m)
i Snap Ring, External -
o Spring, Piston Return -
a Cup, Primary -
s Ring, Back Up -
d Piston -
f Cup, Secondary -
g Dust Boot -
h Pushrod -

14.8 © Copyright
BRAKES
REAR MASTER CYLINDER
14
q Fastener, Rear Master Cylinder Cover 7 in-lbs (1 N·m)
w Cover, Rear Master Cylinder -
e Rubber Diaphragm -
r Reservoir, Rear Master Cylinder -
t Cartridge, Rear Master Cylinder -
y Push Cap -
u Pushrod -
i Dust Boot -
o Washer -
a Snap Ring, External -
s Sight Glass -
d O-Ring, Sight Glass -

© Copyright 14.9
BRAKES
FRONT BRAKE CALIPER
q Fastener, Caliper Body 20 ft-lbs (27 N·m)
w Pad Retaining Pin 120 in-lbs (14 N·m)
e Screw, Bleeder 48 in-lbs (5 N·m)
r Caliper Body, Outboard -
t Piston Seal -
y Dust Seal -
u Piston -
i Brake Pads -
o Pad Spring -
a Dust Seal -
s Piston Seal -
d Caliper Body, Inboard -
f O-Ring, Caliper Passage -

14.10 © Copyright
BRAKES
REAR BRAKE CALIPER
14
q Fastener, Caliper Retainer 31 ft-lbs (42 N·m)
w Pad Retaining Pin 120 in-lbs (14 N·m)
e Caliper Body -
r Guide Pin -
t Piston Seal -
y Dust Seal -
u Piston -
i Brake Pad, Outboard -
o Pad Spring -
a Brake Pad, Inboard -
s Carrier, Caliper -

© Copyright 14.11
BRAKES
ABS MODULE

14.12 © Copyright
BRAKES
WHEEL SPEED SENSOR, FRONT
14

© Copyright 14.13
BRAKES
WHEEL SPEED SENSOR, REAR

14.14 © Copyright
BRAKES
ANTI-LOCK BRAKES SYSTEM (ABS) SERVICE

ABS SYSTEM SAFETY PRECAUTIONS A B S G E N E R A L I N F O R M AT I O N
Before working on an Indian Motorcycle equipped The Anti-Lock Brake System is a safety feature
with anti-lock brakes, review and understand all designed to prevent wheel lock-up and improve
general brake system, brake fluid, and ABS specific control of the motorcycle during extreme braking
precautions and system information. Do not attempt events, including:
maintenance or repair of the anti-lock brake system
without the proper tools. • Panic braking
• Slick surface braking (such as wet road surfaces)
WARNING
Proper brake system bleeding is extremely
• Surface transitions (from asphalt to oily asphalt or 14
cobblestone, etc.)
important to ensure adequate lever reserve in the
system. Always perform the Brake Lever Reserve test Here are a few general points to note about ABS:
described in this manual after bleeding the anti-lock
brake system. • The anti-lock brake system cannot be turned OFF.
• The ABS indicator lamp (located on the Instrument
• Operating with non-recommended tires or improper Cluster) always illuminates when the key is in the
tire pressure may reduce the effectiveness of the ON position and remains on until the anti-lock
anti-lock brake system. system activates, which occurs when vehicle speed
exceeds 6 mph (10 kph).
• Always install the recommended size and type of
tires specified for the vehicle. • If the lamp is not illuminated when the key is ON,
connect Digital Wrench and perform an ABS System
• Always maintain the recommended tire pressure. inspection to determine the cause.
• Indian Motorcycle DOT 4 Brake Fluid is required. • When the ABS lamp is illuminated, the anti-lock
Change every 10,000 miles (16,000 km) or 2 years, brakes will not activate, but the conventional brake
whichever comes first. system will continue to operate normally.
• The anti-lock brake system will not prevent wheel • If the lamp continues to illuminate after the vehicle
lock-up, loss of traction, or loss of control under all speed exceeds 6 mph (10 kph), the system is not
conditions. Always adhere to all safe motorcycle functioning. Connect Digital Wrench and perform an
riding practices as recommended. ABS System inspection to determine the cause.
• It is not unusual to leave tire marks on the road • When the anti-lock brakes engage during a braking
surface during a hard braking event. event, the rider will feel pulsing at the brake lever
• The anti-lock braking system does not compensate or pedal. Continue to apply steady pressure to the
for or reduce the risk associated with: brakes for the best stopping performance.
• excessive speed • The wheel speed sensor-to-pulse ring air gap is
adjustable. Shims can be added or removed to
• reduced traction on rough, uneven or loose bring the air-gap into specification. See adjustment
surfaces procedure outlined in this chapter.
• poor judgement • The ABS system can be reprogrammed.
• improper operation • The ABS light is controlled via CAN BUS.
• Wheel speed sensors provide feedback for both
anti-lock brake operation and vehicle road speed.
• If fuse is open or removed, the ABS light will remain
ON after 6 mph (10 kph). ABS will not be active.
Normal (conventional) braking will be available
provided the system components (master cylinder,
lines, calipers, etc.) are in working order.

© Copyright 14.15
BRAKES
ABS SYSTEM COMPONENTS A B S O V E R V I E W O F O P E R AT I O N

The following parts function in the same manner as the The ABS system is active and available when vehicle
same component in a non-ABS system, although parts speed exceeds 6 mph (10 kph).
are not necessarily interchangeable. Always refer to
the appropriate ABS parts information when replacing The system uses two independent Hall-Effect Wheel
Speed Sensors. One sensor is mounted to the front left
a component or component parts.
fork leg and one is mounted to the rear brake caliper
• Front Brake Calipers bracket. Two Pulse Rings are also used, one mounted
to the left front brake disc hub and one to the rear
• Rear Brake Caliper brake disc hub, which rotate with the wheels. When
the vehicle is in motion, the multiple reluctor
• Front Master Cylinder
segments on each pulse ring pass by the center pole
• Rear Master Cylinder of the respective wheel speed sensor, generating an
electrical pulse signal in the sensor which is sent to
• Brake Light Switch the ABS Module which is located in front of the rear
• Brake Lines wheel.
The ABS Module interprets wheel speed signal pulses
In addition to the brake system components listed to determine speed, rate-of-change, and front / rear
above, the following are exclusive to ABS equipped wheel speed differential to determine if wheel lock-up
vehicles: is about to occur. When wheel lock-up is imminent
during a braking event, the ABS Module controls the
• Wheel Speed Sensors (Front located on front left operation of solenoids and a pressure pump (located
fork leg; Rear mounted on rear caliper bracket) inside the ABS Module) to regulate the amount of line
• Wheel Speed Sensor Pulse Rings (Front and Rear pressure and cycles (length of time) applied to the
mounted to wheel with 3 disc fasteners) caliper pistons and brake pads. This pressure / time
modulation can often be felt at the brake lever or the
• ABS Module Assembly brake pedal during an ABS braking event and is a
• ABS Related Wiring normal condition. Note that the brake fluid is not
diverted inside the module and does not “flow” in the
• ABS Indicator Lamp system any more than occurs in a conventional (non-
ABS) brake system.
If the surface coefficient changes (such as moving from
wet pavement to dry pavement) the ABS system will
recalculate (in a matter of milliseconds) and adjust
pressure output to caliper(s) as required.
In the event of a system fault, the ECM turns on the
ABS indicator lamp (via the CAN BUS) and leaves it on
even after vehicle speed exceeds 6 mph (10 kph)
activation speed.
If a system fault occurs, the light will remain on (and
ABS will not be active) until the ignition key is turned
to OFF position and back to ON.
The ABS Module Assembly is serviceable only as an
assembly. The module itself is not rebuildable.
Disconnect negative (-) battery cable from battery
before servicing ABS brake lines or system
components.
ABS TROUBLE CODES

C1022 520250 7 ABS Pulsar (front) COG Chip ON
C1023 520251 7 ABS Pulsar (rear) COG Chip ON
C1024 520252 5 ABS Solenoid (RRI) Open / Short ON

14.16 © Copyright
BRAKES
C1025 520253 5 ABS Solenoid (RRO) Open / Short ON

C1026 520254 5 ABS Solenoid (FFI) Open/Short ON
C1027 520255 5 ABS Solenoid (FFO) Open/Short ON
C1028 520256 5 ABS Solenoid (RFI) Open/Short ON
C1029 520257 5 ABS Solenoid (RFO) Open/Short ON
C1032 520258 11 ABS Actuator (front) Wheel Lock (or VSS failure) ABS On ON
C103A 520313 11 ABS Actuator (front) Wheel Lock (or VSS failure) ABS Off ON 14
C1033 520259 11 ABS Actuator (rear) Wheel Lock (or VSS failure) ABS On ON
C103B 520314 11 ABS Actuator (rear) Wheel Lock (or VSS failure) ABS Off ON
C0020 8 Motor Lock ON
C1020 520260 3 ABS Motor Off Stick ON
C1021 4 On Stick ON
C1034 520261 7 ABS Fail Safe Relay On/Off Stick ON
C1038 4 Drop ON
520262 ABS Source Voltage
C1039 3 Raise ON
C1040 520263 31 ABS Tire Irregular Tire Size ON
C1041 520264 12 ABS ECU ECU Error ON
C1042 520265 7 ABS Module Incomplete Evacuation and Fill ON
A B S A N D L O W B AT T E R Y V O LTA G E
When attempting to start an engine on a bike with a weak battery (less than 12.5 volts KOEO) it is possible that
the ‘Check Engine’ light will illuminate and trouble code P106B will be stored in the ECM.
The P106B code indicates the engine is not getting a speed signal from the ABS module. This code DOES NOT
indicate the presence of a single faulty wheel speed sensor.
Possible Causes:
• Low battery voltage - particularly while engine is cranking
• CAN bus communication error between the ABS module and the ECM
• Both front and rear wheel speed sensors are faulty
• Faulty connection at ABS module
• ABS module not programmed (partial ECUID present in Digital Wrench)
When diagnosing this code, make sure the battery is fully charged and passes a load test prior to clearing and
retesting.

© Copyright 14.17
BRAKES
WHEEL SPEED SENSOR REPLACEMENT 8. Remove fastener w securing the Wheel Speed
Removal - Front Sensor to the bracket.
1. Remove fastener q securing the Wheel Speed
Sensor to bracket.
9. Withdraw speed sensor and remove any existing

shims.
2. Withdraw speed sensor and remove any existing 10. Noting their position, clip the cable ties securing
shims. the speed sensor harness to the rear brake line
and remove P-clamp e from the left side of the
3. Noting their position, clip cable ties securing the
swingarm.
harness to the motorcycle.
4. Locate connector and disconnect the wheel speed
sensor.
• Chief speed sensor connector is located in the
headlight nacelle.
• Chieftain / Roadmaster speed sensor connector is
located in the fairing behind the headlight
assembly.
Installation - Front
5. Reverse procedure to install.
6. Verify speed sensor air gap is within specification.
Perform adjustment procedure if necessary. See
Wheel Speed Sensor Air Gap Adjustment page
14.19.
NOTICE
Removal - Rear
The P-clamp fastener can be accessed from beneath
7. Remove left hand saddlebag. Refer to Owner’s the motorcycle. Use a short 10 mm socket and ratchet
Manual. between the swingarm and inner fender wall.
11. Remove the battery box / ECM assembly to access

speed sensor plug, and disconnect. See Battery
Box Removal page 15.12.
Installation - Rear
13. Verify speed sensor air gap is within specification.
Perform adjustment procedure if necessary. See
Wheel Speed Sensor Air Gap Adjustment page
14.19.

14.18 © Copyright
BRAKES
WHEEL SPEED SENSOR AIR GAP 6. Reinstall Wheel Speed Sensor and torque to
ADJUSTMENT specification.
Wheel Speed Sensor Air gap: TORQUE

.030” ± .010” (.75 mm ± .25 mm) Wheel Speed Sensor:
96 in-lbs (11 N·m)
NOTICE
Wheel Speed Sensor air gap is adjusted by adding
and removing shims. Shims are added to increase ABS MODULE REPLACEMENT
gap and removed to decrease gap. No more than 3
shims (per Wheel Speed Sensor) should be used at NOTICE 14
one time. Do not disassemble the ABS module. The ABS
module is serviceable only as a sealed (pre-bled)
1. Using a suitable feeler gauge, measure the air gap assembly. If ABS module has failed internally, replace
between the ABS Pulse Ring and the Wheel Speed complete assembly.
Sensor.
WARNING
The hydraulic brake system MUST be completely
bled following removal or replacement of the ABS
module. Follow the brake bleeding procedure
outlined in this chapter after ABS module service.
R E M O VA L
1. Disconnect the negative battery cable.
2. Position motorcycle in an upright position with the
3. California Models ONLY: Remove the
evaporative emissions charcoal canister, if
2. If the Wheel Speed Sensor air gap is out of equipped. See Evaporative Emission Control
specification, proceed to step 3. (California Models) page 1.35
3. Remove Wheel Speed Sensor from bracket. 4. Remove the swingarm assembly. See Swingarm
4. Withdraw the speed sensor and remove any Removal page 12.29
existing shims.
5. Remove nut q securing P-clamp to bottom of ABS
5. Based on air gap measurement, add or remove Module bracket.
shims to achieve the specified air gap.

© Copyright 14.19
BRAKES
6. Remove two starter solenoid fasteners w .
7. Disconnect three multi plugs from the ABS Module.

8. Disconnect hydraulic lines e r from ABS module
and cap off lines to prevent contamination.
9. Remove fastener t securing ABS module to

bracket.
10. Remove ABS module.
2. Bleed brake system as outlined in this chapter.
3. Attach Digital Wrench and check for ABS trouble
codes.

14.20 © Copyright
BRAKES
ABS BRAKE SYSTEM BLEEDING

BRAKE FLUID REPLACEMENT & BLEEDING • The master cylinder reservoirs have limited
PRECAUTIONS capacities. It is easy to empty them during the
bleeding procedure. This introduces air into the
WARNING system which you are trying to purge. Watch the
reservoir closely and add fluid when necessary to
Contaminated brake discs or brake pads greatly keep the level above the LOW mark and prevent air
reduce braking performance and increase stopping from re-entering the system.
distance. Do not attempt to clean contaminated pads.
Replace them. Clean the brake disc with brake • Apply only light to moderate pressure to the lever or
cleaner. pedal when bleeding the brake system. Extreme
pressure or rapid movement will cause a surge of 14
fluid through the small orifices of the brake system
WARNING when the bleeder screw is opened and could
introduce air into the system by means of cavitation.
This brake system requires ethylene-glycol based
fluid (DOT 4). Do not use or mix different types of • Small amounts of air can become trapped in the
fluid such as silicone-based or petroleum-based. banjo fastener fittings at the master cylinder(s) and
junction points of brake lines. These fittings can be
purged of air by following a standard bleeding
WARNING procedure at these fittings (instead of the bleed
screw on caliper) if necessary to speed the bleeding
Do not use brake fluid taken from old, used or process. This is usually only needed if system was
unsealed containers. Never reuse brake fluid. Brake completely drained of fluid. Bleed each line
fluid can accumulate moisture, reducing it’s connection, starting with the fitting closest to the
performance. master cylinder, working toward the caliper, and
ending with the bleed screw.
WARNING • Always torque banjo fasteners and other brake
system fasteners and components to specified
Brake fluid is poisonous. Keep brake fluid tightly torque.
sealed and out of reach of children.
• Always install NEW genuine Indian Motorcycle
replacement parts and rubber parts upon assembly.
WARNING Apply special lubricant where indicated (included
in service kits).
A soft, spongy feeling in the brake lever and/or
brake pedal could indicate a hazardous condition in
the brake system. Do not operate the motorcycle
until the failure in the brake system is corrected. A B S B R A K E VA C U U M B L E E D E R
A vacuum bleeder is recommended for ABS system
bleeding and can also be used to bleed conventional
WARNING (non-ABS) brake systems. One style of bleeder is
An unsafe condition exists when air is trapped in the shown below.
hydraulic brake system. Air in the brake hydraulic
system acts like a soft spring and absorbs a large
percentage of the pressure developed by the master
cylinder. Without this pressure, the braking system
cannot develop full braking force to allow for safe,
controlled stops. It is extremely important to bleed
the brakes properly after any brake system work has
been performed or when inspection reveals spongy
brakes.
Keep these points in mind when bleeding

hydraulic brakes:

© Copyright 14.21
BRAKES
ABS FLUID CHANGE 3. Fill rear brake fluid reservoir and leave cover off
Review Brake Fluid Replacement and Bleeding so fluid can be added as it is drawn through the
Precautions before working with brake fluid. system.
4. Open bleed screw about 1/4 turn.
NOTICE
5. Pump brake pedal repeatedly with smooth full
When bleeding or flushing the system, monitor fluid strokes while adding brake fluid to the reservoir as
level in master cylinder reservoir constantly. DO NOT required. For best results pump the pedal at a
allow fluid level to fall below the LOW level. fairly rapid rate but avoid pumping too fast or fluid
may become aerated. After about 2 cups of fluid
Use only DOT 4 brake fluid from a sealed container. have been run through the system, the bleeder
hose should have clear, bubble-free fluid running
NOTICE through it.
EMPTY LINES - If system is dry or very low on fluid 6. Close bleeder screw and fill the brake fluid
due to parts replacement or disassembly, fill reservoir.
reservoir and pump lever or pedal slowly through
stroke range until air bubbles no longer rise through 7. Repeat the entire bleeding process to be sure all air
the fluid into the reservoir. is purged from the system.
FLUSHING THE SYSTEM - Brake systems should be 8. Torque all bleed screws to specification and install
flushed every 2 years or more often if the fluid is the rubber caps.
discolored. To flush the system, follow normal brake
bleeding process, and pump fluid through the TORQUE
system until fluid moving through the bleeder hose is Caliper Bleeder Screws:
clear. Do not allow reservoir level to fall below the
48 in-lbs (5 N·m)
LOW level or complete system bleeding will be
required.
9. After completing the bleeding procedure a second
time, inspect brake fluid level and add if
necessary.
ABS REAR BRAKE BLEEDING 10. Clean the reservoir cover, diaphragm, and
NOTICE reservoir sealing surface. If diaphragm is
extended, return it to normal (flat) position. Install
The use of a vacuum bleeder is recommended. DO diaphragm and cover.
NOT allow fluid level in reservoir to drop below the
LOW mark at any time during the bleeding 11. If pedal is not firm, repeat bleeding procedure and
procedure. insect brake system.
Repeat entire bleed procedure at least once.
1. Remove rubber cap from rear caliper bleed screw

q and place a box end wrench on the screw.
2. Attach a tight-fitting clear hose from the vacuum
bleeder to the bleed screw and apply vacuum.

14.22 © Copyright
BRAKES
ABS FRONT BRAKE BLEEDING 3. Remove rubber cap from bleeder screw e on front
left caliper and place a box end wrench on the
NOTICE
screw.
Bleed left front caliper first then right caliper.
Repeat the bleeding procedure at least once.
1. Pull brake lever forward and rotate reach

adjustment dial q to the longest reach setting to
maximize lever stroke for bleeding.
14
4. Attach tight fitting clear hose from vacuum

bleeder to bleed screw and apply vacuum.
5. Hold lever to handlebar or hold firm pressure on
lever, then open bleed screw about 1/4 turn.
6. Pump brake lever repeatedly with smooth full
2. Remove front brake fluid reservoir cover w and strokes while adding brake fluid to the reservoir as
leave it off so fluid can be added as it is drawn required. For best results pump the lever at a fairly
through the system. rapid rate but avoid pumping too fast or fluid may
become aerated. After about 2 cups of fluid have
been run through the system, the bleeder hose
should have clear, bubble-free fluid running
through it.
7. Close bleeder screw and fill the brake fluid
reservoir.
8. Proceed to Step 9 to bleed the right front brake
caliper.
9. Remove rubber cap from bleeder screw on front
right caliper and place a box end wrench on the
screw.
10. Connect vacuum bleeder hose to the bleed screw
and start vacuum.
11. Hold lever to handlebar or hold firm pressure on
lever, then open bleed screw about 1/4 turn.
12. Pump brake lever repeatedly with smooth full
strokes while adding brake fluid to the reservoir as
required. For best results pump the lever at a fairly
rapid rate but avoid pumping too fast or fluid may
become aerated. After about 2 cups of fluid have
been run through the system, the bleeder hose
should have clear, bubble-free fluid running
through it.
13. Close bleed screw.
14. Once both front calipers have been bled, repeat
procedure again on left caliper, then right to
ensure all air has been purged.

© Copyright 14.23
BRAKES
15. Fill fluid reservoir and install diaphragm and BRAKE LEVER RESERVE INSPECTION
cover. Torque cover fasteners to specification. This procedure requires use of the Brake Lever Re-
serve Tool (PV-50104).
TORQUE
1. Turn handlebars fully LEFT.
Front Master Cylinder Cover:
14 in-lbs (2 N·m) 2. Set front brake lever reach adjustment q so it is
closest to handlebar.
16. Perform Brake Lever Reserve Inspection. See
Brake Lever Reserve Inspection page 14.24.
3. Place grommet of Brake Lever Reserve Inspection

Tool PV-50104 on ball end of front brake lever.
4. Connect a scale (commercially available) with a
minimum of 25 kg / 50 lb capacity to end of tool.
5. Keep tool centered so it does not touch hand grip.
Pull on scale to specified force.
Brake Lever Reserve Force: 37 lbs (16.8 kg)
6. Have an assistant verify brake lever does not

contact hand grip. Clearance must exist at
specified pull force as shown.
7. If lever makes contact with hand grip or bar end,
bleed the front brake system.
8. See troubleshooting if bleeding problems persist.

14.24 © Copyright
BRAKES
BRAKE SYSTEM SERVICE

F R O N T B R A K E PA D R E P L A C E M E N T 3. Remove pad spring w ; note direction of plate
(wide legs at top) for assembly.
IMPORTANT
Always replace brake pads as a set and always
replace pads in both front calipers at the same time.

each side of the motorcycle and remove the
caliper covers e.
14
4. Push each pad back by hand to gain clearance for

new pads.
NOTICE
Brake fluid will be forced back into the reservoir
when pads are pushed back. Remove reservoir cover
and monitor fluid level, or attach a hose to the brake
. bleeder screw and open the bleed screw while
pushing the pads and pistons back.
2. Remove brake pad pin q .
5. Remove each pad.
6. Wipe brake disc clean with a shop towel sprayed
with brake cleaner (commercially available).
7. Inspect caliper piston seals for any sign of fluid
leakage.
8. Install isolator on new brake pads. Be sure isolator
plate does not protrude from the brake backing
plate.
9. Install new brake pads with friction material
toward disc. Apply silicone grease to O-ring on
pad retaining pin.
10. Insert pin through caliper and through outer pad.
Lay spring in place over pads and press on center
while sliding pin through spring and then through
inner pad.
11. Torque pad retaining pin to specification.
TORQUE
Pad Retaining Pin:
120 in-lbs (14 N·m)
12. Inspect brake fluid in reservoir and set to proper

level.

© Copyright 14.25
BRAKES
13. Slowly pump lever to set brake pads against disc. R E A R B R A K E PA D R E P L A C E M E N T

Lever should be firm, not spongy. If lever is Always replace brake pads as a set. The rear pads can
spongy, inspect pad installation, bleed brake lines be changed with the caliper installed on the
and inspect brake disc. motorcycle.
14. Install reservoir cover and torque to specification. Do not attempt to remove the caliper from the bracket
with bracket installed.
TORQUE
NOTICE
Master Cylinder Reservoir Cover:
14 in-lbs (2 N·m) Brake fluid will be forced back into the reservoir
when pads are pushed back. Remove reservoir cover
and monitor fluid level, or attach a hose to the brake
15. Operate brake lever several times until lever is bleeder screw and open the bleed screw while
firm and pressure can be felt. pushing the pads and pistons back.
WARNING
1. Push caliper toward wheel to push pad and pistons
After pad installation or any brake system repair, back and provide clearance for new pad
safely elevate wheel, apply and release brake pedal installation.
or lever 2-3 times and release. Verify wheel turns
freely without drag. If brake drag is evident, do not
operate the motorcycle. Inspect vehicle to determine
cause and then repair as necessary.
NOTICE
The caliper should move freely on the guide pins.
2. Slide retaining pin q out until inner pad can be

removed. Note orientation of spring plate.

14.26 © Copyright
BRAKES
3. Slide inner pad out front edge of rear caliper. BRAKE DISC INSPECTION
Install new pad. Be sure backing plate is properly 1. Visually inspect disc for cracks or damage.
installed on new pad with insulator between brake
2. Measure brake disc thickness in several locations
pad and plate. Slide pad into place and engage
around disc with a micrometer, and along wear
tab in the back of the caliper.
surface and compare to specifications. See Service
4. Install new outer brake pad. Be sure tab is Specifications page 14.4.
engaged with caliper as it is for the inner pad.
5. Apply silicone grease to O-ring on pad retaining
pin.
TORQUE 14
Brake Pad Retaining Pin:
120 in-lbs (14 N·m)
6. Inspect fluid level in the reservoir and adjust as

necessary.
7. Pump brake pedal slowly several times to set new
pads against disc, until lever is firm and pressure
can be felt.
8. Bleed brake system if necessary.
NOTICE
WARNING
Replace the brake disc if any measurement is worn
After pad installation or any brake system repair, beyond the service limit.
safely elevate wheel, apply and release brake pedal
or lever 2-3 times and release. Verify wheel turns
freely without drag. If rear brake drag is evident, 3. With disc mounted to wheel, inspect for brake disc
inspect pedal clearance. Do not operate the runout / warpage with a dial indicator and
motorcycle if drag is still evident after clearance compare to specifications. See Service
adjustment. Inspect vehicle to determine cause and Specifications page 14.4.
repair as necessary. NOTICE
Runout should be measured 2-4mm in from outside
edge of disc.
4. Replace brake disc if dial indicator reading

displays excessive brake disc runout and other
possible causes have been eliminated.

© Copyright 14.27
BRAKES
FRONT MASTER CYLINDER SERVICE 5. Remove reservoir cover e and diaphragm r .
CAUTION
Brake fluid and brake cleaners could damage paint,
plastics and some rubber compounds. Cover or
remove plastic and painted parts before working on
the brake system. If brake fluid is spilled on cosmetic
surfaces, immediately rinse the area with a mild
solution of soap and water until all traces of brake
fluid are removed. Be sure master cylinder reservoir
is level before removing cover.
NOTICE
Replace all rubber parts upon assembly.
1. Clean the master cylinder. Attach a drain hose to 6. Remove the circlip t and pivot pin y and pull
caliper bleed screw and place the end in a lever assembly out of master cylinder.
suitable container. Drain brake fluid from the front
brake system by slowly pumping brake lever.
2. Remove the RH side mirror from the lever perch.
3. Remove banjo fastener q and brake line from
master cylinder.
7. Pull push rod u and dust boot i out of master

cylinder.
4. Remove fasteners w , clamp, and master cylinder.
8. Remove snap ring.

14.28 © Copyright
BRAKES
9. Slide piston o out with spring. Note spring 16. Assemble the piston / spring assembly as shown.
orientation for assembly of new spring (new Large diameter of beveled edge on piston cups
parts). face toward spring. Install a new retaining ring on
end of piston with machined edge (sharpest of the
two edges).
14
10. Clean master cylinder with isopropyl alcohol and

dry with compressed air. DO NOT soak in alcohol
for more than 30 seconds. DO NOT aim 17. Carefully install spring / piston assembly into
pressurized air directly at the level sight glass. master cylinder bore. Work the front piston seal
carefully past the chamfer and into bore. Use care
11. Inspect cylinder bore and chamfer of bore for
not to damage or fold the seal when working it
corrosion, scratches, scoring, or pitting. Replace
past the chamfer.
master cylinder if any of these conditions are
evident. 18. Continue to install the piston until the rear seal is
past the chamfer. Push and hold the piston in far
12. Measure the diameter of the bore. Replace master
enough to allow the retaining ring to be installed.
cylinder if worn beyond the service limit.
19. Be sure retaining ring is fully seated in the groove.
Master Cylinder Bore Diameter Service Limit: .6886
in (17.49 mm) 20. Clean the bore from the retaining ring outward, so
the outer edge of the new dust boot adheres
properly and will not dislodge from the bore.
13. Measure the diameter of the master cylinder
piston. Replace piston if worn beyond the Service 21. Install new boot, seating the outer edge fully in the
Limit. bore and engage outer lip of boot in piston
groove.
Master Cylinder Piston Diameter Service Limit: .6811
in (17.30 mm) 22. Apply special lubricant from kit to brake lever
contact surface.
14. Clean the compensating port and supply port with 23. Install master cylinder on handlebar. Torque
compressed air to be sure they are clean and clamp fasteners to specification.
unobstructed.
TORQUE
15. Apply a light film of special lubricant from piston
kit to each piston seal cup. Master Cylinder Clamp Fasteners: 70 in-lbs (8 N·m)

© Copyright 14.29
BRAKES
FRONT CALIPER SERVICE 3. Remove front caliper mounting studs w and

remove the caliper.
CAUTION
Brake fluid and brake cleaners will damage paint,
fluid are removed. Make sure the master cylinder
reservoir being worked on is level before removing
the cap.
NOTICE
Replace all rubber parts upon assembly. Keep parts
in order for assembly. The top and bottom pistons in
the caliper are not the same size.
4. Cover the end of brake line (s) to prevent debris
from entering.
each side of the motorcycle and remove the 5. Cover the brake hose connection on the caliper
caliper covers e. and clean the outer surfaces of caliper assembly
with brake cleaner (commercially available) or
isopropyl alcohol. Dry with compressed air.
6. Remove pad retaining pin e and brake pads.
.
2. Remove banjo fastener q , sealing washers, and
brake hose from caliper assembly and allow it to
drain into a container.
NOTICE
Pads contaminated with oil or grease must be
replaced as a set.

14.30 © Copyright
BRAKES
7. Remove the four caliper fasteners r using an E12 14. Inspect each piston bore for corrosion, scratches,
reverse Torx socket. scoring, or pitting. Replace caliper if any of these
conditions are evident.
15. Measure the diameter of each caliper bore.
Replace caliper if any is worn beyond the service
limit.
Front Caliper Bore Diameter:
Standard = 30.23 mm | Limit = 30.31 mm (1.1933
in)
in) 14
16. Measure the outside diameter of each piston in two
spots 90° apart, 5mm from outer edge. Repeat
measurement 5mm from inner edge. Replace
piston if worn beyond service limit at any
8. Separate the halves. Note the O-ring t used to measuring point.
seal the fluid passage. this O-ring must be Front Caliper Piston Outside Diameter:
replaced along with all rubber parts during Standard = 30.15 mm | Limit = 30.09 mm (1.1846
assembly. in)
in)
NOTICE
Install all new rubber parts during assembly. Do not
reuse old seals or boots.
17. Apply special lubricant from service kit to new

piston seals and dust seals.
18. Apply special assembly oil (included in kit) to
outer surface of all pistons.
19. Install piston seals and dust seals in caliper body.
20. Install pistons in their respective bores.
9. Keep parts in order for assembly in the same bore.
Top and bottom pistons (in each caliper half) have 21. Clean threads of each caliper body fastener. Be
different diameters. sure threads are free from any oil, grease, or brake
fluid. Apply a few drops of Loctite 242 (Blue) non
10. Remove each piston with a caliper piston pliers. If permanent locking agent to the threads of each
a caliper piston pliers is not available, wrap the fastener.
caliper in a shop towel and apply short bursts of
compressed air through the brake line hole and 22. Install a new O-ring on fluid transfer passage,
through the transfer passage to force the pistons assemble halves of caliper and start (4) fasteners
out of the bore. while holding pressure on halves to keep O-ring in
place.
11. Remove dust seals and piston seals. Use care not
to damage the seal bores. 23. Evenly tighten fasteners by hand until halves are
secured.
12. Clean all parts thoroughly with isopropyl alcohol.
Be sure the seal bores are clean, removing all 24. Torque caliper body fasteners to specification.
traces of dirt or dried brake fluid.
TORQUE
13. Clean piston seal and dust seal bores to remove
Caliper Body Fasteners: 20 ft-lbs (27 N·m)
residue that could cause the pistons to stick,
resulting in brake drag.

© Copyright 14.31
BRAKES
25. Install brake pads. Torque retaining pin to F R O N T C A L I P E R I N S TA L L AT I O N

specification. 1. Clean mounting surfaces of caliper and fork leg.
TORQUE 2. Apply brake cleaner or isopropyl alcohol to a
clean shop towel and wipe brake discs clean.
Brake Pad Retaining Pin: 120 in-lbs (14 N·m)
3. Separate brake pads and install caliper assembly
over brake disc.
4. Install caliper mounting studs and torque to
specification.
TORQUE
Caliper Mounting Studs: 35 ft-lbs (48 N·m)
5. Connect brake hose to caliper with banjo fastener

and new sealing washers. Torque to specification.
TORQUE
Banjo Fastener (Brake Line): 18 ft-lbs (24 N·m)
6. Fill and bleed the front brake hydraulic system.

See ABS Front Brake Bleeding page 14.23.
WARNING
After pad installation or any brake system repair,
safely elevate the wheel, apply and release the brake
pedal or lever 2-3 times and release. Verify the wheel
turns freely without drag. If brake drag is evident, do
not operate the motorcycle. Inspect the vehicle to
determine the cause and then repair as necessary.

14.32 © Copyright
BRAKES
REAR MASTER CYLINDER SERVICE 3. Remove jam nut e .
CAUTION
Brake fluid and brake cleaners will damage paint,
fluid are removed. Make sure the master cylinder
reservoir being worked on is level before removing
the cap. Replace all rubber parts upon assembly. 14
NOTICE
Replace all rubber parts upon assembly.
4. Remove master cylinder from floorboard support.
1. Remove brake line banjo fastener q , sealing
washers and brake line. Allow fluid to drain into a 5. Remove external snap ring r , washer t and dust
container. boot y and return spring (not shown).
2. Remove cotter pin w from push rod pin and 6. Remove internal snap ring followed by piston and
remove washer. cups.
7. Inspect cylinder bore and chamfer on the front of
the bore for corrosion, scratches, scoring, or
pitting. Replace master cylinder if any of these
conditions are evident.
8. Measure the bore diameter. Replace if worn
beyond the service limit. See Service
9. Clean compensating port and supply port with
compressed air to be sure they are clean and
unobstructed.
10. Clean all parts with clean Indian Motorcycle DOT
4 brake fluid or isopropyl alcohol.
11. Replace ALL RUBBER PARTS with new.
12. Carefully assemble the piston and cups into the
master cylinder bore.
13. Install the push rod, push rod retainer and internal
snap ring.

© Copyright 14.33
BRAKES
14. Install the return spring, dust boot, washer and REAR CALIPER SERVICE
external snap ring. 1. Remove banjo fastener q and sealing washers
from rear caliper and allow fluid to drain into a
15. Install the master cylinder and torque the jamb nut container.
and brake line banjo fastener to specification.
TORQUE
Brake Line Banjo Fastener: 18 ft-lbs (24 N·m)
Rear Master Cylinder Jamb Nut: 35 ft-lbs (47.5 Nm)
16. Install the push rod retaining pin, washer and

cotter pin.
2. Remove caliper fasteners w and lower caliper off

of mounting bracket.
3. Remove pin e and brake pads. Note orientation of

spring plate for assembly.
4. Slide caliper bracket off pins and remove spring

plate.

14.34 © Copyright
BRAKES
5. Remove caliper pistons. Keep pistons in order for 21. Install brake line with new sealing washers and
installation in their respective bores. torque banjo fastener to specification.
6. Remove dust seals and piston seals. Use care not TORQUE
to damage the seal bores.
Banjo Fastener (Rear Caliper): 18 ft-lbs (24 N·m)
7. Clean caliper thoroughly with isopropyl alcohol.
Dry with compressed air. Clean seal grooves 22. Bleed brake system. See ABS Rear Brake Bleeding
thoroughly. Any residue left behind in the grooves page 14.22.
could cause caliper pistons to stick and result in
brake drag.
8. Inspect each bore and surface of each piston for
corrosion, scratches, scoring, or pitting. Replace
14
caliper assembly if any of these conditions are
evident.
9. Measure diameter of each bore and piston.
Replace caliper assembly or parts if worn beyond
service limit.
Caliper Piston Bore DiameterService Limit: 27.05 mm
(1.0649 in)
Caliper Piston DiameterService Limit: 26.935 mm

(1.0604 in)
10. Install all new rubber parts during assembly. Do

not reuse old seals or boots. Apply special
lubricant from service kit to new piston seals and
dust seals.
11. Apply special assembly oil to outer surface of all
pistons.
12. Install piston seals and dust seals in caliper body.
13. Install pistons in their respective bore.
14. Replace caliper pin boot on bracket and on
caliper. Apply special lubricant from service kit to
boots and both pins.
15. Assemble bracket to caliper. Remove excess
lubricant.
16. Install spring plate and outer brake pad. Start pad
pin through outer pad.
17. Install inner pad with insulator and backing plate.
18. Torque brake pad retaining pin to specification.
TORQUE
Brake Pad Retaining Pin: 120 in-lbs (14 N·m)
19. Be sure end tabs of pads are both fully engaged in

the heel plate on bracket.
20. Install caliper to bracket and torque caliper
TORQUE
Caliper Fasteners: 31 ft-lbs (42 N·m)

© Copyright 14.35
BRAKES
R E A R C A L I P E R I N S TA L L AT I O N
1. Install caliper to rear mounting bracket and torque
to specification.
TORQUE
Caliper Fasteners: 31 ft-lbs (42 N·m)
2. Install brake hose, and banjo fastener with new

sealing washers.
TORQUE
Banjo Fastener (Rear Caliper): 18 ft-lbs (24 N·m)
3. Fill and bleed the rear hydraulic brake system.

See ABS Rear Brake Bleeding page 14.22.
WARNING
After pad installation or any brake system repair,
safely elevate the wheel, apply and release the brake
pedal or lever 2-3 times and release. Verify the wheel
turns freely without drag. If brake drag is evident, do
not operate the motorcycle. Inspect the vehicle to
determine the cause and then repair as necessary.

14.36 © Copyright
BRAKES
TROUBLESHOOTING
Weak Brakes or Fluid Leakage (External) Repair or Replace Leaking Component
Erratic Braking Fluid Leakage (Internal of Master Cylinder) Replace Master Cylinder
Action Worn Pads Replace Brake Pads
Oil Contamination of Brake Pads and/or Brake Pads Must Be Replaced. Disc May Be
Disc Cleaned.
Air In System Bleed Air From System
Low Brake Fluid Level In Reservoir Fill Reservoir, Bleed Brakes, Top Off Fluid
Excessive Brake Disc Runout Level.
Worn or Damaged Wheel Bearings Replace Brake Disc. 14
Loose Front Axle Nut or Clamps or Loose Rear Replace Wheel Bearings.
Axle Torque Correctly
Caliper Mount Surface Uneven Or Misaligned; Inspect / Repair
Missing or Damaged Fasteners Replace Line(s)
Clogged or Restricted Hydraulic Line Replace Bracket
Caliper Bracket Misaligned, Bent or Distorted Install New Fasteners. Torque to
Loose Brake Disc Specification
Brake Pads Glazed Replace Pads. Avoid Needless Heavy
Braking for 100-200 miles (Burnish New
Brake Pads).
Poor Brakes or Air In System Bleed Air From System
No Brakes When Low Brake Fluid Level In Reservoir Fill Reservoir, Bleed Brakes, Top Off Fluid
First Applied. Brake Disc is Bent or Warped Level.
Brake Lever Caliper Misalignment Replace Brake Disc
Pressure Present External Leak Determine Cause and Correct
If Lever Is Internal Leak (master cylinder) Repair or Replace Damaged Component
“Pumped”. Faulty Brake Hose Repair or Replace Master Cylinder
Inspect for Bulges / Replace
Brake Pedal or Brake Disc Bent or Warped Replace Brake Disc
Brake Lever Mounting Surface of Brake Disc Uneven / Disc Repair or Replace as Necessary
Pulsates Loose Repair or Replace as Necessary
Caliper Mount Surface Uneven Or Misaligned;
Missing or Damaged Fasteners
Excessive Lever Air in System Bleed Air From System
or Pedal Travel / Loose Mounting Hardware Repair as Necessary
Spongy Brake Low Brake Fluid Level In Reservoir Fill Reservoir, Bleed Brakes, Top Off Fluid
Feel. Incorrect Brake Fluid Used Level.
See “Weak / Erratic Brakes” and Poor Brakes” Flush System and Replace With Correct
possible causes above. Fluid
Fluid Leakage Loose Banjo Fittings Tighten to Specified Torque
Damaged Banjo Fitting Sealing Washers Replace
Cracked / Damaged Hose Replace
Worn Master Cylinder Piston, Caliper Piston(s) Repair / Replace Master Cylinder or
or Seals Wheel Caliper.
Diaphragm (master Cylinder reservoir) Inspect / Replace Cover, Cap, Diaphragm
Leaking or Reservoir as Required
Fluid level too high (new brake pads installed Correct fluid level
without removing added fluid)

© Copyright 14.37
BRAKES

Brakes Drag Reservoir Over Filled Adjust Level As Necessary
Excessively or Brake Pedal Or Lever Not Returning Inspect Linkage, Pivots and Mechanism
Self-Apply Completely To Rest Position For Cause Of Binding Or Restricted
(Brakes Inadequate Freeplay Movement;
Overheat) Compensating Port Plugged Measure Pedal Clearance / Adjust
Internal Corrosion of Components (Master Repair or Replace Master Cylinder
Cylinder / Caliper) Replace Damaged Component
Rear Caliper: Corrosion of Sliding Parts, Bent Repair or Replace As Necessary
or Damaged Parts Flush System, Install Correct Fluid
Contaminated Brake Fluid Repair / Replace Caliper (Corrosion /
Caliper Pistons Sticking Buildup of Residue In Caliper Piston Seal
Rider Error (Operator Riding Brakes) Grooves)
Educate Operator
Brake Squeal/ If noise is minor and inconsistent, some brake Apply non oil-based solvent to a clean
Squeak squeak / squeal is characteristic of disc brakes shop towel and wipe dust / dirt from
and usually caused by dust / dirt on pads and / brake disc.
or brake disc. Repair as Necessary. Inspect Pad
Pad Not Secure in Caliper Installation
Aftermarket (not genuine Indian Motorcycle) Install Genuine Indian Motorcycle Parts
Parts Replace
Worn or Damaged Wheel Bearing(s) Replace
Worn Pads / Disc

14.38 © Copyright
STARTING / CHARGING
CHAPTER 15
STARTING / CHARGING
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.3
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.4
SERVICE SPECIFICATIONS - STARTING / CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.5
ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.6
STARTER MOTOR / SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.6 15
STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.7
REGULATOR / RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.8
BATTERY BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.9
BATTERY SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.10
BATTERY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.10
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.11
BATTERY BOX REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.12
BATTERY BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.13
BATTERY CHARGING - NEW BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.14
BATTERY CHARGING - IN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.14
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.15
BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.15
STARTER MOTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.16
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.16
STARTING SYSTEM DIAGNOSTIC TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.16
STARTER CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.17
TROUBLESHOOTING FLOW CHART 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.17
STARTING SYSTEM TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.20
BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.20
STARTER SOLENOID GROUND CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.20
GEAR POSITION SWITCH NEUTRAL INDICATOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.21
CLUTCH SWITCH CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.22
CLUTCH SWITCH REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.23
STARTER SOLENOID POSITIVE CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.23
STARTER CURRENT DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.24
STARTER CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.24
STARTER MOTOR, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.25
CHARGING SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.26
TROUBLESHOOTING, CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.26
CURRENT DRAIN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.27
REGULATED VOLTAGE / AMPERAGE OUTPUT INSPECTION (ALL MODELS) . . . . . . . . . . . . . . . . . . . . . . . 15.27
STATOR AC VOLTAGE OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.28

© Copyright 15.1
STARTING / CHARGING
STATOR RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.30

STATOR WINDINGS TO GROUND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.30
STATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.31
STATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.32
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.32
RECTIFIER / REGULATOR CONNECTOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.32
DIODE LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.33
REGULATOR / RECTIFIER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.33

15.2 © Copyright
STARTING / CHARGING
All electrical system and component service can be
performed with the engine in the frame. Battery electrolyte is poisonous. It contains sulfuric
acid. Serious burns can result from contact with skin,
IMPORTANT eyes or clothing. Antidote:
• External: Flush with water.
CAUTIONS TO OBSERVE DURING ELECTRICAL
SYSTEM SERVICE • Internal: Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or
• Always turn off ignition switch before vegetable oil. Call physician immediately.
disconnecting any electrical component.
• Eyes: Flush with water for 15 minutes. Call
• Always verify that bullet-type connectors are free physician immediately.
of corrosion, contamination or breaks when
troubleshooting electrical problems. Batteries produce explosive gases. Keep sparks,
• Verify that bullet-type connectors are firmly
flame, cigarettes, etc. away. Ventilate when
charging or using in an enclosed space. Always
15
seated. Listen and/or feel for a click when shield eyes when working near batteries.
connecting them.
KEEP BATTERIES AND BATTERY ACID OUT OF
• Ensure to release the lock on lock-type couplers REACH OF CHILDREN
before disconnecting them to avoid damaging the
connector. The charging system used on the motorcycle is
• Pulling on the wires when disconnecting couplers calibrated for the maintenance free battery that is
can introduce problems. Hold the connectors installed as original equipment. Do not replace with a
themselves when disconnecting them, not their conventional lead-acid battery. Before
associated wires. troubleshooting the charging system, inspect the
battery thoroughly. A discharged, poorly charged or
• Inspect each male and female terminal of multi-pin faulty battery will make the readings obtained
connectors for corrosion, contamination, loose or during charging system troubleshooting erroneous
bent pins. or difficult to interpret.
A battery will self-discharge when the motorcycle is
not in use. Make sure to properly store the battery as
Battery Label outlined later in this section.
Maximum voltage and service life is only achieved
when the battery is properly serviced initially. Make
sure to follow instructions outlined later in this
section.
Overcharging can be caused by a faulty battery
(shorted cell). Test system with a known good
battery when diagnosing an overcharge condition.
New batteries must be properly maintained as
outlined in this section to ensure proper service life.
CAUTION
Even with a good battery, battery voltage can
recover after charging, but under excessive loads the
battery voltage will drop quickly and eventually
“die”. Often the charging system is suspect when it is
not the cause of the problem. Always inspect for
excessive loads if the battery continues to lose its
charge. Items such as incorrect wattage bulbs,
sticking brake light switch(s), continuous low rpm
operation or leaving the lights on without the engine
running for long periods of time can drain a battery
even if the charging system is operating correctly.

© Copyright 15.3
STARTING / CHARGING
CAUTION
SPECIAL TOOLS
WIRE ROUTING TOOL DESCRIPTION PART NUMBER
Make sure that all wires are routed correctly away Battery Tester PU-50296
from moving parts, hot exhaust, or sharp edges.
Electrical Tester Kit PV-43526
Relay Bypass PU-49466
CAUTION
Smartlink Module Kit PU-47471
FUSES
Fuses are in place to protect circuit wiring and USB to Serial Adapter PU-50621
components. Always determine the cause of an open
fuse before installing a new fuse.
Do not increase the value of the fuse to correct the
problem. T O R Q U E S P E C I F I C AT I O N S
Do not use wire, tin foil or other substitutes for fuses. TORQUE
PART DESCRIPTION
SPECIFICATION
CAUTION Torque Compensator 83 ft-lbs (112 Nm)
Fastener
ELECTRONIC COMPONENTS
Semiconductor parts used in electronic components Torque Compensator
88.5 in-lbs (10.0 Nm)
will not withstand careless handling. Locking Plate
Do not drop or strike parts that contain
Primary Cover Fasteners 15 ft-lbs (20.0 Nm)
semiconductors such as the ECM or rectifier/
regulator. Dropping electronic components can Regulator/Rectifier to
cause damage to the component. 84 in-lbs (9.5 Nm)
Bracket
Follow instructions supplied in this chapter, including
Fuel Delivery / EFI chapter and Electrical chapter, Regulator/Rectifier 88.5 in-lbs (10.0 Nm)
very carefully when working on electronic Bracket to Crankcase
components. Failure to follow instructions may cause Stator Mounting
irreparable damage to the part being inspected. 88.5 in-lbs (10 Nm)
Fasteners to Crankcase

15.4 © Copyright
STARTING / CHARGING
S E R V I C E S P E C I F I C AT I O N S - S TA R T I N G / C H A R G I N G
ELECTRICAL SPECIFICATIONS STARTING SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS ITEM SPECIFICATION
Electrical Ignition System Distributor-less Battery Voltage, No Load Above 12.5 V DC
(General) Transistorized Dual Coil
Type Ignition Resistance: Between Any Two Continuity (0 Ohms)
Commutator Bars
Starting System Electric Resistance: Commutator to Armature Infinity (OL on Fluke™
Charging System Permanent Magnet / 3 Phase Shaft 73)
/ Full Wave Rectification Resistance: Battery Input Terminal to Continuity (0 Ohms)
Regulator/Rectifier Solid State Three Phase Insulated Brush
Voltage Regulator/Rectifier Resistance: Bat. Input Terminal to Starter Infinity (OL on Fluke™
Motor Case 73)
Lighting System 12 V DC
Starter Motor Operating Amp Draw 140–160 Amps
CHARGING SPECIFICATIONS
Starter Motor No Load Amp Draw (Bench
Test)
30-37 Amps after
initial surge
15
Starter Torque Limit Clutch Break-Away 50 – 60 ft-lbs (70 - 80
ITEM SPECIFICATIONS Torque Nm) when new
Alternator No Load AC Output @ 800–
17-26.5 VAC @ Idle
1000 RPM (Engine cool)
Alternator No Load AC Output @
2000 RPM (Engine cool) 40-45 VAC at 2000 RPM
Stator Coil Resistance (@ 21oC / 70oF)

(Black to each other black) 90.7 mΩ ± 20%
(Disconnect regulator - see test.)
Stator Coil Resistance To Ground
Infinity (no continuity)
(Each black wire)
Regulated Voltage 14.3 - 14.7 V DC
Alternator Output (Amps / Watts) 56 A / 710 W @ 2000 RPM
Type Yuasa: YTX20HL
Voltage 12 Volts DC
Nominal Capacity @ 10
Battery 18 AH
Hr Rate
Recommended Battery
Charging Current STD: 1.85 A for 5 to 10 hrs
CCA Rating 310

© Copyright 15.5
STARTING / CHARGING
S TA R T E R M O T O R / S O L E N O I D
q Terminal Cover -
w Nut, Starter Terminal (B+) — M6 (QTY.1) 63 in-lbs (7 N·m)
e Starter Motor -
r Fastener, Starter Motor — M6 x 1.0 x 25 (QTY.2) 88 in-lbs (10 N·m)
t Cable, Solenoid to Starter Motor (B+) -
y Starter Solenoid -
u Nut, Solenoid Terminal (B+) — M6 (QTY.2) 63 in-lbs (7 N·m)
i Fastener, Starter Solenoid — M6 x 1.0 x 12 (QTY.2) 88 in-lbs (10 N·m)
o Cable, Battery to Solenoid (B+) -

15.6 © Copyright
STARTING / CHARGING
S TAT O R
15
q Stator -
w Fastener, Stator — M6 x 1.0 x 35 (QTY.3) 88 in-lbs (10 N·m)

© Copyright 15.7
STARTING / CHARGING
R E G U L AT O R / R E C T I F I E R
q Bracket, Regulator / Rectifier -
w Fastener, Regulator Bracket — M6 x 1.0 x 12 (QTY.3) 88 in-lbs (10 N·m)
e Regulator / Rectifier -
r Fastener, Regulator — M6 x 1.0 x 15 (QTY.2) 88 in-lbs (10 N·m)

15.8 © Copyright
STARTING / CHARGING
B AT T E R Y B O X
15
q Fastener, ECM — M4 x 0.7 x 8 (QTY.4) 36 in-lbs (4 N·m)
w Fuse Box, J-Case -
e Fastener, Fuse Box — M6 x 1.0 x 22 (QTY.1) 63 in-lbs (7 N·m)
r Fastener, Battery Box — M6 x 1.0 x 12 (QTY.2) 84 in-lbs (9 N·m)
t Fastener, VCM Mounting Plate — M6 x 1.0 x 25 88 in-lbs (10 N·m)

(QTY.1)
y Battery -
u Fastener, Battery Box — M6 x 1.0 x 25 (QTY.2) 84 in-lbs (9 N·m)
i Battery Box -
o ECM -

© Copyright 15.9
STARTING / CHARGING
B AT T E R Y S E R V I C E
B AT T E R Y R E M O VA L 6. Lift battery straight up and out of the battery box.
IMPORTANT
It is not necessary to disconnect the VCM from
the electrical harness during battery removal. If
the VCM must be disconnected for any reason,
the negative battery cable must be disconnected
first.
1. Remove the upper side covers by pulling the

corners evenly straight outward to disengage each
tab from rubber grommet in frame.
NOTICE
It may be necessary to push the VCM harness away
from the battery, into the RH side of the frame in
order to remove the battery.
2. Remove the seat. See Seat Removal / Installation

- All (except Roadmaster) page 3.19.
3. Remove the fastener securing the Vehicle Control
Module (VCM) mounting plate to the top of the
battery box and move the VCM out of the way. Do
not disconnect VCM.
See Vehicle Control Module (VCM), Removal /
4. Remove negative (-) battery terminal fastener and
cable first q .
5. Remove positive (+) battery terminal fastener and
cable last w .

15.10 © Copyright
STARTING / CHARGING
B AT T E R Y I N S TA L L AT I O N 8. Install upper side covers.

NOTICE
Be sure cable ends and battery terminals are clean.
Apply a light film of di-electric grease to terminal
fastener threads.
1. Carefully install battery with negative terminal

toward front of vehicle.
2. Connect positive cable w to the battery and torque
to specification.
3. If previously removed, plug the three multi-plugs
into the Vehicle Control Module (VCM).
4. Connect ground (negative) cable q to battery and
15
TORQUE
Battery Terminal Fasteners:
36 in-lbs (4.1 Nm)
5. Apply dielectric grease over terminal areas for

corrosion protection.
6. Install Vehicle Control Module (VCM).
See Vehicle Control Module (VCM), Removal /
7. Install seat.
See Seat Removal / Installation - All (except
Roadmaster) page 3.19.

© Copyright 15.11
STARTING / CHARGING
B AT T E R Y B O X R E M O VA L 7. Remove the J-Case fuse box fastener r and move

1. Place motorcycle in an upright position with the fuse box out of the way.
2. Remove the rear fender. See Rear Fender Removal
page 3.31
3. Remove battery. See Battery Removal page 15.10.
4. Remove rear battery box fasteners q .
8. Remove the battery box / ECM assembly t .
5. Remove front battery box fasteners w .
6. Disconnect the multi-plugs e from the ECM.

15.12 © Copyright
STARTING / CHARGING
B AT T E R Y B O X I N S TA L L AT I O N 4. Install the front battery box fasteners r and

1. Lower the battery box / ECM assembly q into torque to specification.
position so the mounting tabs are resting in the
frame and the fastener holes are lined up.
15
TORQUE
2. Move the J-Case fuse box into position and torque Battery Box Fasteners, Front: 84 in-lbs (9 N·m)
fastener w to specification.
5. Install rear battery box fasteners t and torque to
specification.
TORQUE
J-Case Fuse Box Fastener: 63 in-lbs (7 N·m)
TORQUE
3. Connect the ECM multi-plugs e . Battery Box Fasteners, Rear: 84 in-lbs (9 N·m)
6. Install battery. See Battery Installation page 15.11.

7. Install rear fender. See Rear Fender Installation
page 3.32.

© Copyright 15.13
STARTING / CHARGING
B AT T E R Y C H A R G I N G - N E W B AT T E R Y B AT T E R Y C H A R G I N G - I N S E R V I C E
1. Charge the battery at 1.8 amps for 5 to 10 hours. 1. Measure battery voltage with a digital multimeter.
use a straight rate charger (not load sensing or The reading should be above 12.50 V DC. If
battery tender type) for the initial charge of a new battery voltage is lower than 12.50 V DC battery
battery. must be charged according to the instructions
given below.
CAUTION
Do not attempt to quick charge the battery at any CAUTION
time. Do not remove caps on battery while recharging. Do
not attempt to inspect or add fluid to a maintenance
2. Remove battery from charger and let it sit for 30 free battery.
minutes or longer.
2. Charge battery at 1.8 amps for 5 to 10 hours.
NOTE
Measure voltage with a digital multimeter. If lower NOTE
than 12.50 V DC, battery must be recharged again in Specification: 1.8 A for 5-10 hours
accordance with step 1 and 2 above.
3. Remove battery from charger and let it sit for 30
3. After charging battery and letting it sit for 30 minutes or longer.
minutes or more, check battery voltage again. If
battery voltage is still below 12.50 V DC, replace 4. Measure battery voltage with a digital multimeter.
the battery. If battery voltage is lower than 12.50 V DC battery
must be recharged again in accordance with step
1 and 2 above.
5. After charging battery and letting it sit for 30
minutes or more, check the battery voltage again.
If battery voltage is still below 12.50 V DC, replace
battery.
NOTE
When motorcycle is not used for one (1) month or
more, remove battery and store it in a cool, dry area.
Inspect voltage monthly and charge according to
above instructions if necessary.

15.14 © Copyright
STARTING / CHARGING
B AT T E R Y I N S P E C T I O N
1. Remove battery. See Battery Removal page 15.10.
2. Inspect battery tray and hold-down cover for
damage. Be sure all foam strips are in place on
battery box.
3. Inspect for cracked or broken battery case.
CAUTION
Do not remove the battery cap assembly in an
attempt to inspect fluid level, specific gravity or
attempt to add fluid to battery. After initial servicing,
battery should remain sealed.
4. Inspect terminals for corrosion. If corrosion is

found, remove battery and clean terminals with a 15
solution of baking soda and water. Finish process
by cleaning terminals (both battery and battery
cables) with a wire brush.
5. Install battery. See Battery Installation page 15.11.
6. Once connections are secured, apply a thin film of
di-electric grease to terminals.
7. Install VCM / battery cover assembly. See Vehicle
Control Module (VCM), Removal / Installation
page 17.10.
8. Install seat. See Seat Removal / Installation - All
(except Roadmaster) page 3.19.
9. Install upper side covers. See Side Cover (Upper),
B AT T E R Y T E S T I N G
The recommended battery tester for all Indian
Motorcycle batteries is special tool PU-50296. See
Special Tools Index page 1.37.
Conductance describes the ability of a battery to
conduct current. A conductance tester functions by
sending a low frequency AC signal through the battery
and a portion of the current response is captured, from
this output a conductance measurement is calculated.
Conductance testing is more accurate than voltage,
specific gravity, or load testing.

© Copyright 15.15
STARTING / CHARGING
S TA R T E R M O T O R S E R V I C E
S A F E T Y I N F O R M AT I O N
WARNING
Always disconnect the battery (negative terminal first) before servicing the starter motor.
• Inspect the condition of the battery before troubleshooting the starter system. Also inspect main engine ground
and battery cable connections.
S TA R T I N G S Y S T E M D I A G N O S T I C TA B L E
SYMPTOM POSSIBLE CAUSE RECOMMENDATION
Starter motor does not turn with Gear Position Switch or circuit Test Gear Position Switch.
transmission in neutral. Turns with malfunction.
clutch pulled in.
Starter motor does not turn with Clutch Switch or Side Stand switch Test Switches.
transmission in gear and clutch circuit malfunction.
lever pulled in. Turns with
transmission in neutral.
Starter motor will not turn. Low battery voltage. Poor cable See Troubleshooting Flow Chart 1
connections. Main ground loose.
Starter motor turns slowly. Engine Low battery. Faulty starter motor or See Troubleshooting Flow Chart 2
may or may not start. drive mechanism. Engine
mechanical problem.
Starter motor turns, but engine Starter torque limit clutch slipping. See Troubleshooting Flow Chart 3
does not turn.
Starter motor turns at normal Ignition Problem Electrical chapter
speed, but engine does not start. Engine Problem Engine / Cooling / Exhaust chapter
Fuel Delivery Problem Fuel Delivery / EFI chapter

15.16 © Copyright
STARTING / CHARGING
S TA R T E R C I R C U I T D I A G R A M
15
TROUBLESHOOTING FLOW CHART 1

NOTICE
Make sure the Key Fob authorization has occurred before performing troubleshooting.

© Copyright 15.17
STARTING / CHARGING

NOTICE
These procedures require a Digital Multi Meter (DMM) and high a high current shunt, or an inductive ammeter
clamp and a DMM.

15.18 © Copyright
STARTING / CHARGING
15

SYMPTOM POSSIBLE CAUSE
Starter clutch malfunction.
Starter motor turns, but engine does not turn. The Starter torque limit clutch slipping.
starter motor can be heard spinning.
Starter gears damage.

© Copyright 15.19
STARTING / CHARGING
S TA R T I N G S Y S T E M T E S T S
B AT T E R Y L O A D T E S T S TA R T E R S O L E N O I D G R O U N D C I R C U I T T E S T
1. Load test battery using a commercially available
battery load tester. Follow the battery load tester WARNING
manufacturer instructions. Ensure that the motorcycle is secure and that the
NOTICE transmission is in neutral for the following test.
Although not as conclusive, the following test can be
used to direct troubleshooting efforts if a battery load 1. Shift transmission to Neutral.
tester is not readily available. 2. Disconnect the start solenoid connector q .
2. Charge battery until open circuit voltage is above

12.5 Volts.
3. Install battery and connect battery cables.
4. Connect digital multimeter to battery and keep it
connected for duration of test.
5. Turn ignition key on and move head light high
beam switch to High Beam for 1 minute (without
the engine running).
6. Measure battery voltage.
7. If battery voltage has dropped below 10.5 V DC,
re-charge and re-test battery or replace it.
3. Set the multi meter to read resistance and insert

meter leads into the appropriate jacks.
4. Working on the vehicle side of the harness, test
continuity between terminal 2 (black wire) and
chassis ground.
Resistance should be ≤ 0.5 Ω

15.20 © Copyright
STARTING / CHARGING
GEAR POSITION SWITCH NEUTRAL 5. If indicator is not lit with transmission in neutral:
I N D I C AT O R T E S T • Place the RUN/STOP switch in the STOP position and
Symptoms of a faulty Gear Position Switch may turn motorcycle power off.
include:
• Roll the motorcycle forward and back enough to
• Starter motor does not operate when transmission is verify that it is in neutral.
in neutral,
• Disconnect the gear position switch at connector q
but... located beneath the engine at the rear of the cases.
• Starter motor does operate when clutch is pulled in.
1. Press the POWER button to power up the electrical

system.
2. Place engine stop switch in the RUN position.
3. Shift transmission into Neutral. 15
4. Observe neutral indicator light.
• Set the multi meter to test resistance and insert

meter leads into the appropriate jacks.
• Test the gear position switch across terminals 1 & 2.
• Compare reading to the resistance specification.
Gear Position Switch Neutral Resistance

Specification: 42 Ω±0.5Ω
6. If resistance reading is not within specified

parameters, replace neutral switch or repair
wiring as necessary.
7. If neutral indicator switch is working correctly and
neutral indicator did not light with the transmission
in neutral; inspect neutral lamp and circuit wiring
for a open/short circuit.

© Copyright 15.21
STARTING / CHARGING
CLUTCH SWITCH CIRCUIT TEST

NOTICE
2018+ motorcycles communicate using a CAN
system. This test DOES NOT apply to 2018+
motorcycles.
The symptom of a faulty clutch switch circuit is:

• Starter motor will not operate with transmission in
gear and clutch lever pulled in. Starter operates with
transmission in neutral. Use an ohmmeter to
determine if continuity is present when the switch is
closed (lever pulled in).
1. Transmission can be in neutral or in any gear.

2. Disconnect ECM connector 1. See ECM Connector
Removal page 5.52.
3. Set multi meter to measure resistance and insert
meter leads into appropriate jacks.
4. Connect red (+) lead of multi meter to PIN 19 in
ECM connector 1 (harness side). See ECM
Connector Map page .
5. Connect black meter lead to chassis ground.
6. Operate clutch lever while observing meter
display.
7. Pull clutch lever to the handlebar. Meter should
display continuity or very low resistance (less than
1 ohm) when the clutch switch closes.
8. Release clutch lever, meter should display OL
(open line).
9. If clutch switch does not test as described inspect
clutch switch, clutch switch wiring or mounting of
switch to clutch lever for fault.
10. If switch is mounted correctly and physically
operates but does not open and close electrically,
replace switch.

15.22 © Copyright
STARTING / CHARGING
C L U T C H S W I T C H R E M O VA L / I N S TA L L AT I O N 5. Torque clutch switch and cover fasteners to

specification.
1. Remove clutch switch cover fasteners q and clutch
switch cover w . TORQUE
Clutch Switch Fastener: 12 in-lbs (1 N·m)
Clutch Switch Cover Fasteners: 12 in-lbs (1 N·m)
S TA R T E R S O L E N O I D P O S I T I V E C I R C U I T
TEST
WARNING
Secure motorcycle on the side stand and place
transmission in neutral for the following test. 15
1. Place the transmission in neutral.
2. Remove the positive cable q from starter motor.
2. Remove clutch switch retaining fastenere and
toothed washer.
3. Set multi meter to DC Volts and insert meter leads

in the appropriate jacks.
3. Gently pull the clutch switch out of the lever perch 4. Connect the red meter lead (+) to the positive
until the locating pins are free and the switch can starter cable eyelet and the black (-) meter lead to
be disconnected. chassis ground.
CAUTION 5. Press the power button to power up the electrical
system and place the STOP/RUN switch in the RUN
The clutch switch has two locating pins on the top position.
side which slide into the clutch lever perch. Use
caution when removing the clutch switch so the 6. Press starter button. The meter should display
locating pins do not break off. battery voltage. If voltage is more than .2 volts
below battery voltage, inspect the power supply
circuit.
removal procedure.

© Copyright 15.23
STARTING / CHARGING
S TA R T E R C U R R E N T D R AW T E S T 8. Place the engine STOP/RUN switch is in the RUN

position, transmission is in neutral, clutch lever
NOTICE
pulled in and that the ignition system is disabled.
This procedure requires the use of an inductive
ammeter to read current draw and a volt meter to 9. Press starter switch and crank starter for about 5
monitor battery voltage during the test. seconds and observe both meters and the
tachometer.
10. The battery voltage should remain above 9.6 volts.
WARNING
11. The amperage draw of the starter should not
Do not allow any part of the jumper cable clamp exceed 160 amps.
to touch the chassis or any other ground.
Starter current draw @ 77°F (25°C): ≤160 Amps
CAUTION
Disable the ignition system so that the engine will not S TA R T E R C L U T C H R E M O VA L
start during this test. 1. See Starter Drive Removal page 10.19.
• Remove spark plug caps.
• Install test spark plugs into plug caps.
• Ground spark plugs against engine.

(except Roadmaster) page 3.19.
2. Inspect the battery. Charge or replace battery as
necessary before proceeding.
3. Place transmission in neutral.
4. Position an inductive ammeter clamp on battery
positive cable.
5. Set the multi meter to Volts DC scale and connect
red lead of meter to positive post of battery.
6. Connect black lead of meter to negative post of
battery.
7. Press the power button to power up the electrical

system and observe ammeter. It should register
negative amps. If it does not, turn the ammeter
probe around.

15.24 © Copyright
STARTING / CHARGING
S TA R T E R M O T O R , R E M O VA L /
WARNING
Ensure that the ignition switch is turned off.
Remove the negative cable at the battery before
removing the starter motor.
1. Disconnect the negative battery cable. See Battery

Removal page 15.10.
2. Disconnect the positive terminal q from the
starter motor.
3. Remove the two fasteners w from the rear of the
starter motor and slide assembly to the LH side of
the motorcycle to release from engine case. 15
4. Remove starter motor.

5. To install the starter motor, reverse the
removal procedure.
6. Torque the starter mounting fasteners to
specification.
TORQUE
Starter Mounting Fasteners:
88 in-lbs (10 N·m)
7.
NOTICE
Hold the lower terminal nut with an open ended
wrench while tightening the upper nut to avoid
damage.
Torque the starter motor positive terminal nut to

specification.
TORQUE
Starter Motor Positive Terminal Nut:
63 in-lbs (7 N·m)

© Copyright 15.25
STARTING / CHARGING
CHARGING SYSTEM SERVICE

TROUBLESHOOTING, CHARGING SYSTEM
NOTICE: The battery must be fully charged and in good condition to obtain accurate readings. Battery charging
current is automatically reduced by the regulator / rectifier if the regulator / rectifier unit reaches a critical
temperature (overheated). The system should be cool when testing DC charging output or when testing the
regulator / rectifier to ensure accurate readings. Refer to test procedure for individual charging system
components for more information.

15.26 © Copyright
STARTING / CHARGING
CURRENT DRAIN INSPECTION R E G U L AT E D V O LTA G E / A M P E R A G E O U T P U T

IMPORTANT INSPECTION (ALL MODELS)
Current drain should only be measured after all NOTICE
systems have timed out and gone to sleep. Leave
This procedure requires the use of an inductive
power OFF and do not disturb for approximately 12
ammeter to read current draw and a volt meter to
MINUTES for an accurate reading.
monitor battery voltage during the test.
Current drain is suspect if battery discharges when
motorcycle is not in operation (short periods of 1. Remove seat. See Seat Removal / Installation - All
storage). (except Roadmaster) page 3.19.
1. Remove seat. See Seat Removal / Installation - All 2. Place the inductive ammeter over the positive (+)
(except Roadmaster) page 3.19. battery cable.
2. Disconnect ground cable (-) from battery. 3. Set multi meter to V DC scale.
3. Set multi meter to read milliamps (mA) and insert 4. Connect voltmeter red (+) lead to battery red (+) 15
meter leads into appropriate jacks. Connect red lead and black (-) voltmeter lead to battery black
meter lead to ground cable eyelet and connect (-) lead.
black meter lead to battery negative (-) terminal.
5. Start engine and warm to operating temperature.

NOTICE
6. At 1000 RPM or slightly above; the ammeter should
Do not operate electric starter or meter fuse will be reach the “break-even” point (no amperage
damaged. leaving the battery) and the voltmeter should be
rising toward 14 VDC.
4. With ignition switch off, and after 12 minutes
have passed, read current drain. Specification: Break-even point for charging System:
1500 RPM ± 25%
5. If current drain exceeds specifications inspect
wiring and components for short to ground.
7. Increase engine RPM to 2500. The ammeter should
Parasitic Draw Specification (after 12 minutes with rise a slight amount, then stabilize. Volt meter
power OFF): 4.5 mA should read above 14 V DC.
6. Locate the faulty component or wiring by

disconnecting accessories, wiring connections,
and fuses one-at-a-time while observing current
drain. When current drain falls within
specifications, focus efforts on the last circuit or
component that was disconnected.

© Copyright 15.27
STARTING / CHARGING
8. Use results obtained from preceding tests and the S TAT O R A C V O LTA G E O U T P U T T E S T
following descriptions to determine if charging
NOTICE
system is functioning properly.
Set multi meter to VAC (alternating current). Engine
CHARGING SYSTEM OPERATING cold. Regulator / Rectifier disconnected (2-pin and 3-
CORRECTLY: Ammeter goes up a small amount, pin connector). Engine must be running. Be sure to
then stabilizes slightly above +0 amps. Volt meter heed the following Warnings and Cautions.
rises toward 14.8 ± V DC, drops off a little and
starts to stabilize.
LOW BATTERY: Amperage continues to rise, WARNING
voltage levels off as battery is absorbing voltage.
HOT COMPONENTS:
Charging system may be okay. Need to charge
battery fully or use a good battery and repeat test. The engine and exhaust system become very hot
Meters will indicate similar reading to the during operation and remain hot for a period of time
overcharging chart. after the engine is shut off. Wear insulated protection
for hands and arms or wait until the engine and
CHARGING SYSTEM UNDERCHARGING: Ammeter exhaust system have cooled sufficiently before
drops to 0 or remains below 0 (negative reading) at working on the machine.
all rpm, volt meter remains the same or goes down.
Go to voltage drop inspection.
CHARGING SYSTEM OVERCHARGING: Ammeter WARNING
rises well above 0 and remains there or continues CARBON MONOXIDE:
to rise. Volt meter goes well above 14.8 V DC and Never run an engine in an enclosed area. Exhaust
may continue to rise. contains poisonous carbon monoxide gas that can
EXCESSIVE LOAD: Current levels off or starts to cause loss of consciousness and may lead to death. If
drop, voltage continues to rise. Load may be you must run the engine to do some repairs, do so in
excessive (accessories or shorted components). an open area or with an exhaust evacuation system
Determine if excessive loads are present. operating.
Disconnect accessories and re-test.
9. Turn ignition key off. CAUTION
10. Remove inductive ammeter clamp. VOLTAGE / ARCING:
11. Install seat. See Seat Removal / Installation - All Use caution not to touch any of the connections or
(except Roadmaster) page 3.19. allow the exposed terminals to come close to any
other part of the vehicle or other objects, as an arc
may occur.
1. Disconnect the 3-pin stator connector.

2. Set multi meter to measure AC Volts.

15.28 © Copyright
STARTING / CHARGING
3. Connect one lead of the multi meter to pin A e and

one lead to pin B r on the 3-pin stator connector.
15
CAUTION
VOLTAGE / ARCING
Use caution not to touch any of the connections or
allow the exposed terminals to come close to any
other part of the vehicle or other objects, as an arc
may occur.
4. Start the engine and let it run at idle. Observe the

multi meter reading.
5. The meter should indicate the following readings:
No load AC Volts @ 800 RPM:
All Models: 22 VAC ±25%
6. Repeat test for pins A e & C t.

7. Repeat test for pins B r & C t.
NOTICE
The test results in Steps 6, 7, and 8 can read more
than the specified voltage, but it is important that
the reading for each pair of wires is
approximately equal.
8. Increase RPM to 2000. Repeat Steps 4-7.

9. At 2000 RPM the meter should indicate the
following readings:
No Load AC Volts @ 2000 RPM:All Models: 40 VAC ±
25%
NOTICE
The test results obtained in step 10 can read more
than the specified voltage, but it is important that
they are all approximately equal.

© Copyright 15.29
STARTING / CHARGING
S TAT O R R E S I S TA N C E T E S T S TAT O R W I N D I N G S T O G R O U N D I N S P E C T I O N
CAUTION CAUTION
The engine must not be running while performing the The engine must not be running while performing the
following resistance test. following resistance test.
NOTICE NOTICE
Set multi meter to measure resistance. Engine OFF Set multi meter to measure resistance. Engine OFF
and cold. Regulator Rectifier 3–pin connector and cold. Regulator Rectifier 3–pin connector
unplugged. unplugged.
1. Disconnect the 3 pin connector q from stator. 1. Disconnect the 3 pin connector q from stator.
2. Set the multi meter to measure resistance (Ω) and 2. Connect one multi meter lead to pin A w and
insert the meter leads in to the appropriate jacks. place the other lead of the multi meter in contact
with a good engine ground, observe resistance to
3. Connect one meter lead into pin A w and the
ground reading.
other lead into pin B e on the stator connector and
read resistance value.
Stator to Ground (-) Continuity Specifications: Open

Stator Resistance: Less than 1 Ohm Circuit (OL)
4. Repeat test for pins A w & C r. 3. Repeat test for other two stator leads e & r to
ground.
5. Repeat test for pins B e & C r.
4. There should be no connection from stator
6. If resistance values do not match specification, windings to ground.
inspect stator and replace as necessary.

15.30 © Copyright
STARTING / CHARGING
S TAT O R R E M O VA L 8. Remove the three fasteners q from stator.

Removal page 9.8.
2. Remove the clutch assembly. See Clutch Removal
page 9.15
3. Remove the torque compensator assembly. See
Torque Compensator Removal page 9.21.
4. Remove the flywheel. See Flywheel Removal page
9.23
5. Disconnect the stator from the regulator / rectifier.
6. Using a flat head screwdriver or similar tool,
remove the terminal retainer from the back of the
stator connector.
15
9. Push the rubber harness seal through to the inside
of the primary case and remove stator assembly.
7. Using a terminal tool or pick tool, remove the three

electrical terminals from the stator connector.

© Copyright 15.31
STARTING / CHARGING
S TAT O R I N S TA L L AT I O N F LY W H E E L R E M O VA L
The electrical connector must be removed from the See Flywheel Removal page 9.23.
stator assembly before it can be installed in the motor-
cycle. See Stator Removal page 15.31 for information
on connector removal. R E C T I F I E R / R E G U L AT O R C O N N E C T O R
1. Feed the stator wires through the hole in the LH INSPECTION
engine case and push the rubber harness seal q 1. Remove the regulator / rectifier assembly. See
through until fully seated. Rectifier / Regulator Replacement page 15.33.
2. Place stator in position over the crankshaft and 2. Disconnect both 2-pin q and 3-pin connector w .
install fasteners w . Torque to specification.
3. Inspect male and female pins in the 3-pin

TORQUE connector and the 2-pin connector carefully.
Check for corrosion, loose pins, poor connections,
Stator Fasteners: 88 in-lbs (10 N·m) or evidence of overheating or other damage.
4.
3. Press the three wire terminals into the connector
housing until there is an audible “click” and the IMPORTANT
wires cannot be backed out. If damage is found to either connector, there may be
NOTICE auxiliary damage to the ground wire of the gear
position switch. See Gear Position Switch
Wires can be installed into any position on the Troubleshooting page
electrical connector. Charging performance will not
be affected.
5. If the wiring and connectors are undamaged and
4. Install the silicone plugs into each of the connector appear to be clean and tight, inspect the battery,
cavities and snap the terminal retaining clip into stator, and related wiring. Test the regulator /
place. rectifier for diode leakage.
5. Plug the stator connector into the regulator /

rectifier connector.
6. Install the flywheel. See Flywheel Installation
page .
7. Install the torque compensator. See Torque
8. Install the clutch assembly and clutch rack. See
Clutch Installation page 9.20.

15.32 © Copyright
STARTING / CHARGING
DIODE LEAKAGE TEST R E G U L AT O R / R E C T I F I E R R E P L A C E M E N T

IMPORTANT 1. Disconnect the stator q from the regulator /
Engine must be OFF. Perform this test at the regulator rectifier.
/ rectifier 2-Pin connector. Testing at any other point 2. Remove the two fasteners w securing the regulator
(between battery and battery cable for example) / rectifier to the bracket.
could include leakage not attributable to the
Regulator / Rectifier unit.
1. Disconnect the 2-pin connector at voltage

regulator / rectifier unit.
2. Install a jumper across the connectors as shown for
the Bk wire to provide a complete ground path.
3. Connect meter as shown, with red (+) meter lead
to the RD / BK wire on harness side, and the black
meter lead to the RD / BK wire on the regulator /
15
rectifier side.
3. Remove the three fastenerse securing the

regulator / rectifier bracket to the engine.
4. Compare leakage to specification below.

Specification:
Leakage: Less than 1.0 mA
4. Noting their position for use during installation,

remove the two plastic darts retaining the wiring
harness to the regulator / rectifier bracket.
5. Disconnect the regulator / rectifier 2–pin connector
from the vehicle harness and remove from vehicle.
6. Remove the regulator / rectifier bracket from
vehicle.

© Copyright 15.33
STARTING / CHARGING

removal procedure.
8. Torque the bracket and regulator / rectifier
TORQUE
Bracket Fasteners: 88 in-lbs (10 N·m)
Regulator / Rectifier Fasteners: 88 in-lbs (10 N·m)

15.34 © Copyright
IGNITION SYSTEM
CHAPTER 16
IGNITION SYSTEM
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.2
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.4
BASICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.4
TEST LEAD ADAPTER KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.4
ECM CONNECTOR MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.4
IGNITION SYSTEM TEST FLOWCHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.5
BATTERY VOLTAGE INSPECTION: TEST 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.5
16
SPARK INSPECTION: TEST 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.6
IGNITION CABLE RESISTANCE: TEST 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.6
IGNITION COIL POWER & GROUND SIGNAL TEST 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.7
IGNITION COIL RESISTANCE: TEST 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.8
CRANKSHAFT POSITION SENSOR (CPS) RESISTANCE INSPECTION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.8
IGNITION COIL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.9

© Copyright 16.1
IGNITION SYSTEM
SERVICE NOTES GENERAL PRECAUTIONS
There are many hazards present when working on or
around the ignition system. Read and pay close • This ignition system is controlled electronically and
attention to the following warnings and cautions when no provisions are available to inspect or change
working on any component in this section. ignition timing. A timing light is still valuable as a
diagnostic tool.
WARNING • Poor connections are the most common cause of
ignition problems. Inspect all connections and
Never run an engine in an enclosed area. Exhaust replace the spark plugs before doing extensive
contains poisonous carbon monoxide gas that can ignition system troubleshooting.
cause loss of consciousness and may lead to death. If
you must run the engine to do some repairs, do so in • Make sure the battery is fully charged and that the
an open area or with an exhaust evacuation system charging system is operating correctly.
operating. • A signal from the Crankshaft Position Sensor must
be present at the ECM for spark to occur.
WARNING
The engine and exhaust system become very hot
during operation and remain hot for a period of time
SPECIAL TOOLS
after the engine is shut off. Wear insulated protection SPECIAL TOOL PART NUMBER
for hands and arms or wait until the engine and
exhaust system have cooled before working on the Electrical Tester Kit PV-43526
machine. Digital Multimeter Commercially Available
Inductive Timing Light Commercially Available
CAUTION
Some procedures call for the engine to be run in
order to warm the engine to operating temperature. T O R Q U E S P E C I F I C AT I O N S
If this is done the exhaust pipes can “blue” if a
cooling air stream is not provided by means of a shop PART / FASTENER TORQUE
fan directed the exhaust system. SPECIFICATION
Spark Plug 12.7 ft-lbs (17.2 Nm)
CAUTION Ignition Coil to Bracket 84 in-lbs (9.5 Nm)
Parts containing semi-conductors can be easily
damaged if handled carelessly. Do not drop or
subject the electronic components to shock loads.
ITEM SPECIFICATIONS
CAUTION
Spark Plug NGK DCPR8E
Follow the instructions closely when troubleshooting
items in this section. Some electrical components can Spark Plug Gap .034 in (.9 mm)
be damaged if they are connected or disconnected
while the ignition is powered ON and current is Primary 0.3 - 0.6 Ohms ± 20%
present. Secon-
Ignition Coil /
dary See coil test
Cables
Resistance
CAUTION Values Plug Wire
Using incorrect heat range spark plugs can damage (with 1860 Ohms ± 20%
the engine. Always follow the manufacturer’s cap*)
recommendations for spark plug heat range. Crank Position Sensor 1050 Ohms ± 10% @
Resistance 68°F (20°C)
* Spark plug end caps are not removable

16.2 © Copyright
IGNITION SYSTEM
16

© Copyright 16.3
IGNITION SYSTEM
TROUBLESHOOTING
BASICS TEST LEAD ADAPTER KIT
Before troubleshooting the ignition system, ensure that 1. Tests in this section may include the testing of
the engine STOP/RUN switch is in the RUN position, voltage and / or resistance at the connectors for
the battery is fully charged, and system related fuses various sensor and system components. Use the
are not open (blown). Check visually for corroded, appropriate test adapter lead when performing
loose, or broken connections in critical areas (e.g. these tests at connector pin(s).
sensor connector). Check for loose wire pins in the 2. Forcing an incorrect or oversized probe into a
individual sensor connectors and at the ECM (beneath connector may cause inaccurate test results (due
the battery box). to lack of a solid mechanical connection to the
Don’t forget the spark plugs! terminal). It can also damage the connector being
probed or the connector housing, creating another
The Ignition System Troubleshooting flow chart (and problem which greatly complicates the diagnostic
the accompanying text) is designed to help you process. Extreme care must be taken not to
troubleshoot ignition system problems. It will not lead introduce problems while probing a connector.
you to faulty or fouled spark plugs. Always inspect Electrical Tester Kit: PV-43526
spark plug condition first (and replace if necessary)
when troubleshooting ignition system problems.
CAUTION
Be sure that the spark plugs are the correct heat range
and are the correct size specification. Once the ECM connector has been disconnected, do
not touch the pins on the ECM. Static electricity from
your body can damage the ECM. Do not attempt to
WARNING perform tests on the ECM.
Extremely high voltage is present in the ignition
system. Do not touch the ignition coil, wires or spark
plugs during test procedures.
ECM CONNECTOR MAP
See ECM Connector Map in the Fuel Delivery / EFI
Chapter.

16.4 © Copyright
IGNITION SYSTEM
IGNITION SYSTEM TEST FLOWCHART
16
B AT T E R Y V O LTA G E I N S P E C T I O N : T E S T 1
1. Remove the seat. See Seat Removal / Installation -
All (except Roadmaster) page 3.19.
2. Set multi meter to measure DC Volts.

© Copyright 16.5
IGNITION SYSTEM
3. Inspect battery voltage. I G N I T I O N C A B L E R E S I S TA N C E : T E S T 3

1. Remove high tension leads by pulling firmly on the
boots at the coil and spark plug. DO NOT pull on
the wire or it may become permanently damaged.
NOTICE
The plug caps or coil ends are NOT removable. Wire
must be replaced as an assembly.
2. Test each high tension lead with an ohmmeter and

compare to specification. Move wire to detect
internal breaks or poor connections at terminal
ends.
4. If the battery voltage is below 12.5 V DC charge or
replace the battery with a fully charged battery.
NOTICE
When operating the starter with a low battery, the
voltage available for the ignition coils can drop
below the minimum required to produce spark.
S PA R K I N S P E C T I O N : T E S T 2
1. Connect an inductive timing light to one spark
plug wire.
2. Press ON to power up the motorcycle and place
the STOP/RUN switch in the RUN position.
High Tension Lead Resistance: 1860Ω ± 20%
3. Shift transmission into neutral and pull in clutch
lever.
4. Depress starter button and observe timing light.
5. Determine if timing light flashes without
interruption for both cylinders.
6. Consistent flashes indicate that some secondary
voltage is present. The likelihood of an ignition
related problem is reduced but not eliminated.
Keep the following points in mind:
• There is a threshold voltage and amperage
requirement for timing lights below which they will
not trigger and therefore, not flash.
• Fouled spark plugs may drop secondary voltage so
low that a timing light will not trigger and therefore,
not flash.
• With no current flowing (open secondary side of the
ignition coil) the timing light will not flash.
• A faulty high tension lead (plug wire) or poor
connection is one example of an open secondary.
7. Replace spark plugs, connect plug wires and re-

test.
8. If timing light does not flash consistently for one or
both cylinders, test high tension leads (Test 3).

16.6 © Copyright
IGNITION SYSTEM
IGNITION COIL POWER & GROUND SIGNAL TEST 4

Power To Ignition Coil 14. Repeat the test on the other outside wire in the
Battery voltage must be present at the ignition coil (Pin connector.
B) when the power button is switched on and the • If no pulse is present, test the Crankshaft Position
electrical system powered up. Sensor.
1. Disconnect the electrical connector from the
ignition coil. See Ignition Coil Removal / • If the signal is present on one wire and not the other,
Installation page 16.9. test related wiring and connections.
2. Set the multi meter to measure VDC and insert the • If both signals are present and there was battery
meter leads into the appropriate jacks. voltage on the RD wire (center terminal) but still no
spark, test the ignition coil windings. (Test 5).
3. Connect the black lead to ground (on the engine).
4. Connect a small thin test adapter lead to the
center terminal of the ignition coil primary
connector and the red meter lead to the test
adapter.
motorcycle electrical system and place the STOP/
RUN switch in the RUN position.
6. Battery voltage should appear on the center
16
terminal of the coil connector (RD wire).
7. With transmission in Neutral, crank the engine.
Battery voltage should again be present on center
wire.
Ignition Coil Ground Signal
The following steps will test the ECM (Ground)
Signal To Ignition Coil
ECM ground signal must be present at each of the
outer terminals of the ignition coil primary
harness connector. The signal will appear as a
pulse on the meter between Ground (-) and Open
(OL).
8. Set the multi meter to measure resistance (Ω).
9. Place a small thin test adapter into one of the outer
terminals of the ignition coil connector (either the
WH or BK wire) and connect one meter lead to the
test adapter..
10. Ground the other lead to the engine.
11. Place transmission in Neutral.
motorcycle electrical system and place the STOP/
RUN switch in the RUN position.
13. Crank the engine with the electric starter and
watch the display on the multi meter. The meter
display should pulse evenly while engine is
cranking, indicating a ground signal is present.

© Copyright 16.7
IGNITION SYSTEM
I G N I T I O N C O I L R E S I S TA N C E : T E S T 5 9. Repeat measurements on each secondary coil with

Ignition Coil Primary Winding meter leads reversed.
1. Remove ignition coil. See
2. Set the multi meter to measure resistance (Ω) and
insert the meter leads into the appropriate jacks.
3. Measure resistance between terminal 3 and
terminal 2 on the coil. Compare to specification.
4. Measure resistance between terminal 1 and
terminal 2 on the coil. Compare to specification.
NOTICE
Diode inside the secondary coil requires the Diode
Check function of multi meter.
Secondary Coil Resistance: 2.0–2.5 VDC

or
Open Line (OL) with leads reversed
Primary Coil Resistance: 0.4–0.6 Ω 10. Compare readings to specification. Resistance

should be low with leads one way and OL with
Ignition Coil Secondary Windings leads reversed.
5. Remove ignition coil. See Ignition Coil Removal /
Installation page 16.9. CRANKSHAFT POSITION SENSOR (CPS)
6. Select DIODE CHECK function on the multi meter. R E S I S TA N C E I N S P E C T I O N :
7. Place red meter lead on terminal 2 (center) of coil See Crankshaft Position Sensor, Test / Replace page
primary and black lead on secondary terminal 5.56.
and record.
8. Move black DMM lead to the other secondary
terminal and record. (Reading should be the same
for both secondary windings).

16.8 © Copyright
IGNITION SYSTEM
I G N I T I O N C O I L R E M O VA L / I N S TA L L AT I O N
1. Verify that motorcycle is not powered up and the
STOP / RUN switch is in the OFF position.
2. Remove the horn assembly. See Horn Removal /
3. Remove the ignition cables from the coil and
disconnect the electrical connector from the coil.
4. Remove the ground wire q from the coil bracket.
16
5. Release harness retainer from coil bracket.

6. Using a 10mm socket, remove the four fasteners w
securing the coil bracket to the engine and
remove the coil assembly.
7. INSTALLATION of the ignition coil is

performed by reversing the removal
procedure. Torque fasteners to specification.
TORQUE
Coil Ground to Bracket: 88 in-lbs (10 N·m)
Ignition Coil to Bracket: 88 in-lbs (10 N·m)

© Copyright 16.9
IGNITION SYSTEM
NOTES

16.10 © Copyright
CHASSIS ELECTRICAL
CHAPTER 17
CHASSIS ELECTRICAL
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.3
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.3
ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.4
HEAD LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.4
TAIL LIGHT / LICENSE PLATE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.5
FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.6
FUSE BOX LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.6
FUSE APPLICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.7
VEHICLE CONTROL MODULE (VCM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.9
VEHICLE CONTROL MODULE (VCM) SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.9
VEHICLE CONTROL MODULE (VCM), REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.10
VCM CONNECTOR MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.10 17
HEADLIGHT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.14
HEADLIGHT BULB REPLACEMENT - ALL MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.14
HEADLIGHT WARNING INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.15
HORN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.16
HORN REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.16
TAIL LIGHT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.17
LED TAIL / BRAKE LIGHT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.17
TAIL / BRAKE / LICENSE PLATE LIGHT, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.17
TRUNK LED REPLACEMENT - BRAKE / INTERIOR (ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.19
TURN SIGNAL / HAZARD SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.20
TURN SIGNAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.20
FRONT TURN SIGNAL REMOVAL / INSTALLATION (CHIEFTAIN / ROADMASTER) . . . . . . . . . . . . . . . . . . 17.20
FRONT TURN SIGNAL, REMOVAL / INSTALLATION (CLASSIC / VINTAGE / DARK HORSE /
SPRINGFIELD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.20
REAR TURN SIGNAL,REMOVAL / INSTALLATION (ALL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.21
INSTRUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.22
INSTRUMENT CLUSTER (CHIEF CLASSIC / CHIEF VINTAGE / CHIEF DARK HORSE /
SPRINGFIELD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.22
INSTRUMENT CLUSTER, CHIEFTAIN / ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.25
CRUISE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.27
CRUISE CONTROL OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.27
CRUISE CONTROL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.28
SHIFT DRUM SPRING / PIN INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.29
SECURITY ALARM SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30
SECURITY ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30
POWER WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.32
POWER WINDSHIELD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.32

© Copyright 17.1
CHASSIS ELECTRICAL
POWER WINDSHIELD MOTOR, REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.33

POWER WINDSHIELD MOTOR, INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.34
GEAR POSITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.35
GEAR POSITION SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.35
GEAR POSITION SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.42
SWITCH TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.43
BRAKE LIGHT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.43
CLUTCH SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.43
TIPOVER SENSOR (ANGLE SENSOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.43
SIDE STAND SWITCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.44
BREAKOUT WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.45
ANTI-LOCK BRAKE SYSTEM, WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.45
CENTRAL LOCKING SYSTEM, WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.46
STARTING SYSTEM, WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.47
KEYLESS IGNITION SYSTEM, WIRING DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.48
POWER WINDSHIELD, WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.49

17.2 © Copyright
CHASSIS ELECTRICAL
SERVICE NOTES PART DESCRIPTION TORQUE
Keep the following notes in mind when diagnosing an SPECIFICATION
electrical problem: Tail Light Fastener 84 in-lbs (9.5)
• Refer to wiring diagram for stator and electrical Turn Signal Fastener 18 ft-lbs (24.4 Nm)
component resistance specifications.
Turn Signal, Front 36 in-lbs (4.1 Nm)
• When measuring resistance of a component that has
(Chieftain / Roadmaster)
a resistance value under 10 Ohms, remember to
subtract meter lead resistance from the reading. VCM Mounting Plate 84 in-lbs (9.5 Nm)
Connect the leads together and record the
resistance. The resistance of the component is equal
to tested value minus the lead resistance.
• Become familiar with the operation of your meter. Be
sure leads are in the proper jack for the test being
performed (i.e. 10A jack for current readings). Refer
to the Owner’s Manual included with your meter for
more information.
• Pay attention to the prefix on the multimeter reading
(K, M, etc.) and the position of the decimal point.
• For resistance readings, isolate the component to be
tested. Disconnect it from the wiring harness or
power supply.
17
SPECIAL TOOLS
Battery Tester PV-50296
Electrical Tester Kit PV-43526
Smartlink Module Kit PU-47471
TPMS Activation Tool PF-51288
USB to Serial Adapter PU-50621
PART DESCRIPTION TORQUE
SPECIFICATION
Head Light Bezel 36 in-lbs (4.1 Nm)
(Chieftain / Roadmaster)
Head Light Retaining 12 in-lbs (1.4 Nm)
Ring
Horn to Bracket Nut 84 in-lbs (9.5)
Ignition Cover 84 in-lbs (9.5)
License Plate Bracket to 84 in-lbs (9.5)
Tail Light
License Plate Light 15 in-lbs (1.7 Nm)

© Copyright 17.3
CHASSIS ELECTRICAL
HEAD LIGHT
q Fastener, Retaining Ring (QTY.4) 12 in-lbs (1 N·m)
w Retaining Ring -
e Head Light Housing -
r Fastener, Head Light Mount NA
t Fastener, Adjuster NA
y Spring, Adjuster -
u Head Light Carrier -

17.4 © Copyright
CHASSIS ELECTRICAL
TA I L L I G H T / L I C E N S E P L AT E L I G H T
17
q Fastener, Turn Signal — M8 x 1.25 x 12 (QTY.2) 18 ft-lbs (24 N·m)
w Fastener, Tail Light Asm — M6 x 1.0 x 10 88 in-lbs (10 N·m)

(QTY.3)
e Pad, Tail Light Bezel -

© Copyright 17.5
CHASSIS ELECTRICAL
FUSE BOX
F U S E B O X L O C AT I O N
There are two fuse boxes utilized on the full size Indian Motorcycle platform.
• The J-Case fuse box q which is located on the rear of the battery box.
• The main fuse box w which is located beneath the

LH upper side cover.

17.6 © Copyright
CHASSIS ELECTRICAL
F U S E A P P L I C AT I O N C H A R T
17
PIN CIRCUIT DESCRIPTION FROM TO

1 Engine Breaker Output Fuse Box Splice (ENGBRK)
2 Engine Relay Power Output Fuse Box Splice (ENGPWR)
4 Fuel Pump Power Fuse Box Fuel Pump
6 Main Engine Relay Control Fuse Box Splice (E115)
7 Run / Stop Switch Power Fuse Box Splice (ENGBRK)
8 Fuel Pump Relay Control ECM 1 Fuse Box
10 Starter Solenoid Control Fuse Box Starter Solenoid
11 Chassis Fuse Power Output Fuse Box Splice (CHPWR)
12 Auxiliary Engine Relay Power Output Fuse Box Splice (AUXENG)
13 Engine Relay Power Output Splice (ENGPWR) Fuse Box
14 Starter Relay Control ECM 1 Fuse Box
15 Chassis Fuse Power Output Fuse Box Splice (CHPWR)
16 Main Engine Relay Control Fuse Box Splice (E115)
17 Auxiliary Engine Relay Power Output Fuse Box Splice (AUXENG)

© Copyright 17.7
CHASSIS ELECTRICAL
PIN CIRCUIT DESCRIPTION FROM TO

18 Accessory Switched Output Fuse Box Splice (ACCSW)
19 Switched Power Control VCM A Fuse Box
20 Switched Power Fuse Box Fuse Box
21 Auxiliary Switched Fuse Output Fuse Box Fuse Box
22 Auxiliary Switched Relay Control ECM 1 Fuse Box
23 VCM Accessory Power Output Fuse Box Splice (VCMACC)
24 Ground Splice (GND2) Fuse Box
25 Main Fuse Output Splice (MPWR) Fuse Box
26 Not Used — —
27 Not Used — —
28 Not Used — —
29 VCM Power Control VCM B Fuse Box
30 Not Used — —
31 Not Used — —
32 Not Used — —
33 Main Fuse Output Fuse Box Splice (MPWR)
38 Chassis Fuse Output Power Fuse Box Splice (CHPWR)
39 Switched Power Fuse Box Fuse Box
40 Radio Fuse Output Power Fuse Box Fairing
45 Accessory Constant Fuse Output Fuse Box Splice (ACCCONST1)
46 Auxiliary Switched Fuse Output Fuse Box Fuse Box
47 Instrumentation Fuse Output Fuse Box Speedometer
48 Trunk Amp Power Fuse Box Trunk

17.8 © Copyright
CHASSIS ELECTRICAL
VEHICLE CONTROL MODULE (VCM)

VEHICLE CONTROL MODULE (VCM)
SERVICE NOTES
Replacement of the Vehicle Control Module (VCM)
should only be performed by a qualified dealer.
Vehicle Control Module (VCM) setup and
initialization requires the use of Digital Wrench.
17

© Copyright 17.9
CHASSIS ELECTRICAL
VEHICLE CONTROL MODULE (VCM), 8. Lift the VCM / mounting plate assembly from the
R E M O VA L / I N S TA L L AT I O N rear and disengage hinge pins from the battery
box to remove.
CAUTION
The negative battery cable MUST be disconnected
before the VCM can be removed.
Electrical tape can be used to cover the negative
battery terminal and cable end to prevent a short
from occurring across the VCM during removal.
1. Connect to vehicle using Digital Wrench.

2. Using Digital Wrench, access and record the Key
Fob number.
3. Record the 4 digit consumer PIN (as provided by
the consumer).
(except Roadmaster) page 3.19. 9. INSTALLATION is performed by reversing the
removal procedure.
5. Using a 5mm hex wrench, remove the bolt w
securing the VCM mounting plate to the battery 10. Torque the VCM mounting fastener to
box. specification.
TORQUE
Vehicle Control Module Mounting Plate Fastener:
88 in-lbs (10 N·m)
11. Reconnect to vehicle using Digital Wrench.

12. Using Digital Wrench, program the Key Fob
number.
13. Set a new consumer PIN.
14. Record the new Master PIN by uploading a new
Service Report.
15. Chieftain / Roadmaster ONLY: Initialize /
reactivate the TPMS sensors.
6. Disconnect the negative battery cable. 16. Test ride the vehicle to verify all systems are
7. Disconnect the three multi-plugs q from the VCM. operating correctly.
VCM CONNECTOR MAP

17.10 © Copyright
CHASSIS ELECTRICAL
CONNECTOR: VCM A
PIN WIRE FUNCTION
NUM- COLOR
BER
1 YE/WH START SWITCH OUTPUT
2 BU/WH BAG UNLOCK
3 BU/DG BAG LOCK
4 VT/YE IGNITION SWITCH SIGNAL
5 WH NOT USED
6 - -
7 WH NOT USED
8 YE CAN HIGH
9 DG CAN LOW
10 PK NOT USED
11 OG/YE SWITCHED POWER
CONTROL
12 GY/RD AUX LIGHT SWITCH
INDICATOR LIGHT
13 BU/RD HEATED GRIP SWITCH
OUTPUT
14 - -
17
15 - -
16 - -
17 YE/BK TRANS GEAR POSITION
SENSOR OUTPUT
18 BK NOT USED

© Copyright 17.11
CHASSIS ELECTRICAL
CONNECTOR: VCM 1
PIN WIRE FUNCTION
NUM- COLOR
BER
1 YE HIGH BEAM OUTPUT
2 DG LOW BEAM OUTPUT
3 PK HEATED GRIPS OUTPUT
4 WH HORN POWER
5 RD VCM POWER
6 GY/DB WINDSHIELD MOTOR A
7 GY/DG WINDSHIELD MOTOR B
8 OG/WH LOCK B SIGNAL
9 RD/WH LOCK A SIGNAL
10 - -
11 RD VCM POWER
12 DG/RD LH AUX LIGHT POWER
13 DG/BN RH AUX LIGHT POWER
14 BN/WH NOT USED
15 - -
16 - -
17 BK VCM GROUND
18 - -
19 - -
20 RD VCM POWER

17.12 © Copyright
CHASSIS ELECTRICAL
CONNECTOR: VCM B
PIN WIRE FUNCTION
NUM- COLOR
BER
1 RD/YE VCM CONTOL POWER
2 WH/BK MODE SWITCH 1
3 GN MODE SWITCH 2
4 GY HORN SWITCH OUTPUT
5 DG/YE HEADLIGHT CONTROL
6 DG/BK AUX LIGHT SWITCH
OUTPUT
7 DB/BK HAZARD SWITCH OUTPUT
8 YE/BD OIL PRESSURE SWITCH
9 BK GROUND
10 OG CRUISE CONTROL ON/OFF
SWITCH OUTPUT
11 WH CRUISE CONTROL SET/
ACCEL SWITCH
12 WH/DG CRUISE CONTROL RESUME 17
/ DECEL SWITCH
13 BU/YE HEATED GRIP SWITCH
INCREASE
14 BU/BK HEATED GRIP SWITCH
DECREASE
15 YE/DG LEFT TURN SIGNAL
CONTROL
16 BN RIGHT TURN SIGNAL
CONTROL
17 BN/DB WINDSHIELD SWITCH UP
18 DG/DB WINDSHIELD SWITCH
DOWN

© Copyright 17.13
CHASSIS ELECTRICAL
HEADLIGHT SERVICE
HEADLIGHT BULB REPLACEMENT - ALL 4. Perform headlight adjustment. See “HEADLIGHT
MODELS AIM INSPECTION”.
IMPORTANT Chieftain Dark Horse / Chieftain / Roadmaster

Avoid touching a halogen bulb with bare fingers. Oil 1. Remove two fasteners q and head light bezel w.
from your skin leaves a residue, causing a hot spot
that will shorten the life of the bulb. If a bulb is
touched, clean it thoroughly with denatured alcohol.
Chief Classic / Chief Vintage / Chief Dark Horse /

Springfield
NOTICE
It is not necessary to remove the headlight nacelle to
replace the headlight bulb on Chief Classic / Chief
Vintage / Chief Dark Horse / Springfield models.
1. Turn handlebar all the way to the left.
2. Gently pull out on the top of the bezel to release it

from the body. Tilt the bezel out and remove.
2. Reach in the space between the head tube and

nacelle to remove bulb and disconnect electrical
connection q.
3. Remove fasteners e and headlight retaining ring

r. Withdraw the reflector assembly far enough to
remove bulb.
3. Using a clean, oil-free cloth, replace the headlight

bulb.

17.14 © Copyright
CHASSIS ELECTRICAL
4. Remove the headlight bulb from the reflector and H E A D L I G H T WA R N I N G I N D I C AT O R S

unplug. Indian motorcycles are equipped with “tell tales”
5. Using a clean, oil-free cloth, install the new indicating when a fault occurs with the low or high
headlight bulb. beam headlight.
6. Install headlight retaining ring r and fasteners e

to the headlight bracket. Torque fasteners to 2014 models: If a fault occurs with the headlight bulb
specification. (low or high beam) the ‘Check Engine’ light will
illuminate and fault codes will be stored. Once the
TORQUE bulb has been replaced and the issue corrected, the
‘Check Engine’ light will turn off however stored fault
Headlight Retaining Ring Fasteners: codes will need to be erased.
12 in-lbs (1 N·m)
7. Perform headlight adjustment. See “HEADLIGHT

AIM INSPECTION”.
8. Install headlight bezel w and retain with two
fasteners q. Torque to specification.
2015 and later models: If a fault occurs with the
TORQUE headlight bulb (low or high beam) the high beam
Bezel Fasteners: indicator light will flash on the instrument cluster.
36 in-lbs (4 N·m) Once the bulb has been replaced and the issue
corrected, the high beam indicator will return to
normal operation.
17

© Copyright 17.15
CHASSIS ELECTRICAL
HORN SERVICE
H O R N R E M O VA L / I N S TA L L AT I O N
1. Remove the three fasteners q securing the horn
cover to the bracket and remove cover.
2. Disconnect the horn electrical connector w .

3. Using a 10mm wrench, remove the fastener e
securing the horn to the ignition coil bracket.
Remove the horn.

removal procedure.
5. Torque fasteners to specification.
TORQUE
Horn to Bracket: 88 in-lbs (10 N·m)
TORQUE
Ignition Coil Cover: 88 in-lbs (10 N·m)

17.16 © Copyright
CHASSIS ELECTRICAL
TA I L L I G H T S E R V I C E
L E D TA I L / B R A K E L I G H T O P E R AT I O N TA I L / B R A K E / L I C E N S E P L AT E L I G H T ,
The multiple LED tail / brake lamp functions much like R E M O VA L / I N S TA L L AT I O N
a conventional incandescent tail / brake lamp. LED
lights require a regulated current supply to prevent NOTICE
damage, so a current regulation circuit is incorporated The tail and brake lights are LEDs and cannot be
inside the tail lamp unit. Direct 12 volt battery power replaced individually. If the lights fail to function
can be applied directly to the brake or tail lamp wire when activated, and all circuit tests indicate correct
for testing purposes, but polarity MUST be observed power and ground distribution, the tail /brake light
or the LEDs will be permanently damaged. must be replaced as an assembly. The license plate
Tail / Brake Light Power Supply: light can be replaced individually.
When the motorcycle is powered ON, battery voltage 1. Place the motorcycle in an upright position with
is delivered to the TAIL / BRAKE LEDs on the DARK the front wheel clamped in a wheel vise.
BLUE / PINK wire from the Secondary Engine Relay.
Current through each TAIL LED (WHITE wire) is 2. Working from beneath the rear fender, access the
limited (inside tail lamp unit) to approximately 250 three tail light fasteners q and remove.
mA.
Tail / Brake Light Ground Signal:

The front and rear brake light switches provide a path
to ground to the ECM via WHITE / RED wire (front
brake switch) and YELLOW / VIOLET wire (rear brake
switch). When the ECM receives a grounding signal
from either of the brake switches, ground is provided
17
to the tail / brake light LED, thus illuminating the light.
When the motorcycle is powered ON, the ECM

provides a ground path to the tail light LED, thus
illuminating the light.
3. Lift the tail light assembly off of the rear fender

and disconnect the electrical connectors w noting
their position for reassembly.
4. Remove the tail light assembly.

License Plate Light Removal

© Copyright 17.17
CHASSIS ELECTRICAL
5. Remove nuts e and washers. 8. Remove fastener y and remove the tail light from
the mount.
6. Remove the two fasteners r and separate the

license plate bracket from the tail light assembly. 9. Installation is performed by reversing the
removal procedure. Torque all fasteners to
specification.
TORQUE
Tail Light to Mount:
88 in-lbs (10 N·m)
TORQUE
License Plate Light to Mount:
88 in-lbs (10 N·m)
TORQUE
License Plate Bracket to Tail Light:
7. Remove the license plate light t from the license 88 in-lbs (10 N·m)
plate bracket.
TORQUE
Tail Light Asm to Fender:
88 in-lbs (10 N·m)
Tail / Brake Light Removal

17.18 © Copyright
CHASSIS ELECTRICAL
TRUNK LED REPLACEMENT - BRAKE /

INTERIOR (ROADMASTER)
1. Open trunk lid.
2. Disconnect the interior light electrical connector
from the base of the switch plunger.
3. Locate the brake LED connector q where it is
tucked into the trunk lid and disconnect.
17
4. Remove the three fasteners w securing the LED to
the trunk lid using a 3mm hex wrench.
5. Feed the LED electrical connector through the

conduit and remove the LED assembly.
specification.
TORQUE
LED Trunk Light Fasteners: 36 in-lbs (4 N·m)

© Copyright 17.19
CHASSIS ELECTRICAL
TURN SIGNAL / HAZARD SYSTEM SERVICE

T U R N S I G N A L O P E R AT I O N F R O N T T U R N S I G N A L , R E M O VA L /
The turn signal / hazard light system does not utilize a I N S TA L L AT I O N ( C L A S S I C / V I N TA G E / D A R K
conventional “flasher module”, but instead receives a HORSE / SPRINGFIELD)
grounding signal from the ECM. Power to the LED turn
signals is provided via the SEC ENGINE RELAY NOTICE
located in the main fuse box. Turn Signal INPUTS &
Turn signals are LEDs and must be replaced as an
OUTPUTS can be located in the ECM Connector Map
assembly. Turn signal bulbs cannot be replaced
and Fuse Application Chart.
independently.
See ECM Connector Map page .
1. Locate turn signal connectors inside the nacelle
F R O N T T U R N S I G N A L R E M O VA L / and disconnect.
I N S TA L L AT I O N ( C H I E F TA I N / R O A D M A S T E R ) 2. Remove fastener q and remove turn signal from
bracket.
NOTICE
The turn signals are LED and must be replaced as an
assembly. Bulbs cannot be replaced individually.
1. Remove the outer fairing. Depending on model see

or .
2. Remove two fasteners q securing the turn signal
light to the fairing.

specification.
TORQUE
Turn Signal Fastener: 36 in-lbs (4 N·m)
3. Remove turn signal.

specification.
TORQUE
Turn Signal Fasteners: 36 in-lbs (4 N·m)

17.20 © Copyright
CHASSIS ELECTRICAL
R E A R T U R N S I G N A L , R E M O VA L /
I N S TA L L AT I O N ( A L L M O D E L S )
1. Remove the tail light assembly. See Tail Light /
License Plate Light page 17.5.
2. Remove fastener q and withdraw the turn signal
from the tail light assembly.

specification. 17
TORQUE
Turn Signal Fastener: 18 ft-lbs (24 N·m)

© Copyright 17.21
CHASSIS ELECTRICAL
I N S T R U M E N TAT I O N
I N S T R U M E N T C L U S T E R ( C H I E F C L A S S I C / C H I E F V I N TA G E / C H I E F D A R K H O R S E /
SPRINGFIELD)
For detailed information regarding MODE selection and Multi-Function Display operation refer to the
Indian Motorcycle Owner’s Manual.
The instrument cluster includes the speedometer, indicator lamps, Multi-Function Display (MFD) and fuel gauge
(where applicable).
NUMBER LIGHT INDICATES CONDITION

Cruise Control Amber Lamp: Cruise control is enabled, but not set. Green
Status Lamp: Cruise control is set to the desired speed.
q
Low Oil Pressure This lamp illuminates when oil pressure drops below a
safe operating pressure while the engine is running. If this
lamp illuminates while the engine is running above idle
w speed, turn the engine off as soon as safely possible and
check the oil level. If the oil level is correct and the lamp
remains on after the engine is restarted, turn the engine off
immediately. See your dealer.
Vehicle speed When standard mode is selected, speed displays in miles
e per hour.
Chassis Fault The alert symbol illuminates if a chassis fault occurs.
r

17.22 © Copyright
CHASSIS ELECTRICAL
NUMBER LIGHT INDICATES CONDITION

Tire Pressure (If equipped) The TPMS indicator illuminates if low tire
Monitoring System pressure is detected. It will also illuminate along with the
t (TPMS) Low Battery Voltage indicator when TPMS battery power
is low, requiring service.
Neutral The transmission is in neutral.
y
High Beam The headlight switch is set to high beam. This indicator
u will flash if there is a problem with the low or high beam
light.
Turn Signal The turn signal indicator flashes when the left, right, or
both turn signals (hazard) are active. If there is a problem
i in the signal system, the lamps will flash at twice the normal
rate.
Anti-Lock Brake The indicator remains on until the anti-lock system
System Status activates, which occurs when vehicle speed exceeds 6
o MPH (10 km/h). When the lamp is illuminated, the anti-
lock brakes will not activate, but the conventional brake
system will continue to operate normally.
Check Engine If this lamp illuminates while the engine is running, see your 17
dealer promptly. The light will remain on if the tilt sensor
shuts down the engine. If abnormal sensor or engine
a operation is detected the light will remain on as long as
the fault condition exists. Retrieve the error codes for
diagnosis.
Vehicle Speed When metric mode is selected, speed displays in
s kilometers per hour.
Low Battery This lamp illuminates when battery voltage is low. Turn
Voltage / Charge non-essential accessories off to conserve power. Make
Status sure the charging system is operating properly. This lamp
d also illuminates with the security light and/or power
switch when the key fob battery is low, and with the TPMS
lamp when the TPMS sensor battery is low.
Security System This indicator lamp illuminates while the security system
Status is searching for the key fob signal and when the security
system is locked. The lamp flashes if the key fob is not
f detected within range or if the fob is not programmed
properly. It also illuminates with the low battery voltage
indicator when the key fob battery is low.

© Copyright 17.23
CHASSIS ELECTRICAL
Multi-Function Display (MFD) Gear position displays at all times while the engine is
running, unless a fault occurs with the gear position
The power switch must be ON to access the MFD. Use
sensor.
the mode switches to toggle through the modes of the
MFD and to change settings in the display. The LH
mode switch q is located on the backside of the LH Temperature
switch cube. The temperature area displays ambient air
temperature.
Fuel Gauge
The segments of the fuel gauge show the level of fuel
in the fuel tank. When the last segment clears, a low
fuel warning is activated. All segments including the
fuel icon will flash. Refuel promptly.
Fuel Range
The fuel range displays the distance the motorcycle
can travel on the remaining fuel in the fuel tank.
Average Fuel Economy

MODES AVAILABLE Average Fuel Economy displays as of the last time the
Odometer Engine Speed mode was reset. To reset, press and hold LEFT-
TOGGLE while viewing the fuel economy display.
Trip Odometer 1 Average Fuel Economy
Trip Odometer 2 DC Voltage
Clock Ambient Air
Temperature
Gear Indicator Fuel Range
Odometer
The odometer displays total distance traveled.
Trip Odometers
The trip odometers (Trip 1 and Trip 2) display total
distance traveled since being reset. To reset a trip
odometer, toggle to the trip odometer, then press and
hold the LEFT-TOGGLE switch until the trip odometer
resets to zero.
Engine Speed
Engine Speed displays in revolution per minute (RPM).
DC Voltage
The volt meter displays battery voltage. If the engine
is not running, approximate battery voltage displays. If
the engine is running, approximate charging voltage
displays.
Gear Position

17.24 © Copyright
CHASSIS ELECTRICAL
I N S T R U M E N T C L U S T E R , C H I E F TA I N /
ROADMASTER
For detailed information regarding MODE
selection and Multi-Function Display operation
refer to the Indian Motorcycle Owner’s Manual.
17
q Speedometer r Tachometer
w Multi-Function Display (MFD) t Fuel Gauge
e Indicator Lights
INDICATOR LIGHTS
LIGHT INDICATES CONDITION
The transmission is in neutral.
Neutral
The headlight switch is set to high beam. This indicator will flash
if there is a problem with the low or high beam light.
High Beam
The turn signal indicator flashes when the left, right, or both turn
signals (hazard) are active. If there is a problem in the signal
Turn Signal system, the lamps will flash at twice the normal rate.
Amber Lamp: Cruise control is enabled, but not set. Green Lamp:
Cruise control is set to the desired speed.
Cruise Control Status

© Copyright 17.25
CHASSIS ELECTRICAL
LIGHT INDICATES CONDITION

If this lamp illuminates while the engine is running, see your dealer
promptly. The light will remain on if the tilt sensor shuts down the
Check Engine engine. If abnormal sensor or engine operation is detected the
light will remain on as long as the fault condition exists. Retrieve
the error codes for diagnosis.
The indicator remains on until the anti-lock system activates,
which occurs when vehicle speed exceeds 6 MPH (10 km/h).
Anti-Lock Brakes NOT When the lamp is illuminated, the anti-lock brakes will not
Activated activate, but the conventional brake system will continue to
operate normally.
When metric mode is selected, speed displays in kilometers per
hour.
Vehicle Speed Units
When standard mode is selected, speed displays in miles per

hour.
Vehicle Speed Units
This lamp illuminates when oil pressure drops below a safe

operating pressure while the engine is running. If this lamp
illuminates while the engine is running above idle speed, turn
Low Oil Pressure the engine off as soon as safely possible and check the oil level. If
the oil level is correct and the lamp remains on after the engine is
restarted, turn the engine off immediately. See your dealer.
This lamp illuminates when approximately one gallon (3.8 liters)
of fuel remains in the fuel tank. The LCD Display will switch into a
Low Fuel Low Fuel Mileage Counter Mode to provide the rider with
mileage tracking from the time the indicator was activated.
The TPMS indicator illuminates if low tire pressure is detected. It

will also illuminate along with the Low Battery Voltage indicator
Tire Pressure Warning when TPMS battery power is low, requiring service.
This lamp illuminates when battery voltage is low. Turn non-

essential accessories off to conserve power. Make sure the
charging system is operating properly. This lamp also illuminates
Low Battery Voltage
with the security light and/or power switch when the key fob
battery is low, and with the TPMS lamp when the TPMS sensor
battery is low.
This indicator lamp illuminates while the security system is
searching for the key fob signal and when the security system is
Security System Locked locked. The lamp flashes if the key fob is not detected within
range or if the fob is not programmed properly. It also illuminates
with the low battery voltage indicator when the key fob battery is
low.

17.26 © Copyright
CHASSIS ELECTRICAL
CRUISE CONTROL
CRUISE CONTROL OVERVIEW • CRUISE ON / OFF — Discrete input to the VCM then
The Indian Motorcycle cruise control system operates CAN message to ECM
in conjunction with the Electronic Throttle Control • CRUISE RES / ACC — Discrete input to the VCM
(ETC) eliminating the need for a conventional actuator then CAN message to ECM
/ cable assembly. The Engine Control Module (ECM)
uses several inputs to determine the position of the • CRUISE SET / DEC — Discrete input to the VCM
ETC in order to maintain the desired vehicle speed. then CAN message to ECM
Momentary signals are sent to the Vehicle Control Cruise Related Inputs / Outputs (other controls):
Module (VCM) from the right hand switch cube based
on operator input. The VCM converts these operator
inputs to CAN and relays the message to the Engine • Brake Pressure Switch (Front & Rear) — Discrete
Control Module (ECM). input to ECM
Cruise control only operates in gears 4 — 6. • Clutch Switch — Discrete input to the ECM
• Vehicle Speed (Wheel Speed Sensors) — Discrete
Cruise Related Control Modules: inputs to ABS module and then CAN message to
ECM
• Electronic Throttle Control (ETC)
• Engine Control Module (ECM)
• Vehicle Control Module (VCM)
• Anti-Lock Brake Control Module
Cruise Related Inputs / Outputs (RH Switch
Cube): 17

© Copyright 17.27
CHASSIS ELECTRICAL
CRUISE CONTROL DIAGNOSTICS

17.28 © Copyright
CHASSIS ELECTRICAL
SHIFT DRUM SPRING / PIN INSPECTION IMPORTANT

Remove the shift drum pin and spring. See Gear If the nose of the pin is visibly worn or does not move
Position Switch Replacement page 17.35 freely in the drum bore, the pin must be replaced.
SHIFT DRUM SPRING:

Measure the free length of the shaft drum spring. If the
measurement is out of specification, the spring must
be replaced.
17
MEASUREMENT
q
12.5 mm ± 0.5 mm
SHIFT DRUM PIN:

Examine pin for excessive wear at contact point. The
pin should move freely in shift drum bore and be
smooth and rounded at contact point.
MEASUREMENT
w
14.5 mm ± 0.5 mm

© Copyright 17.29
CHASSIS ELECTRICAL
SECURITY ALARM SYSTEM

SECURITY ALARM C: Does the bike lock or unlock when the key fob
Overview button is pushed (Fairing bikes only)?
A 2–button key fob is required for use of the security D: Does the Tire Pressure Monitoring System work
alarm. when the PIN code is used?
To activate the security alarm, double push the lock
button on the key fob. The horn will sound briefly to
confirm that the alarm is activated.
With the key fob within range, the following actions
will deactivate the alarm.
NOTICE
The security light and / or power switch will turn
on briefly until the key fob is detected. If the key
fob is not detected within 20 seconds, the horn
(alarm) will sound repeatedly for 60 seconds.
• Press the unlock button on the key fob.

• Press the power switch on the center console.
• Press the starter button.
• Press the lock / unlock switch on the center console.
• Move the motorcycle to the fully upright position
from leaning on sidestand. (The horn will sound
repeatedly if the key fob is not detected within 5
seconds)
NOTICE
Each time the alarm has been deactivated, a
double press of the key fob lock button will
reactivate.
GUIDED DIAGNOSTICS
NOTICE
Things to consider prior to performing the following

diagnostic tests:
• When was the last time the battery was
disconnected?
• How many hours are on the vehicle (Fairing bikes
only)?
• Has any servicing been done to the bike recently?
• Any other notable events occur before or during
the start of this issue?
Bike Does Not Authenticate with Key Fob

A: Does the LED on the key fob blink when the bike is
turned on?
B: Does the LED on the key fob blink when a key fob
button is pressed?

17.30 © Copyright
CHASSIS ELECTRICAL
A B C D
No No No No Look at VCM (1,2)
No Yes NA NA Antenna or serial number in key fob (2,3)
No No NA NA Bad key fob battery or key fob (1)
No Yes Yes Yes Look at 125 kHz antenna (3)
Yes Yes NA NA Connect to bike with Digital Wrench (2)
Yes This means the 125 kHz antenna is working properly
This means the correct serial number is stored in the VCM
Yes This means the correct serial number is stored in the VCM
This means the key fob counter is working properly
This means the 434 MHz receiver is working properly
Yes This means the 434 MHz receiver is working properly
No Yes Look at key fob battery and serial number in Digital Wrench (2)
Yes Yes No Yes Connect to bike with Digital Wrench (2)
Troubleshooting
1. Remove the key fob battery and test voltage.
• Is the battery voltage OK? 17
• YES: Install battery and retest authentication.
• NO: Proceed to next step.
2. Replace key fob battery with new cell.

• Did this fix the issue?
• YES: No further action required.
• NO: Connect to Digital Wrench and write a new
key fob serial number in Slot 2.
3. Connect to Digital Wrench and verify the correct

VCM software is installed.
4. Verify that serial numbers match the key fob being
used.
5. Inspect the 125 kHz antenna for broken wires.

© Copyright 17.31
CHASSIS ELECTRICAL
POWER WINDSHIELD
P O W E R W I N D S H I E L D O P E R AT I O N When the windshield adjustment switch is moved to
The Chieftain and Roadmaster models are equipped the up or down positions it is providing a path to
with an electronically adjustable windshield which is ground, through the appropriate limit switch, to an H-
controlled through a switch q located on the LH bridge located in the VCM. The VCM then sends
switchcube. power and ground to the windshield adjustment motor
based on switch position (switching action reverses
polarity). Once the windshield reaches the upper or
lower limits of travel, the normally closed (NC) limit
switch will become open (O/C) thus breaking the
ground path to the VCM and stopping power supply to
the adjustment motor.

17.32 © Copyright
CHASSIS ELECTRICAL
P O W E R W I N D S H I E L D M O T O R , R E M O VA L 5. Remove the four bolts t securing the windshield

cowl panel to the inner fairing and remove cowl
1. Remove the outer fairing and windshield. SeeOuter
panel.
Fairing Removal, Chieftain / Roadmaster page 3.40.
2. Raise the windshield to expose the hex-head bolts
q on the lift arms.
6. Remove the four nuts y securing the windshield lift

3. Remove the hex-head bolts w the nut and bolt e motor to the mounting bracket.
securing the windshield lift bracket to the hinge.
4. Remove the windshield lift bracket r . 17
NOTE
There are two small spacers located in the
windshield lift bracket. One spacer for each bolt at
the lift arms. Recover the spacers when the bolts are
removed.
7. Disconnect the electrical connector(s) and remove

motor assembly.

© Copyright 17.33
CHASSIS ELECTRICAL
P O W E R W I N D S H I E L D M O T O R , I N S TA L L AT I O N 4. Fit the windshield cowl panel into position and

install the four screws w securing the panel to the
1. If the limiter switch is being replaced, attach the
inner fairing. Torque screws to specification.
switch to the motor assembly at this time.
2. Plug the electrical connector(s) into the windshield NOTE
lift motor assembly and lower onto the mounting It is necessary to move the windshield lift arms
studs. toward the front of the vehicle when fitting the cowl
panel.
3. Tighten nuts q to specification.
TORQUE
TORQUE
Windshield Motor Nuts: 36 in-lbs (4.1 Nm)
Windshield Cowl Panel Screws: 36 in-lbs (4.1 Nm)
5. Verify the necessary spacers are installed in the

windshield lift bracket and install onto lift arms and
drive motor hinge.

17.34 © Copyright
CHASSIS ELECTRICAL
6. Install the two screws e into the lift arms and screw GEAR POSITION SWITCH
and nut r onto the drive motor hinge. Torque all
bolts to specification. GEAR POSITION SWITCH REPLACEMENT
NOTE NOTICE
The gear position switch is different based off of
Lift Arm Screws (3): 84 in-lbs (9.5 Nm)
engine build date. These switches are not
Drive Motor Hinge Screw (4): 84 in-lbs (9.5 Nm) interchangeable.
17
7. Install the outer fairing and windshield. See Outer
Fairing Removal, Chieftain / Roadmaster page 3.40.
8. Verify the windshield moves up and down through
the travel range.
2017–19 (MULTIPLE RESISTANCE SWITCH) 2020+ (ROTARY SWITCH)

© Copyright 17.35
CHASSIS ELECTRICAL
R E M O VA L 4. Remove right-hand passenger footpeg r (if

equipped).
1. Remove upper right-hand sidecover q.
5. Remove right-hand lower sidecover t.

2. Remove right-hand saddlebag w (if equipped).
6. Loosen clamps and remove right-hand rear

3. Remove right-hand rear tip-over bar e (if
heatshield y.
equipped).

17.36 © Copyright
CHASSIS ELECTRICAL
7. Remove drive sprocket cover u. 9. Remove P-clip o securing the gear position switch
wire.
IMPORTANT
NOTICE
Use of short (stub-nose) allen wrench is necessary for
bottom two bolts and front bolt. It can be helpful to use a zip-tie to hold the belt out of
the way during this step.
8. From under the motorcycle, unplug gear position
connector i. IMPORTANT
Use of 1/4" drive, deep-well, 7mm socket is
necessary for screw removal.
17
10. Remove gear position switch a.

© Copyright 17.37
CHASSIS ELECTRICAL
11. Remove shift drum pins s and springs d (if

necessary).
NOTE
Use magnet to aid in removal and re-installation of
pins and springs (assemble spring onto pin).
12. Inspect the shift drum pins and springs. See SHIFT
DRUM SPRING / PIN INSPECTION page 17.29
GEAR POSITION SWITCH CLEANING

Using a Very-Fine abrasive pad, such as Scotch-Brite
green (600 grit or finer), apply light pressure by hand
in a rotary motion to the contact points f on the switch
face until they are clean and uniform in color.. Use
only enough movement to put a light shine on the
brass contacts.
CAUTION
Scotch-Brite Green (600 grit is the coarsest abrasive
that should be used). DO NOT use a power tool or
rotary tool to polish.

17.38 © Copyright
CHASSIS ELECTRICAL
I N S TA L L AT I O N 4. Install P-clip o and fastener securing the gear

position switch wire. Torque fastener to
1. Install shift drum pins s and springs d (if
specification.
removed).
TORQUE
2. Install gear position switch a. Torque fasteners to
specification. P-clip Fastener:
88 in-lbs (10 N·m)
5. From under the motorcycle, plug in the gear

position connector i.
17
TORQUE
Gear Position Switch Fasteners:
43 in-lbs (5 N·m)
IMPORTANT
3. Using a multimeter, test the switch for proper
resistance. See Gear Position Switch Test page Listen for an audible click to indicate the connection
17.42. is secure.

© Copyright 17.39
CHASSIS ELECTRICAL
6. Install drive sprocket cover u. Torque fasteners to 8. Install right-hand lower sidecover t.
specification.
9. Install right-hand passenger footpeg r (if

NOTICE equipped). Torque fastener to specification.
When re-installing, bolts must be loosely assembled
into the cover before assembling onto motorcycle.
TORQUE
Drive Sprocket Cover Fasteners:
88 in-lbs (10 N·m)
7. Install right-hand rear heatshield y. Torque clamps

to specification.
TORQUE
Footpeg Fastener:
18 ft-lbs (24 N·m)
TORQUE
Heat Shield Clamps:
31 in-lbs (4 N·m)

17.40 © Copyright
CHASSIS ELECTRICAL
10. Install right-hand rear tip-over bar e (if 13. Road test the motorcycle to ensure the correct gear
equipped). Torque fasteners to specification. position is indicated on the instrument cluster.
TORQUE
Tip-Over Bar Fasteners:
18 ft-lbs (24 N·m)
11. Install right-hand saddlebag w (if equipped).

17
12. Install upper right-hand sidecover q.

© Copyright 17.41
CHASSIS ELECTRICAL
GEAR POSITION SWITCH TEST 3. Connect one meter lead to each of the pins on the
1. Disconnect the gear position switch 2– pin switch connector.
connector q located at the rear of the engine 4. Watch the resistance readings as the transmission
below the ABS module. is shifted through each of the 6 gear positions
including Neutral. The meter readings should
match the resistance specifications given in the
following diagram.
2. Set multi meter to measure resistance (Ohms).
Gear Position Switch Voltage and Resistance

Specifications
RESISTANCE (OHMS) VOLTAGE

GEAR
NOMINAL MIN MAX NOMINAL MIN MAX
1st 261.1833 248.1241 274.2424 5.223665 4.466234 6.033333
N 41.61654 39.53571 43.69737 0.832331 0.711643 0.961342
2nd 73.17666 69.51783 76.83549 1.463533 1.251321 1.690381
3rd 108.9113 103.4657 114.3569 2.178226 1.862383 2.515851
4th 146.5044 139.1792 153.8296 2.930088 2.505226 3.384252
5th 196.3043 186.4891 206.1196 3.926087 3.356804 4.53463
6th 7.481359 7.107291 7.855427 0.149627 0.127931 0.172819

17.42 © Copyright
CHASSIS ELECTRICAL
SWITCH TESTING
BRAKE LIGHT SWITCH TEST CLUTCH SWITCH TEST
1. Place the motorcycle in an upright position with 1. Remove the clutch switch cover fasteners q and
front wheel clamped in a wheel vise. clutch switch cover.
2. Locate the brake light switch connectors q on the
ABS module and disconnect.
2. Disconnect clutch switch 2 pin connector. Measure

the resistance of the switch with lever pulled to
handlebar (less than 1 Ohm resistance) and with
3. Set multi meter to measure resistance.
lever released (OL).
4. Connect meter leads to each terminal of the front
brake switch w . 17
TIPOVER SENSOR (ANGLE SENSOR)
5. Apply the front brake. OVERVIEW OF OPERATION
Resistance Specification: Continuity with pedal / The Tipover Sensor (TOS) is used to disable the fuel
lever depressed pump, fuel injector, and ignition circuits in the event of
a crash or tipover condition.
6. Connect meter leads to each terminal of the rear The ECM sends a 5VDC reference to the sensor and
brake switch e . monitors the output voltage. From the output signal,
the ECM can tell whether the TOS system is in normal
7. Apply the rear brake.
operation, if the vehicle is tipped over, or if there is an
Resistance Specification: Continuity with pedal / open or short in the system wiring. Only a tipover
lever depressed voltage from the sensor will cause the ECM to disable
the fuel pump and ignition circuits. If the TOS system
wiring is disconnected (open / high) the ECM will set
a fault code (and subsequent CHK ENG light) but will
not disable the engine’s operational circuits. The same
is true for a TOS system short to ground (low).
Only in the event of an actual tipover condition is the

voltage output within a range that will cause the ECM
to disconnect the fuel and ignition circuits as well as
the internal drivers that control them.

© Copyright 17.43
CHASSIS ELECTRICAL
TIPOVER SENSOR RESET S I D E S TA N D S W I T C H T E S T I N G

1. Inspect side stand. Be sure that when the side
After a Tipover Condition Has Occurred:
stand is fully retracted (UP) that the switch plunger
1. Return the motorcycle to the upright position and is extended and that when the side stand is
place it on the side stand. extended (down) the plunger is depressed.
2. Press the power button to power up the 2. Remove the voltage regulator bracket to access
motorcycle electrical system. the side stand switch connector and disconnect.
3. Place the engine STOP / RUN switch in the RUN See Regulator / Rectifier Replacement page 15.33.
position. 3. Set multi meter to measure resistance and insert
4. The fuel pump should cycle and the system should meter leads into appropriate jacks.
return to normal operation. 4. Place one meter lead onto each of the side stand
SENSOR LOCATION switch connector pins.
The tipover sensor q is mounted on the rear inner 5. Read resistance with the side stand switch plunger
fender debris flap behind the battery box. The depressed and extended.
sensor and wire connector can be accessed by
removing the seat. Switch Depressed (Stand DOWN): No Continuity
(OL)
Switch Extended (Stand UP): Continuity (Less than
1Ω)
DIAGNOSTICS
5. If the tipover sensor was activated (vehicle was
actually tipped over) reset the system as outlined
above. If the system fault is still present, continue.
6. Remove the seat.
7. Visually inspect the sensor. Be sure it is securely
mounted to the debris flap and the debris flap is
secure in the chassis. The sensor should be level
relative to the motorcycle.
8. Disconnect the sensor from the main wire harness
and look at connector pins for signs of corrosion
or misalignment that would cause a poor
connection.
9. Connect Digital Wrench for further diagnosis of
the tipover sensor circuit.

17.44 © Copyright
CHASSIS ELECTRICAL
BREAKOUT WIRING DIAGRAMS

ANTI-LOCK BRAKE SYSTEM, WIRING
DIAGRAM
17

© Copyright 17.45
CHASSIS ELECTRICAL
CENTRAL LOCKING SYSTEM, WIRING DIAGRAM

17.46 © Copyright
CHASSIS ELECTRICAL
S TA R T I N G S Y S T E M , W I R I N G D I A G R A M
17

© Copyright 17.47
CHASSIS ELECTRICAL
KEYLESS IGNITION SYSTEM, WIRING DIAGRAM

17.48 © Copyright
CHASSIS ELECTRICAL
POWER WINDSHIELD, WIRING DIAGRAM
17

© Copyright 17.49
CHASSIS ELECTRICAL
NOTES

17.50 © Copyright
WIRING DIAGRAMS
APPENDIX A WIRING DIAGRAMS A

© Copyright A.1
CHASSIS ELECTRICAL
NOTES

A.2 © Copyright
INDEX
A Stator ..................................................................15.7
ABS
Suspension, Front ..................................................11.6 I-
Swingarm........................................................... 12.11
Trouble Code List................................................ 14.16
ABS Battery Voltage Fault ......................................... 14.17
Torque Compensator .............................................. 9.6 X
Transmission ........................................................10.9
ABS Module Triple Clamp ........................................................11.7
Replacement ...................................................... 14.19 Trunk ..................................................................3.12
ABS System Wheel (Cast), Front ...............................................11.8
Special Tools ........................................................14.3 Wheel (Spoked), Front ...........................................11.9
Air Box Axle Inspection
Assembly View .....................................................5.11 Front ................................................................. 11.13
Installation ...........................................................5.23 Axle, Rear
Removal...............................................................5.22 Inspection .......................................................... 12.23
Air Filter
Replacement ........................................................2.19
Alarm, Operation / Diagnostics ................................ 17.30
Angle Sensor B
Testing .............................................................. 17.43 Balance Shaft
Assembly View Assembly View ................................................... 10.12
ABS Module........................................................ 14.12 Installation ......................................................... 10.17
Air Box ................................................................5.11 Removal............................................................. 10.16
Balance Shaft ...................................................... 10.12 Special Tools ........................................................10.3
Battery Box...........................................................15.9 Specifications .......................................................10.4
Brake Caliper, Front............................................. 14.10 Battery
Brake Caliper, Rear ............................................. 14.11 Assembly View .....................................................15.9
Brake Line Routing.................................................14.7 Current Drain Test ............................................... 15.27
Cam Chain ............................................................ 7.7 Inspection ...................................................2.36, 15.15
Camshafts ............................................................. 7.8 Installation ......................................................... 15.11
Clutch .................................................................. 9.7 Load Test ........................................................... 15.20
Clutch Pinion Shaft (2017-2020) ................................ 9.5 Maintenance.........................................................2.36
Crankcase..................................................... 10.6-10.7 Removal............................................................. 15.10
Cylinder ............................................................... 8.4 Safety Precautions .................................................15.3
Cylinder Head ......................................................7.10 Storage................................................................2.37
Exhaust................................................................5.13 Testing .............................................................. 15.15
Fenders ................................................................ 3.4 Battery Box
Floorboards........................................................... 3.6 Assembly View .....................................................15.9
Foot Pegs .............................................................. 3.6 Installation ......................................................... 15.13
Fork ....................................................................11.6 Removal............................................................. 15.12
Frame................................................................... 3.5 Battery, In Service
Front Brake...........................................................14.5 Charging ........................................................... 15.14
Front Master Cylinder ............................................14.8 Battery, New
Front Wheel (Cast) ................................................11.8 Charging ........................................................... 15.14
Front Wheel (Spoked) ............................................11.9 Bearing Clearance Inspection .................................. 10.30
Front Wheel Speed Sensor.................................... 14.13 Bearing Selection
Fuel System ........................................................... 5.7 Connecting Rod .................................................. 10.32
Handlebar............................................................11.5 Belt
Handlebar Controls ...............................................11.4 Adjustment...........................................................2.42
Lifters / Pushrods ................................................... 7.9 Alignment ............................................................2.42
Lower Fairing......................................................... 3.8 Inspection ...................................................2.38, 12.12
Lubrication System ................................................. 4.8 Installation ......................................................... 12.12
Motor Mounts ........................................................ 6.3 Removal............................................................. 12.12
Nacelle (Vintage / Springfield) ................................3.14 Specifications .......................................................2.39
Oil Filter Adapter ................................................... 4.5 Tension Measurement ............................................2.40
Piston ................................................................... 8.4 Body
Primary Cover (2017–2020)...................................... 9.4 Service Notes ........................................................ 3.3
Rear Master Cylinder.............................................14.9 Special Tools ......................................................... 3.3
Rear Suspension............................................ 12.6, 12.8 Brake Bleeding Precautions...................................... 14.21
Rear Wheel ..........................................................12.9 Brake Disc, Front
Rear Wheel Speed Sensor..................................... 14.14 Removal / Installation........................................... 11.13
Regulator / Rectifier...............................................15.8 Brake Disc, Rear
Rocker Assembly ................................................ 12.10 Removal / Installation........................................... 12.25
Saddlebag ...........................................................3.13 Brake Fluid
Seat (All Models Except Roadmaster) ........................ 3.9 Changing........................................................... 14.22
Seat (Roadmaster) .................................................3.10 Brake Fluid Replacement ......................................... 14.21
Shock, Rear ..........................................................12.8 Brake Lever
Side Panels...........................................................3.11 Inspection, Front ...................................................2.25
Starter Motor / Solenoid .........................................15.6 Lubrication, Front ..................................................2.25

© Copyright IX.1
INDEX
Reach, Front .........................................................2.26 ABS Trouble Codes.............................................. 14.16

Brake Lever Reserve Inspection ................................ 14.24 ABS Troubleshooting............................................ 14.17
Brake Light Brake Pad Inspection, Front.....................................2.30
Operation Overview ............................................ 17.17 Brake Pad Inspection, Rear .....................................2.31
Removal / Installation........................................... 17.17 Brake Pedal, Inspection ..........................................2.26
Brake Light Switch Brake Pedal, Lubrication.........................................2.26
Testing .............................................................. 17.43 CHMSL Replacement ........................................... 17.19
Brake Light, Center................................................. 17.19 Fluid Level Inspection ............................................2.29
Brake Line Routing Front Brake Lever, Inspection ..................................2.25
Assembly View .....................................................14.7 Front Brake Lever, Lubrication .................................2.25
Brake Pads, Front Front Brake Lever, Reach ........................................2.26
Replacement ...................................................... 14.25 Braking System
Brake Pads, Rear ABS Overview of Operation................................... 14.16
Replacement ...................................................... 14.26 ABS System Components ...................................... 14.16
Brake Pedal Break-In, Engine ......................................................2.18
Inspection ............................................................2.26 Breather
Lubrication...........................................................2.26 Inspection ............................................................2.31
Brake System
ABS Brake Fluid Change ....................................... 14.22
ABS General Information ...................................... 14.15
ABS Module Replacement ..................................... 14.19
C
ABS System Safety Precautions .............................. 14.15 Caliper, Front
ABS Wiring Diagram ............................................ 17.45 Assembly View ................................................... 14.10
Front Caliper Installation ...................................... 14.32 Installation ......................................................... 14.32
Front Caliper Service ........................................... 14.30 Rebuilding ......................................................... 14.30
Front Master Cylinder ............................................14.8 Removal............................................................. 14.30
Front Master Cylinder Service ............................... 14.28 Caliper, Rear
Lever Reserve Inspection...................................... 14.24 Assembly View ................................................... 14.11
Precautions ........................................................ 14.21 Installation ......................................................... 14.36
Rear Caliper Installation ....................................... 14.36 Rebuilding ......................................................... 14.34
Rear Caliper Service............................................ 14.34 Removal............................................................. 14.34
Rear Master Cylinder.............................................14.9 Cam Chain
Rear Master Cylinder Service................................ 14.33 Assembly View ...................................................... 7.7
Service Notes .......................................................14.3 Installation ...........................................................7.16
Service Specifications ............................................14.4 Removal...............................................................7.15
Special Tools ........................................................14.3 Cam Chain Cover
Torque Specifications.............................................14.4 Installation ...........................................................7.12
Troubleshooting.................................................. 14.37 Removal...............................................................7.12
Vacuum Bleeder.................................................. 14.21 Cam Chain Guide
Wheel Speed Sensor Adjustment (Air Gap) ............. 14.19 Installation ...........................................................7.15
Wheel Speed Sensor Replacement ......................... 14.18 Removal...............................................................7.15
Brake System Disc, Rear Cam Chain Tensioner
Removal / Installation........................................... 12.25 Inspection ............................................................7.14
Brake System, ABS Module Installation ...........................................................7.14
Assembly View ................................................... 14.12 Removal...............................................................7.13
Brake System, Disc Cam Chain, Inner Cover
Inspection .......................................................... 14.27 Installation ......................................................... 10.18
Brake System, Front Removal............................................................. 10.16
Assembly View .....................................................14.5 Camshaft
Disc Removal / Installation .................................... 11.13 Carrier Assembly..................................................7.22
Brake System, Front Brake Pads Carrier Disassembly ..............................................7.19
Replacement ...................................................... 14.25 Carrier Installation ................................................7.24
Brake System, Front Brakes Carrier Removal....................................................7.19
Bleeding ............................................................ 14.23 Inspection ............................................................7.20
Brake System, Front Caliper Removal - In Bike...................................................7.26
Assembly View ................................................... 14.10 Synchronization ....................................................7.22
Brake System, Line Routing Timing......................................................... 7.11, 7.22
Assembly View .....................................................14.7 Camshaft Bearings
Brake System, Rear Assembly View ...................................................... 7.8
Assembly View .....................................................14.6 Camshaft Carrier
Brake System, Rear Brake Pads Assembly.............................................................7.22
Replacement ...................................................... 14.26 Disassembly .........................................................7.19
Brake System, Rear Brakes Installation ...........................................................7.24
Bleeding ............................................................ 14.22 Removal...............................................................7.19
Brake System, Rear Caliper Camshafts
Assembly View ................................................... 14.11 Installation - In Bike ...............................................7.41
Brakes Camshafts, Assembly View ......................................... 7.8

IX.2 © Copyright
INDEX
CAN Diagnostics ......................................................5.61 Temperature.........................................................1.43

Carbon Canister ......................................................2.32 CPS I-
Center Brake Light ................................................. 17.19 Test / Replace .......................................................5.56
Charging System Crankcase X
Output Test......................................................... 15.27 Assembly........................................................... 10.39
Service Notes .......................................................15.3 Assembly View .....................................................10.6
Service Specifications ............................................15.5 Assembly, Left Side.............................................. 10.36
Special Tools ........................................................15.4 Assembly, Right Side ........................................... 10.36
Torque Specifications.............................................15.4 Disassembly ....................................................... 10.22
Troubleshooting.................................................. 15.26 Fastener Location ..................................................10.8
Cleaning............................................................... 17.35 Resealing ........................................................... 10.39
Clutch Separation.......................................................... 10.22
Assembly.............................................................9.19 Torque Sequence ..................................................10.8
Assembly View ...................................................... 9.7 Crankcase Emission Control ......................................1.35
Disassembly .........................................................9.15 Crankcase Ventilation
Inspection ............................................................9.17 Inspection ............................................................2.31
Installation ...........................................................9.20 Crankshaft
Pinion Shaft Bearing Inspection................................. 9.9 Assembly View .....................................................10.7
Pinion Shaft Installation (2017-2020) .........................9.10 Cleaning............................................................ 10.35
Pinion Shaft Removal (2017-2020).............................. 9.9 Inspection .......................................................... 10.33
Pinion Shaft Seal Replacement .................................. 9.9 Installation ......................................................... 10.37
Rack, Removal / Installation ....................................9.15 Locking for Service................................................7.12
Removal...............................................................9.15 Main Bearing Inspection ....................................... 10.35
Service Notes ........................................................ 9.2 Main Bearing Oil Clearance .................................. 10.35
Special Tools ......................................................... 9.2 Removal............................................................. 10.28
Specifications ........................................................ 9.2 Service Notes .......................................................10.3
Torque Specifications.............................................. 9.2 Special Tools ........................................................10.3
Troubleshooting....................................................9.24 Specifications .......................................................10.4
Clutch Cable Troubleshooting.................................................. 10.43
Lubrication...........................................................2.23 Crankshaft Position Sensor
Removal / Installation........................................... 11.11 Test / Replace .......................................................5.56
Clutch Lever Cross Over Pipe
Free Play Adjustment .............................................2.24 Installation ...........................................................5.19
Lubrication...........................................................2.24 Removal...............................................................5.15
Clutch Pinion Shaft Cruise Control
Assembly View (2017-2020) ..................................... 9.5 Diagnostics ........................................................ 17.28
Clutch Rack Overview / Operation .......................................... 17.27
Removal / Installation.............................................9.15 Troubleshooting.................................................. 17.28
Clutch Switch Current Drain
Circuit Test......................................................... 15.22 Testing .............................................................. 15.27
Removal / Installation........................................... 15.23 Cylinder
Testing .............................................................. 17.43 Assembly View ...................................................... 8.4
Coil, Ignition Bore Measurement.................................................. 8.6
Removal / Installation.............................................16.9 Inspection ............................................................. 8.6
Compression Test (Wet) Installation ...........................................................8.11
Engine.................................................................2.36 Misfire .................................................................5.59
Compression Test, Engine .........................................2.35 Removal................................................................ 8.6
Connecting Rod Service Notes ........................................................ 8.2
Bearing Clearance Inspection ............................... 10.30 Special Tools ......................................................... 8.2
Bearing Inspection .............................................. 10.30 Specifications ........................................................ 8.2
Bearing Selection ................................................ 10.32 Stud Replacement .................................................8.11
Inspection .................................................... 8.9, 10.29 Torque Specifications.............................................. 8.2
Inspection, Big End.............................................. 10.30 Warpage Measurement ........................................... 8.7
Installation ......................................................... 10.33 Cylinder / Piston
Removal............................................................. 10.29 Troubleshooting....................................................8.13
Side Clearance ................................................... 10.29 Cylinder Head
Connecting Rods Assembly.............................................................7.60
Specifications .......................................................10.4 Assembly View .....................................................7.10
Controller Area Network Disassembly .........................................................7.55
Resistance Values ..................................................5.61 Inspection ............................................................7.56
Controls Installation ...........................................................7.60
Assembly View .....................................................11.4 Removal...............................................................7.54
Conversion Chart Special Tools ......................................................... 7.3
Metric .................................................................1.41 Cylinder Head / Valve Train
Conversion Charts....................................................1.42 Service Notes ........................................................ 7.3
Measurement........................................................1.43 Cylinder Head / Valves
SAE .....................................................................1.41 Specifications ........................................................ 7.4

© Copyright IX.3
INDEX
Torque Specifications.............................................. 7.4 EFI

Troubleshooting....................................................7.62 Service Notes ........................................................ 5.3
Cylinder Head Temperature Sensor Service Precautions ................................................ 5.5
Replacement ........................................................5.54 Special Tools ......................................................... 5.4
Test.....................................................................5.54 Specifications ........................................................ 5.4
Cylinder Studs Torque Specifications.............................................. 5.4
Replacement ........................................................8.11 Electrical System
Service Notes .......................................................17.3
Special Tools ........................................................17.3
D Torque Specifications.............................................17.3
Electronic Fuel Injection (EFI)
Detonation Sensor Sensor Locations ...................................................5.12
Test / Replace .......................................................5.57 Electronic Throttle Control Module
Diagnostic Trouble Codes (DTC) ................................5.42 Removal...............................................................5.58
Digital Wrench Emission Control Systems ..........................................1.35
Communication Errors ...........................................5.62 Emission Sources .....................................................1.35
Diagnostic Connector ............................................5.62 Engine
ECM Reflash .........................................................5.66 Compression Test..................................................2.35
ECM Replacement.................................................5.62 Compression Test (Wet) .........................................2.36
Feature Map .........................................................5.65 Installation ...........................................................6.11
Guided Diagnostics ...............................................5.62 Limiting / Misfire ...................................................5.59
Overview .............................................................5.62 Locking the Crankshaft...........................................7.12
Serial Number Location ..........................................5.63 Oil / Filter Change.................................................2.19
Update Information................................................5.62 Oil Level ..............................................................2.20
Update Process .....................................................5.63 Specifications ........................................................ 6.2
Version Updates....................................................5.63 Timing.................................................................7.11
Discs, Brake Engine Break-In Procedure ........................................2.18
Inspection .......................................................... 14.27 Engine Number Location ............................................ 1.2
Drill Sizes Engine Removal
Metric .................................................................1.41 Preliminary Steps ................................................... 6.5
SAE .....................................................................1.41 Removing Engine from Frame .................................. 6.6
Drive Belt Service Notes ........................................................ 6.2
Adjustment...........................................................2.42 Special Tools ......................................................... 6.2
Alignment ............................................................2.42 Torque Specifications.............................................. 6.2
Inspection ...................................................2.38, 12.12 EVAP System ...........................................................2.32
Installation ......................................................... 12.12 Evaporative Emissions Control ...................................1.35
Removal............................................................. 12.12 Evaporative Emissions System....................................2.32
Specifications .......................................................2.39 Evaporative System
Tension Measurement ............................................2.40 Line Routing, 49 State .............................................. 5.6
Drive Gear Line Routing, CA .................................................... 5.7
Inspection .......................................................... 10.19 Exhaust
Installation ......................................................... 10.20 Assembly View .....................................................5.13
Removal............................................................. 10.19 Installation .................................................... 5.18-5.19
Drive Sprocket Muffler Removal ....................................................5.14
Inspection .......................................................... 12.15 Removal....................................................... 5.15, 5.17
Installation ......................................................... 12.16 Exhaust Emission Control ..........................................1.35
Removal............................................................. 12.13
Drive Sprocket, Cover
Removal / Installation........................................... 12.13
Driven Sprocket
F
Bearing Replacement........................................... 12.18 Fairing
Inspection .......................................................... 12.17 Assembly View ...................................................... 3.7
Installation ......................................................... 12.20 Installation ...........................................................3.44
Removal............................................................. 12.17 Fairing, Inner
Installation (Chieftain)............................................3.43
Removal (Chieftain) ...............................................3.42
E Fairing, Outer
Removal (Chieftain / Roadmaster)............................3.40
ECM Fault Codes .............................................................5.42
Connector Map .....................................................5.41 Fender, Front
Connectors ..........................................................5.52 Installation ...........................................................3.26
Disconnect ...........................................................5.52 Removal...............................................................3.24
Pinout Chart .........................................................5.41 Fender, Rear
Pinout Testing .......................................................5.51 Installation ...........................................................3.32
Reflash Procedure .................................................5.66 Removal...............................................................3.31
Removal / Installation.............................................5.52 Fenders
ECM Replacement Information ...................................5.62 Assembly View ...................................................... 3.4

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INDEX
Final Drive Specification.........................................................5.26

Troubleshooting.................................................. 12.37 Test.....................................................................5.26 I-
Floorboards Fuel Pump
Assembly View ...................................................... 3.6 Current Draw Test .................................................5.39 X
Installation ...........................................................3.17 Installation ...........................................................5.34
Removal...............................................................3.16 Pressure Test ........................................................5.26
Flywheel Removal...............................................................5.30
Installation ...........................................................9.23 Supply Voltage Test ...............................................5.38
Removal...............................................................9.23 Fuel System
Foot Pegs Assembly View ...................................................... 5.7
Assembly View ...................................................... 3.6 Depressurization ...................................................5.27
Foot Pegs (Passenger) EFI Overview........................................................5.40
Installation ...........................................................3.19 Inspection ............................................................2.33
Removal...............................................................3.19 Line Routing, 49 State .............................................. 5.6
Fork Line Routing, CA .................................................... 5.7
Assembly........................................................... 11.21 Priming ...............................................................5.39
Assembly View .....................................................11.6 Service Notes ........................................................ 5.3
Disassembly ....................................................... 11.17 Service Precautions ................................................ 5.5
Installation ......................................................... 11.25 Special Tools ......................................................... 5.4
Removal............................................................. 11.15 Specifications ........................................................ 5.4
Fork Lock Torque Specifications.............................................. 5.4
Removal / Installation........................................... 11.29 Troubleshooting....................................................5.68
Frame Fuel Tank
Assembly View ...................................................... 3.5 Assembly View .....................................................5.10
Front Casting, Installation .......................................3.36 Installation ...........................................................5.36
Front Casting, Removal...........................................3.33 Mounting .............................................................5.10
Service Notes ........................................................ 3.3 Removal...............................................................5.29
Special Tools ......................................................... 3.3 Vent Inspection (49 State) .......................................2.32
Front Axle Vent Inspection (CA)..............................................2.32
Inspection .......................................................... 11.13 Fuse Box
Front Brake Fuse Application Chart...........................................17.7
Assembly View .....................................................14.5 Location...............................................................2.44
Front Casting (Main Frame) Locations .............................................................17.6
Installation ...........................................................3.36 Fuses
Removal...............................................................3.33 Location...............................................................2.44
Front Fender Replacement ........................................................2.44
Installation ...........................................................3.26
Removal...............................................................3.24
Front Fork
Inspection .......................................................... 11.20
G
Front Wheel Gear Position Switch ............................................... 17.35
Bearing Inspection .............................................. 11.14 Neutral Indicator Test........................................... 15.21
Inspection .......................................................... 11.13 Test................................................................... 17.42
Removal / Installation........................................... 11.12 Gear Ratios .............................................................10.4
Front Wheel (Cast) General Information
Assembly View .....................................................11.8 Tire Changing.......................................................13.9
Front Wheel (Spoked) Gross Vehicle Weight Rating (GVWR) ..........................1.28
Assembly View .....................................................11.9 Guided Diagnostics ..................................................5.62
Front Wheel & Suspension
Troubleshooting.................................................. 11.32
Front Wheell
Bearing Replacement........................................... 11.15
H
Fuel Filter Handlebar
Replacement ........................................................5.32 Assembly View .....................................................11.5
Fuel Injection Removal / Installation........................................... 11.10
Overview of Operation ...........................................5.40 Head Light
Fuel Injector Assembly View .....................................................17.4
Installation ...........................................................5.55 Head Pipe
Removal...............................................................5.55 Installation ...........................................................5.18
Resistance Test .....................................................5.55 Removal...............................................................5.17
Fuel Level Sensor Headlight
Resistance Test .....................................................5.37 Aim Inspection......................................................2.45
Fuel Line Bulb Replacement ............................................... 17.14
Routing, 49 State..................................................... 5.6 Warning / MIL 2014 ............................................. 17.15
Routing, CA ........................................................... 5.7 Warning 2015 ..................................................... 17.15
Fuel Pressure Headlight Aim
Inspection ............................................................5.26 Adjustment...........................................................2.47

© Copyright IX.5
INDEX
Highway Bars Assembly View ...................................................... 3.8

Installation ...........................................................3.22 Lower Fairing (Roadmaster)
Removal...............................................................3.22 Installation ...........................................................3.23
Horn Removal...............................................................3.23
Removal / Installation........................................... 17.16 Lubrication System
Assembly View ...................................................... 4.8
I
Idle Speed
M
Adjustment...........................................................2.21 Main Bearing
Ignition Coil Inspection .......................................................... 10.35
Power and Ground Signal Test .................................16.7 Oil Clearance Inspection ...................................... 10.35
Removal / Installation.............................................16.9 Maintenance
Resistance Test .....................................................16.8 Engine Break-In Procedure .....................................2.18
Ignition System Service Notes .......................................................2.18
Service Notes .......................................................16.2 Special Tools ........................................................2.18
Service Specifications ............................................16.2 Specifications ........................................................ 2.3
Special Tools ........................................................16.2 Maintenance Interval Chart......................................... 2.5
Test 1: Battery Voltage Inspection.............................16.5 Manufacturer Label Location ....................................... 1.3
Test 2: Spark.........................................................16.6 Master Cylinder, Front
Test 3: Ignition Cable Resistance..............................16.6 Assembly View .....................................................14.8
Test 4: Ignition Coil Power and Ground Signal ............16.7 Rebuilding ......................................................... 14.28
Test 5: Ignition Coil Resistance ................................16.8 Removal............................................................. 14.28
Test Flowchart.......................................................16.5 Master Cylinder, Rear
Testing Precautions................................................16.4 Assembly View .....................................................14.9
Torque Specifications.............................................16.2 Rebuilding ......................................................... 14.33
Troubleshooting Basics ..........................................16.4 Removal............................................................. 14.33
Inspection ......................................................2.33, 17.29 Misfire Detection ......................................................5.59
Rear Axle ........................................................... 12.23 Model Number Decoder............................................. 1.2
Installation Model Number Location ............................................. 1.3
Cylinder ..............................................................8.11 Model Numbers
Engine.................................................................6.11 Classic ................................................................1.12
Muffler ................................................................5.20 Dark Horse............................................................ 1.8
Piston ..................................................................8.11 Roadmaster ..........................................................1.24
Piston Ring ...........................................................8.10 Motor Mounts
Instrument Cluster Assembly View ...................................................... 6.3
Overview, Chief Classic / Chief Vintage / Chief Dark Muffler
Horse / Springfield ............................................ 17.22 Installation ...........................................................5.20
Overview, Chieftain / Roadmaster.......................... 17.25 Removal...............................................................5.14
Instrument Panel
Removal / Installation.............................................3.39
Instrument Panel (Chieftain Dark Horse)
Removal / Installation.............................................3.38
N
Intake Manifold Nacelle
Removal / Installation.............................................5.26 Installation ...........................................................3.48
Removal...............................................................3.46
Nacelle (Vintage / Springfield)
K Assembly View .....................................................3.14
Noise Emission Control .............................................1.35
Knock Sensor
Test / Replace .......................................................5.57
O
L Oil Change
Checking Oil Level ................................................2.20
License Plate Light Procedure ............................................................2.19
Assembly View .....................................................17.5 Oil Cooler
Removal / Installation........................................... 17.17 Exploded View ...................................................... 4.4
Lifter Inspection ............................................................4.14
Installation ...........................................................7.18 Installation ...........................................................4.15
Lifters Removal...............................................................4.13
Assembly View ...................................................... 7.9 Oil Filter Adapter
Removal...............................................................7.17 Assembly View ...................................................... 4.5
Lock Replacement Oil Level
Trunk ..................................................................3.28 Check .................................................................2.20
Lower Fairing Oil Pressure Sensor

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INDEX
Test...................................................................... 4.9 R
Oil Pump
Rear Axle
I-
Installation ...........................................................4.11
Removal...............................................................4.10 Inspection .......................................................... 12.23
Rear Brake
X
Oiling System
Assembly Views..................................................... 4.4 Assembly View .....................................................14.6
Oil Flow Diagram ................................................... 4.6 Rear Fender
Oil Pressure Test .................................................... 4.9 Installation ...........................................................3.32
Service Notes ........................................................ 4.2 Removal...............................................................3.31
Special Tools ......................................................... 4.2 Rear Sprocket
Specifications ........................................................ 4.2 Inspection .......................................................... 12.17
Troubleshooting..................................................... 4.2 Installation ......................................................... 12.20
Output Shaft Seal Removal............................................................. 12.17
Replacement ...................................................... 12.16 Rear Suspension
Owner’s Manuals, Part Numbers .................................1.29 Assembly View ............................................. 12.6, 12.8
Rear Wheel
Bearing Inspection .............................................. 12.23
P Inspection .......................................................... 12.23
P-Codes..................................................................5.42 Removal / Installation........................................... 12.21
Paint Rear Wheel and Suspension
Color, By Model ....................................................1.30 Special Tools ........................................................12.3
Passenger Foot Pegs / Blanks (Dark Horse) Torque Specifications.............................................12.4
Removal / Installation.............................................3.16 Reflash Authorization ................................................5.66
PCV System Regulated Voltage Test............................................ 15.27
Inspection ............................................................2.31 Regulator / Rectifier
Periodic Maintenance ................................................ 2.5 Assembly View .....................................................15.8
Pinion Shaft, Clutch Bracket, Replacement .......................................... 15.33
Bearing Inspection ................................................. 9.9 Connector Inspection........................................... 15.32
Installation (2017-2020) ..........................................9.10 Diode Leakage Test ............................................. 15.33
Removal (2017-2020) .............................................. 9.9 Replacement ...................................................... 15.33
Seal Replacement................................................... 9.9 Replacement ......................................................... 17.35
Piston Ride Height
Assembly View ...................................................... 8.4 Adjustment (Air Shock) ..........................................2.51
Clearance Worksheet.............................................. 8.6 Adjustment (Chief Models) .....................................2.51
Inspection ............................................................. 8.8 Inspection ............................................................2.49
Installation ...........................................................8.11 Rings
Profile & Orientation ............................................... 8.5 End Gap Measurement............................................ 8.8
Removal................................................................ 8.7 Installation ...........................................................8.10
Service Notes ........................................................ 8.2 Profile & Orientation ............................................... 8.5
Special Tools ......................................................... 8.2 Removal................................................................ 8.7
Specifications ........................................................ 8.2 Rocker Arm
Torque Specifications.............................................. 8.2 Inspection ............................................................7.55
Piston Pin Removal...............................................................7.54
Inspection ............................................................. 8.9 Rocker Assembly
Piston Ring Assembly View ................................................... 12.10
Inspection ............................................................. 8.8
Installation ...........................................................8.10
Profile & Orientation ............................................... 8.5 S
Removal................................................................ 8.7
Power Windshield Saddlebag
Motor, Installation (Chieftain / Roadmaster)............. 17.34 Assembly View .....................................................3.13
Motor, Removal (Chieftain / Roadmaster) ................ 17.33 Seat
Operation (Chieftain / Roadmaster)........................ 17.32 Assembly View ...................................................... 3.4
Primary Cover Seat (all except Roadmaster)
Assembly View (2017–2020)..................................... 9.4 Removal / Installation.............................................3.19
Installation (2017-2020) ..........................................9.13 Seat (All Models Except Roadmaster)
Removal (2017-2020) .............................................. 9.8 Assembly View ...................................................... 3.9
Primary Drive Seat (Dark Horse)
Service Notes ........................................................ 9.2 Removal / Installation.............................................3.21
Special Tools ......................................................... 9.2 Seat (Roadmaster)
Specifications ........................................................ 9.2 Assembly View .....................................................3.10
Torque Specifications.............................................. 9.2 Removal / Installation.............................................3.20
Troubleshooting....................................................9.24 Security System, Operation / Diagnostics ................... 17.30
Priming the Fuel System ............................................5.39 Sensor Diagnostics ...................................................5.50
Pushrods Sensors
Assembly View ...................................................... 7.9 Location...............................................................5.12

© Copyright IX.7
INDEX
Service Intervals Preload Inspection.................................................2.49

Maintenance.......................................................... 2.5 Side Cover (Lower)
Service Manuals, Part Numbers ..................................1.29 Removal / Installation.............................................3.15
Service Notes Side Cover (Upper)
Body .................................................................... 3.3 Removal / Installation.............................................3.15
Brake System ........................................................14.3 Side Panels
Clutch .................................................................. 9.2 Assembly View .....................................................3.11
Crankshaft ...........................................................10.3 Side Stand Switch
Cylinder ............................................................... 8.2 Testing .............................................................. 17.44
Cylinder Head / Valve Train ..................................... 7.3 Sidestand
EFI ....................................................................... 5.3 Inspection ............................................................2.48
Electrical System...................................................17.3 Lubrication...........................................................2.48
Engine Removal ..................................................... 6.2 Removal / Installation.............................................2.48
Front Suspension ...................................................11.2 Spark Plug
Front Wheel .........................................................11.2 Gap.....................................................................2.34
Fuel System ........................................................... 5.3 Inspection ............................................................2.34
Ignition System .....................................................16.2 Installation ...........................................................2.35
Maintenance.........................................................2.18 Removal...............................................................2.34
Oiling System ........................................................ 4.2 Special Tools ...........................................................1.37
Piston ................................................................... 8.2 ABS System ..........................................................14.3
Primary Drive ........................................................ 9.2 Balance Shaft ........................................................10.3
Rear Suspension....................................................12.3 Body .................................................................... 3.3
Rear Wheel ..........................................................12.3 Brake System ........................................................14.3
Starting System .....................................................15.3 By System ............................................................1.36
Tires....................................................................13.2 Charging System...................................................15.4
Transmission ........................................................10.3 Clutch .................................................................. 9.2
Wheels ................................................................13.2 Crankshaft ...........................................................10.3
Service Specifications Cylinder ............................................................... 8.2
Brake System ........................................................14.4 Cylinder Head / Valves ........................................... 7.3
Charging System...................................................15.5 EFI ....................................................................... 5.4
Front Suspension ...................................................11.3 Electrical System...................................................17.3
Front Wheel .........................................................11.3 Engine Removal ..................................................... 6.2
Ignition System .....................................................16.2 Frame................................................................... 3.3
Rear Suspension....................................................12.5 Front Suspension ...................................................11.2
Rear Wheel ..........................................................12.5 Front Wheel .........................................................11.2
Starting System .....................................................15.5 Fuel System ........................................................... 5.4
Tire Pressure Monitoring System (TPMS) ...................13.3 Ignition System .....................................................16.2
Tires....................................................................13.3 Locating...............................................................1.36
Wheels ................................................................13.3 Maintenance.........................................................2.18
Shift Drum Oiling System ........................................................ 4.2
Assembly View ................................................... 10.11 Ordering Information .............................................1.36
Inspection .......................................................... 10.25 Piston ................................................................... 8.2
Removal............................................................. 10.25 Primary Drive ........................................................ 9.2
Shift Drum Pin ........................................................ 17.29 Rear Wheel and Suspension ....................................12.3
Shift Drum Spring ................................................... 17.29 Starting System .....................................................15.4
Shift Fork Tire Pressure Monitoring System (TPMS) ...................13.2
Assembly View ................................................... 10.11 Tires....................................................................13.2
Removal............................................................. 10.25 Transmission ........................................................10.3
Shift Pedal Wheels ................................................................13.2
Adjustment...........................................................2.28 Specifications
Inspection ............................................................2.27 Balance Shaft ........................................................10.4
Shift Ratchet Clutch .................................................................. 9.2
Inspection ............................................................9.10 Connecting Rods...................................................10.4
Installation ...........................................................9.12 Crankshaft ...........................................................10.4
Removal...............................................................9.10 Cylinder ............................................................... 8.2
Shift Shaft Seal Cylinder Head / Valves ........................................... 7.4
Replacement ........................................................9.13 EFI ....................................................................... 5.4
Shifting Engine.................................................................. 6.2
Troubleshooting....................................................9.24 Fuel System ........................................................... 5.4
Shock Absorber Maintenance.......................................................... 2.3
Inspection .......................................................... 12.26 Oiling System ........................................................ 4.2
Installation ......................................................... 12.28 Piston ................................................................... 8.2
Removal............................................................. 12.26 Primary Drive ........................................................ 9.2
Shock, Rear Specifications, General
Assembly View .....................................................12.8 Classic ................................................................1.12
Preload Adjustment (Air Shock) ...............................2.51 Dark Horse............................................................ 1.8
Preload Adjustment (Chief Models) ..........................2.51 Roadmaster ..........................................................1.24

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INDEX
Specifications, GeneralModel Numbers Inspection ............................................................2.49

Chieftain ..............................................................1.20 Swingarm I-
Springfield ............................................................ 1.4 Assembly View ................................................... 12.11
Vintage................................................................1.16 Bushing / Bearing Replacement ............................. 12.31 X
Sprocket Installation ......................................................... 12.33
Inspection, Rear ....................................................2.43 Removal............................................................. 12.29
Sprocket, Drive
Inspection .......................................................... 12.15
Installation ......................................................... 12.16
Removal............................................................. 12.13
T
Sprocket, Driven Tail Light
Inspection .......................................................... 12.17 Assembly View .....................................................17.5
Installation ......................................................... 12.20 Operation Overview ............................................ 17.17
Removal............................................................. 12.17 Removal / Installation........................................... 17.17
Stake Nut Throttle Body
Installation ......................................................... 10.42 Removal...............................................................5.58
Starter Timing Marks ..........................................................7.11
Solenoid, Ground Circuit Test................................ 15.20 Tipover Switch
Starter Motor Testing .............................................................. 17.43
Assembly View .....................................................15.6 Tire & Wheel
Current Draw Test ............................................... 15.24 Troubleshooting.................................................. 13.25
Inspection .......................................................... 10.19 Tire Changing
Installation ................................................ 10.20, 15.25 General Information ..............................................13.9
Removal.................................................... 10.19, 15.25 Tire Pressure Monitoring System
Safety Information ............................................... 15.16 Activation.............................................................13.7
Starter Solenoid Overview .............................................................13.6
Ground Circuit Test ............................................. 15.20 Sensor Replacement ..............................................13.6
Positive Circuit Test ............................................. 15.23 Tire Pressure Monitoring System (TPMS)
Starting System ...................................................... 15.18 Service Specifications ............................................13.3
Circuit Operation ................................................ 15.17 Special Tools ........................................................13.2
Diagnostic Table ................................................. 15.16 Tire Wear Patterns ....................................................13.5
Service Notes .......................................................15.3 Cupping ..............................................................13.5
Service Specifications ............................................15.5 Tires
Special Tools ........................................................15.4 Balance Dots..................................... 13.16, 13.18, 13.20
Torque Specifications.............................................15.4 Balancing ........................................................... 13.22
Troubleshooting, No Crank ................................... 15.17 Directional Arrows............................. 13.16, 13.18, 13.20
Troubleshooting, Starter Drive............................... 15.19 Inflation / Precautions ........................ 13.16, 13.18, 13.20
Wiring Diagram .................................................. 15.17 Information ........................................................... 1.3
Stator Inspection ............................................................2.21
Assembly View .....................................................15.7 Ozone Cracking ....................................................13.5
Ground Continuity Test ........................................ 15.30 Pressure...............................................................2.21
Installation ......................................................... 15.32 Repair Precautions............................................... 13.14
Output Test......................................................... 15.28 Service Notes .......................................................13.2
Removal............................................................. 15.31 Service Specifications ............................................13.3
Resistance Test ................................................... 15.30 Size Specifications .................................................2.21
Steering Head Special Tools ........................................................13.2
Bearing Adjustment ............................................. 11.30 Specifications ........................................................ 1.3
Bearing Inspection ................................................2.48 Tread Wear ..........................................................13.5
Storage Valve Stem Installation, Metal ................................ 13.15
Battery.................................................................2.37 Valve Stem Installation, Rubber ............................. 13.15
Suspension, Front Valve Stem, Inspection ......................................... 13.15
Assembly View .....................................................11.6 Tires (Chieftain / Roadmaster)
Fork Assembly .................................................... 11.21 Installation ......................................................... 13.16
Fork Installation .................................................. 11.25 Removal............................................................. 13.10
Fork Removal...................................................... 11.15 Tires (Classic / Vintage)
Service Notes .......................................................11.2 Installation ......................................................... 13.18
Service Specifications ............................................11.3 Removal............................................................. 13.11
Special Tools ........................................................11.2 Tires (Dark Horse)
Torque Specifications.............................................11.2 Installation ......................................................... 13.20
Suspension, Front Fork Removal............................................................. 13.12
Disassembly ....................................................... 11.17 TMAP Sensor
Suspension, Rear Overview .............................................................5.53
Rocker Assembly ................................................ 12.10 Replacement ........................................................5.53
Service Notes .......................................................12.3 Tools, Special ..........................................................1.37
Service Specifications ............................................12.5 Torque Compensator
Troubleshooting.................................................. 12.36 Assembly View ...................................................... 9.6
Swing Arm Inspection ............................................................9.21

© Copyright IX.9
INDEX
Installation ...........................................................9.22 V
Removal...............................................................9.21
Torque Specifications Vacuum Bleeder..................................................... 14.21
Brake System ........................................................14.4 Valve Cover
Charging System...................................................15.4 Installation ...........................................................7.52
Clutch .................................................................. 9.2 Removal...............................................................7.52
Cylinder ............................................................... 8.2 Valve Guide
Cylinder Head / Valves ........................................... 7.4 Removal / Installation.............................................7.59
EFI ....................................................................... 5.4 Valve Seat
Electrical System...................................................17.3 Inspection ............................................................7.59
Engine Removal ..................................................... 6.2 Reconditioning .....................................................7.59
Front Suspension ...................................................11.2 Valve Spring
Front Wheel .........................................................11.2 Free Length ..........................................................7.56
Fuel System ........................................................... 5.4 Valve Spring Free Length
Ignition System .....................................................16.2 Inspection ............................................................7.56
Piston ................................................................... 8.2 Valve Stem
Primary Drive ........................................................ 9.2 Inspection .......................................................... 13.15
Rear Wheel and Suspension ....................................12.4 Installation, Metal ................................................ 13.15
Starting System .....................................................15.4 Installation, Rubber ............................................. 13.15
TPMS Valve Train
Overview .............................................................13.6 Special Tools ......................................................... 7.3
Sensor Replacement ..............................................13.6 Valves
Trademark Information ................................................. 2 Assembly View .....................................................7.10
Transmission Inspection ............................................................7.57
Assembly View .....................................................10.9 Wear Patterns .......................................................7.58
Gear Ratios ..........................................................10.4 VCM
Gear Train.......................................................... 10.13 Service Notes .......................................................17.9
Inspection .......................................................... 10.25 Vehicle Control Module
Installation ......................................................... 10.38 Removal / Installation........................................... 17.10
Power Flow......................................................... 10.13 Vehicle Control Module (VCM)
Removal............................................................. 10.25 Connector Map ................................................... 17.10
Service Notes .......................................................10.3 Service Notes .......................................................17.9
Special Tools ........................................................10.3 Vehicle Identification Number ..................................... 1.2
Troubleshooting.................................................. 10.43 VIN Decoder ............................................................ 1.2
Triple Clamp VIN/PIN Location....................................................... 1.3
Assembly View .....................................................11.7 Voltage Output Test ................................................ 15.27
Bearing Adjustment ............................................. 11.30 Voltage Regulator
Installation ......................................................... 11.30 Assembly View .....................................................15.8
Removal............................................................. 11.27
Troubleshootin
Cylinder / Piston ...................................................8.13 W
Troubleshooting
Brake System ...................................................... 14.37 Wheel
Crankshaft ......................................................... 10.43 Inspection .......................................................... 13.14
Cylinder Head / Valves ..........................................7.62 Lacing ............................................................... 13.24
Final Drive ......................................................... 12.37 Spoke Inspection...................................................2.52
Front Wheel & Suspension .................................... 11.32 Spoke Tightening ................................................ 13.23
Misfire Detection ...................................................5.59 Wheel (Cast), Front
Rear Suspension.................................................. 12.36 Assembly View .....................................................11.8
Rear Wheel ........................................................ 12.36 Wheel (Spoked), Front
Tire & Wheel ...................................................... 13.25 Assembly View .....................................................11.9
Transmission ...................................................... 10.43 Wheel Bearings
Trunk Inspection, Front ...................................................2.48
Assembly View .....................................................3.12 Wheel Speed Sensor
Interior Lamp Replacement................................... 17.19 Adjustment (Air Gap)........................................... 14.19
Lock Replacement .................................................3.28 Replacement ...................................................... 14.18
Trunk (Roadmaster) Wheel Speed Sensor, Front
Installation ...........................................................3.27 Assembly View ................................................... 14.13
Removal...............................................................3.26 Wheel Speed Sensor, Rear
Turn Signal Assembly View ................................................... 14.14
Front, Removal / Installation (Chieftain) .................. 17.20 Wheel Truing ........................................................ 13.23
Front, Removal / Installation (Classic / Vintage) ....... 17.20 Wheel, Front
Operation Overview ............................................ 17.20 Bearing Inspection .............................................. 11.14
Rear, Removal / Installation (All Models) ................. 17.21 Bearing Replacement........................................... 11.15
Inspection .......................................................... 11.13
Service Notes .......................................................11.2

IX.10 © Copyright
INDEX
Service Specifications ............................................11.3

Special Tools ........................................................11.2 I-
Torque Specifications.............................................11.2
Wheel, Rear X
Assembly View .....................................................12.9
Bearing Inspection .............................................. 12.23
Inspection .......................................................... 12.23
Service Notes .......................................................12.3
Troubleshooting.................................................. 12.36
Wheels
Service Notes .......................................................13.2
Special Tools ........................................................13.2
Wiring Diagram
ABS System ........................................................ 17.45
Central Locking System........................................ 17.46
Keyless Ignition System ........................................ 17.48
Power WIndshield ............................................... 17.49
Starting System ................................................... 17.47

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2014-16 Indian Motorcycle (Full-Size)

Publication Printed April 2016 (PN 9925933 R10)

• Added maintenance interval for gear position switch inspection /

Updated Fuel Line connection instructions in:

• Update torque value of exhaust clamps

Connecting Rod Torque value from bulletin I-18-06

CHAPTER 1 : GENERAL / SPECIFICATIONS

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

N= 14 = C= Cruiser C = Chief A = Standard A = 1811cc A = Full-size, A = 49 State A = Thunder Black

Vehicle Descriptors Vehicle Identifiers

* Model Year: E = 2014; F = 2015; G = 2016

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

2016 INDIAN DARK HORSE

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

2014 - 2016 INDIAN CHIEF CLASSIC

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

2015 - 2016 INDIAN ROADMASTER

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

The maximum load capacity of your motorcycle is the

• operator body weight

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

MODEL YEAR / SERVICE MANUAL OWNER’S MANUAL PARTS BOOK

2016 Indian Motorcycle Dark Horse 9925931

2016 Indian Motorcycle Dark Horse 9925931

2016 Indian Motorcycle Dark Horse 9925931

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

N14CCCAABE MODEL PAINT

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

2014 VINTAGE 2016 VINTAGE

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

2014 CHIEFTAIN 2016 CHIEFTAIN

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

2015 ROADMASTER 2016 ROADMASTER

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual

2016 DARK HORSE 2016 SPRINGFIELD

9925933 R10 - 2014-16 Indian Motorcycle (Full-Size) Service Manual