2017–21 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 September 2020 (PN 9850035 R07)

© Copyright 2020 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 9/10/2020 Model Year 2021 Content Added
R02 12/15/2020 Gear Position Switch Troubleshooting Content Added
Connecting Rod Torque value from bulletin I-18-06
R03 12/18/2020 Connecting Rod Installation Topic Updated
 REV DATE CHANGES
R04 1/14/2021 Air Filter Replacement Interval Updated

R05 2/10/2021 Gear Position Troubleshooting resistance values updated

R06 4/28/2021 Clutch Rack, Removal / Installation updated

R07 6/22/2021 Cylinder Head Torque value updated

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.
2017–21 Indian Motorcycle (Full-Size)
Service Manual
Chapter Summary

CHAPTER 1 : GENERAL / SPECIFICATIONS

CHAPTER 2 : MAINTENANCE
CHAPTER 3 : ENGINE / COOLING / EXHAUST
CHAPTER 4 : FUEL DELIVERY / EFI
CHAPTER 5 : CLUTCH / PRIMARY / SHIFT
CHAPTER 6 : TRANSMISSION / CRANKSHAFT
CHAPTER 7 : FRAME / BODY
CHAPTER 8 : STEERING / SUSPENSION
CHAPTER 9 : BRAKES
CHAPTER 10 : ELECTRICAL
 GENERAL / SPECIFICATIONS

1
CHAPTER 1
GENERAL / SPECIFICATIONS
VEHICLE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN/PIN) DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VIN/PIN LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MANUFACTURER LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
TIRE INFORMATION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2017 MODEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2018 MODEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
2019 MODEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.16
2020 MODEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.22
2021 MODEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.31
VEHICLE LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.40
GROSS VEHICLE WEIGHT RATING (GVWR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.40
PUBLICATIONS & TECHNICAL LITERATURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.41
PUBLICATIONS PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.41
EMMISIONS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.46
EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.46
EMISSION SOURCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.46
EXHAUST EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.46
NOISE EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.46
CRANKCASE EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.46
EVAPORATIVE EMISSION CONTROL (CALIFORNIA AND INTERNATIONAL MODELS) . . . . . . . . . . . . . . .1.46
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.47
USING SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.47
TOOL ORDERING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.47
SPECIAL TOOLS INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.48
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.52
MASTER TORQUE TABLE - 9850035 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.52
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.63
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.63
DECIMAL EQUIVALENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.64
FAHRENHEIT TO CELSIUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.65
MEASUREMENT CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.66

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GENERAL / SPECIFICATIONS

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: N17CCDAAAH

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= 17 = C= Cruiser E = Chief A = Premium A = 1811cc A = 92 HP (111 ci) A = 49 State (49S) A = Thunder Black
Indian 2017 T = Touring V = Chief VIN/ w/ABS (111ci) V-Twin B = 92 HP (116 ci) B = 50 State (50S) B = Thunder Black /
Motor- 18 = PINtage B = Standard w/ B = 1890cc C = Canadian (CAN) Gloss Steel Gray
cycle 2018 C= Chieftain ABS (116ci) V-Twin E = EU (WVTA) C = Ivory Cream
19 = F = Chieftain D = Dark Horse K = Braxil CKD D = Burgundy
2019 Classic w/ABS (BRZ) Metallic / Thunder
20 = H = Springfield E= Limited X = China (XNA) Black
2020 J = Springfield Edition w/ABS E = Indian Red /
21 = (2020 bags) Cream
2021 R = Roadmaster F = Springfield Blue
B = Roadmaster / Cream
Classic G = Willow Green /
Cream
H = Black Smoke
J = Burgundy
Metallic / Star Silver
K = Polished Bronze
/ Black
L = Bronze Smoke
M = Star Silver
Smoke
N = Sky Blue /
White Pearl
P = Gloss Pearl
White / Star Silver
R = Indian Red
S = Star Silver
T = Brilliant Blue
V = Burgundy
Metallic
W = Pearl White
X = Steel Gray
Z = Unpainted

* = digits that would transfer to 17 digit VIN/PIN 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/PIN.

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 /
P I N ) D E S I G N AT I O N
Example: 56KTCAAA0E3000024

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: H = 2017; J = 2018; K = 2019; L = 2020; M = 2021

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E N G I N E N U M B E R L O C AT I O N M A N U FA C T U R E R L A B E L
The engine number q is stamped into the bottom of
the RH engine case.. The stamping identifies the
The manufacturer label q located on the left side of
the steering head contains the following information:
1
engine model and serial number.
Vehicle Identification Number / Product Identification
Number (VIN/PIN)
Gross Vehicle Weight Rating (GVWR)
Gross Axle Weight Rating (GAWR)
Tire Type and Load Information.

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.

T I R E I N F O R M AT I O N L A B E L
See Manufacturer Labelpage 1.3 for tire information.

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G E N E R A L S P E C I F I C AT I O N S
2 0 1 7 M O D E L S P E C I F I C AT I O N S
MODEL
YEAR PAINT COLOR / CODE MODEL IMAGE
NUMBERS
2017 Chief N17CCCAAAD, Pearl White = P-566
Classic AK, AZ, BD, BK, Burgundy Metallic / Thunder Black =
BZ, CD, CK, CZ, P-639 / P-266
ED, EK, KD, KK Unpainted

2017 Chief N17CCDAAAH, Thunder Black Smoke = P-463

Dark Horse BH, CH, EH

2017 Chief N17CCVAAAA, Thunder Black = P-266

Vintage AE, AF, AG, AZ, Indian Red / Ivory Cream = P-639 /
BA, BE, BF, BG, P-646
BZ, CA, CE, CF, Willow Green / Ivory Cream = P-670
CG, CZ, EA, EE, / P-646
EF, EG, KA, KE Springfield Blue / Ivory Cream = P-
640 / P-646
Unpainted

2017 N17THAAAAA, Thunder Black = P-266

Springfield AL, AM, AR, AZ, Indian Red = P-639
BA, BL, BM, BR, Steel Gray /Burgundy Metallic = P-
BZ, CA, CL, CM, 1530 / P-1531
CR, CZ, EA, EL, Blue Sapphire / Star Silver = P-598 /
EM, ER, KA, KL P-354
Unpainted

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MODEL
YEAR PAINT COLOR / CODE MODEL IMAGE
NUMBERS 1
2017 N17TCAAAA1, Thunder Black Pearl = P-666
Chieftain A6, C1, C6, AP, White Smoke = P-675
CP, AS, CS, AT, Silver Smoke = P-581
CT, AZ, CZ, B1, Star Silver / Thunder Black = P-354 /
E1, B6, E6, BP, EP, P-266
BS, ES, BT, ET, BZ, Wildfire Red / Thunder Black = P-
KS 676 / P-266
Unpainted

2017 N17TCDAAAH, Thunder Black Smoke = P-463

Chieftain BH, CH, EH
Dark Horse

2017 N17TCNAAAA, Thunder Black = P-266

Chieftain AP, BP, CP, EP, A6,
Limited B6, C6, E6, AT,
BT, CT, ET, AS, BS,
CS, ES

2017 N17TCEAAA4 Red Candy / Thunder Black = P-1627

Chieftain
Elite

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MODEL
YEAR PAINT COLOR / CODE MODEL IMAGE
NUMBERS
2017 N17TRAAAAA, Thunder Black = P-266
Roadmaster AB, AG, AV, AX, Willow Green / Ivory Cream = P-670
AX, BA, BB, BG, / P-646
BV, BX, BZ, CA, Burgundy Metallic = P-629
CB, CG, CV, CX, Thunder Black / Ivory Cream = P-266
CZ, EA, EB, EG, / P-646
EV, EX, KA, KD Steel Gray / Thunder Black = P-266 /
P-692
Unpainted

2017 N17TRLAAAA, Thunder Black = P-266

Roadmaster BA, CA, EA, AG, Indian Red / Ivory Cream = P-639 /
Classic BG, CG, EG, AE, P-646
BE, CE, EE Willow Green / Ivory Cream = P-670
/ P-646

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MODEL YEAR CHIEF SPRINGFIELD CHIEFTAIN / ROADMASTER ROADMASTER

2017 CHIEFTAIN CLASSIC
DARK HORSE 1
DIMENSIONS
Overall Length 103.5 in. (2630 101.7 in. (2583 101.2 in. (2571 103.5 in. (2630 104.6 in. (2656
mm) Classic / mm) mm) mm) mm)
Dark Horse
103.7 in. (2634
mm) Vintage
Overall Width 39.4 in. (1000 39 in. (990 mm) 39.4 in. (1000 39.4 in. (1000 39.4 in. (1000
mm) mm) mm) mm)
Overall Height 46.3 in. (1176 56.6 in. (1438 54.6 in. (1512 58.7 in. (1491 58.7 in. (1491
mm) Classic / mm) mm) mm) mm)
Dark Horse
58.7 in. (1491
mm) Vintage
Seat Height 26 in. (660 mm) 26 in. (660 mm) 26 in. (660 mm) 26.5 in. (673 mm) 26.5 in. (673 mm)
Wheelbase 68.1 in. (1730 67 in (1701 mm) 65.7 in. (1668 65.7 in. (1668 65.7 in. (1668
mm) mm) mm) mm)
Ground 5.5 in. (140 mm) 5.6 in. (142 mm) 5.6 in. (142 mm) 5.5 in. (140 mm) 5.5 in. (140 mm)
Clearance
Rake (frame)/ 29°/6.1 in. (155 25°/5.2 in. (133 25°/5.9 in. (150 25°/5.9 in. (150 25°/5.9 in. (150
Trail mm) mm) mm) mm) mm)
WEIGHT
Dry Weight 751 lbs. (341 kg) 830 lbs. (376 kg) Chieftain Dark 864 lbs. (392 kg) 912 lbs. (414 kg)
(without fuel/ Classic / Dark Horse 799 lbs.
fluids) Horse (362 kg)
824 lbs. (374 kg) Chieftain 828 lbs.
Vintage (376 kg)
Wet Weight (with 783 lbs. (356 kg) 862 lbs. (391 kg) Chieftain Dark 896 lbs. (406 kg) 944 lbs. (428 kg)
fuel/fluids) Classic / Dark Horse 831 lbs.
Horse (377 kg)
856 lbs. (388 kg) Chieftain 860 lbs.
Vintage (391 kg)
Gross Vehicle 1260 lbs. (573 1385 lbs. (628 1385 lbs. (628 1385 lbs. (630 1385 lbs. (630
Weight Rating kg) kg) kg) kg) kg)
(GVWR)
Gross Axle Front 485 lbs. Front 500 lbs. Front 500 lbs. Front 500 lbs. Front 500 lbs.
Weight Rating (220 kg) (227 kg) (227 kg) (227 kg) (227 kg)
(GAWR) Rear 775 lbs. Rear 885 lbs. Rear 885 lbs. Rear 885 lbs. Rear 885 lbs.
(352 kg) (401 kg) (401 kg) (403 kg) (403 kg)
Maximum Load 477 lbs. (216 kg) 523 lbs. (237 kg) 545 lbs. (247 kg) 489 lbs. (222 kg) 441 lbs. (200 kg)
Capacity (riders, Classic / Dark Chieftain
cargo, Horse 554 lbs. (251 kg)
accessories) 404 lbs. (183 kg) Chieftain Dark
Vintage Horse

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MODEL YEAR 2017 CHIEF SPRINGFIELD / CHIEFTAIN DARK HORSE /

CHIEFTAIN MODELS/
ROADMASTER CLASSIC / ROADMASTER
CAPACITIES
Engine Oil 5.5 qts. (5.2 l) with filter at 5.5 qts. (5.2 l) with filter at oil change
oil change
Fuel 5.5 gal. (20.8 l) 5.5 gal. (20.8 l)
Fuel Reserve (fuel light on) 1.0 gal. (3.8 l) 1.0 gal. (3.8 l)
Fork Oil 20.3 oz. (599 cc) 18.8 oz. (557 cc)

MODEL YEAR 2017 ALL MODELS

ENGINE
Engine Type ThunderStroke 111, Air Cooled
Configuration V-Twin
Displacement 111 cu. in. (1811 cc)
Cooling System Air Cooled (CHIEF, SPRINGFIELD)Air/Oil Cooler (CHIEFTAIN DARK HORSE)
Compression Ratio 9.5:1
Valve Train 2 Valves Per Cylinder, Hydraulic Lifters
Bore and Stroke 3.976" x 4.449" (101mm x 113mm)
Fuel System/Throttle Body Closed Loop Fuel Injection/54 mm
Bore
Exhaust System 1 into 2 with Catalytic Converter
Split Dual Exhaust with Cross-over
Rev Limit 5400 RPM
Idle RPM 800 +/- 50 RPM Fully Warm
Lubrication System Semi-Dry Sump
Spark Plug/Gap NGK DCPR8E/.034 inch (0.90 mm)
DRIVETRAIN
Primary Drive Gear Drive Wet Clutch
Crank Gear 55 Teeth
Clutch Gear 86 Teeth
Clutch Type Wet, Multi-Plate
Primary Reduction Ratio 1.564:1
Transmission Type 6 Speed/Constant Mesh/Foot Shift
1st Gear Ratio 2.733:1
2nd Gear Ratio 1.864:1
3rd Gear Ratio 1.385:1
4th Gear Ratio 1.103:1
5th Gear Ratio 0.943:1
6th Gear Ratio 0.811:1
Gear Shift Pattern 1 Down/5 Up
Final Drive Type Belt Drive, 152-Tooth
Transmission 30-Tooth
Rear Wheel 66-Tooth
Ratio 2.2:1
Overall Gear Ratio
1st Gear 9.403:1
2nd Gear 6.411:1
3rd Gear 4.763:1
4th Gear 3.796:1
5th Gear 3.243:1
6th Gear 2.789:1
ELECTRICAL
Stator 710W @ 2000 RPM
610W @2000 RPM (Chief/Chief Dark Horse)

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MODEL YEAR 2017 ALL MODELS

ENGINE 1
Battery 12 Volt, 18 amp/hour, 310 CCA, Sealed Glass Mat
Power Points Front - 10 amp maximum
Rear - 10 amp maximum
(Combined - 10 amp maximum)
Voltage Regulator 14.4 volts/42 amp
Headlight H4 12V 60/55W LL
Roadmaster Classic/Roadmaster/Chieftain Elite: Non-Serviceable LED
Auxiliary Light Chief Vintage/Springfield/Chief Dark Horse/Chieftain/Chieftain Limited: H8 35W
Roadmaster Classic/Roadmaster/Chieftain Elite: Non-Serviceable LED
Tail/Brake Light Non-Serviceable LED
Turn Signal Non-Serviceable LED
License Plate Non-Serviceable LED
Front Fender Light Non-Serviceable LED
Speedometer Non-Serviceable LED
Indicator Lights Non-Serviceable LED

MODEL YEAR 2017 CHIEF MODELS SPRINGFIELD CHIEFTAIN DARK

HORSE / CHIEFTAIN /
ROADMASTER CLASSIC
/ ROADMASTER
SUSPENSION
Front Suspension Type/ Telescopic Fork/4.7 in. (119 mm)
Travel
Front Fork Tube Diameter 46 mm
Rear Suspension Type/ Single Shock/3.7 in. Single Shock w/ Air Adjust/4.5 in. (114mm)
Travel (94mm)
Swing-arm Cast Aluminum
WHEELS / BRAKES
Front Wheel Size/Type 3.5 in. x 16 in. Cast
Aluminum (Classic)
3.5 in. x 16 in. Spoked 3.5 in. x 16 in. Cast Aluminum
(Vintage)
Rear Wheel Size/Type 5 in. x 16 in. Cast
Aluminum (Classic)
5 in. x 16 in. Spoked 5 in. x 16 in. Cast Aluminum
(Vintage)
Front Tire Type/Size 130/90-B16 73H Dunlop
Elite 3 (Classic)
130/90-B16 73H Dunlop Elite 3
130/90-B16 67H American
Elite (Vintage)
Rear Tire Type/Size 180/65B16 81H Dunlop 180/60R16 80H Dunlop Elite 3 Multi-Compound
American Elite
Front Brakes Dual / 4 Piston Caliper / Floating Rotor
Rear Brakes Single / 2 Piston Caliper / Floating Rotor

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2 0 1 8 M O D E L S P E C I F I C AT I O N S
MODEL
YEAR PAINT COLOR / CODE MODEL IMAGE
NUMBERS
2018 Chief N18CCBAAAX, Steel Gray = P-692
BX, CX, EX, XX,
KX

2018 Chief N18CCAAAAV, Burgundy Metallic = P-639

Classic BV, CV, XV, EV

2018 Chief N18CCDAAAH, Thunder Black Smoke = P-463

Dark Horse BH, CH, XH, HH,
KH, EH

2018 Chief N18CVAAAAA, Thunder Black = P-266

Vintage BA, CA, XA, EA, Willow Green / Ivory Cream = P-670
AG, BG, CG, XG, / P-646
KG, EG, AN, BN, Sky Blue / Pearl White = P-737 / P-
CN, XN, KN, EN, 566
AS, BS, CS, XS, Star Silver / Thunder Black = P-1470
ES, AZ, BZ, CZ / P-1573
Unpainted

2018 N18THAAAAA, Thunder Black = P-266

Springfield BA, CA, XA, KA, Steel Gray / Burgundy Metallic = P-
EA, A5, B5, C5, 1530 / P-1531
E5, X5, A8, B8, Metallic Jade / Thunder Black = P-
C8, X8, E8 745 / P-266

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MODEL
YEAR PAINT COLOR / CODE MODEL IMAGE
NUMBERS 1
2018 N18THDAAAH, Thunder Black Smoke = P-463
Springfield BH, CH, EH, XH
Dark Horse

2018 N18TCBAAAX, Steel Gray = P-692

Chieftain BX, CX, EX, XX

2018 N18TFAAAEA, Indian Red = P-639

Chieftain XA, AM, BM, CM, Thunder Black Pearl = P-266
Classic EM, XM Star Silver Smoke = P-601

2018 N18TCDAAAH, Thunder Black Smoke = P-463

Chieftain BH, CH, EH, HH,
Dark Horse KH, XH

2018 N18TCEAAAY, BY, Black Hills Silver = P-763 / 1727 /

Chieftain CY, EY, KY, XY 1728
Elite

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MODEL
YEAR PAINT COLOR / CODE MODEL IMAGE
NUMBERS
2018 N18TRAAAAA, Thunder Black = P-266
Roadmaster BA, CA, EA, KA, Burgundy Metallic = P-629
XA, AV, BV, CV, Bronze / Thunder Black = P-714 / P-
EV, XV, AK, BK, 266
CK, EK, XK, AP, Pearl White / Star Silver = P-566 / P-
BP, CP, EP, A3, B3, 610
C3, E3, A9, B9, Unpainted
C9, E9, A2, B2,
C2, E2, A0, B0,
C0, E0, A4, B4,
C4, E4
2018 N18TBAAAAR, Willow Green / Ivory Cream = P-670
Roadmaster BR, CR, ER, XR, / P-646
Classic AG, BG, CG, EG, Indian Red = P-639
XG

2018 N18TREAAA5, B5, Cobalt Candy / Black Crystal w/ 23k

Roadmaster C5, E5, X5 Gold Trim = P-1674
Elite

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MODEL CHIEF SPRING- CHIEFTAIN / CHIEFTAIN ROADMAS- ROADMAS-

YEAR 2018 FIELD / CHIEFTAIN LIMITED / TER CLASSIC TER /
SPRING- DARK HORSE CHIEFTAIN ROADMAS- 1
FIELD DARK ELITE TER ELITE
HORSE
DIMENSIONS
Overall Length 103.5 in. (2630 101.7 in. (2583 101.2 in. (2571 98.7 in. (2506 103.5 in. (2630 104.6 in. (2656
mm) Classic / mm) mm) mm) mm) mm)
Dark Horse 99.1 in. (2634
103.7 in. (2634 mm) Dark
mm) Vintage Horse
Overall Width 39.4 in. (1000 39 in. (990 39.4 in. (1000 39.4 in. (1000 39.4 in. (1000 39.4 in. (1000
mm) mm) mm) mm) mm) mm)
Overall Height 46.3 in. (1176 56.8 in. (1442 54.6 in. (1388 Limited: 54.6 58.7 in. (1491 58.7 in. (1491
mm) Classic / mm) mm) in. (1388 mm) mm) mm)
Dark Horse Elite: 57 in.
58.7 in. (1491 (1448 mm)
mm) Vintage
Seat Height 26 in. (660 26 in. (660 26 in. (660 26 in. (660 26.5 in. (673 26.5 in. (673
mm) mm) mm) mm) mm) mm)
Wheelbase 68.1 in. (1730 67 in (1701 65.7 in. (1668 65.7 in. (1668 65.7 in. (1668 65.7 in. (1668
mm) mm) mm) mm) mm) mm)
Ground 5.5 in. (140 5.6 in. (142 5.6 in. (142 5.6 in. (142 5.5 in. (140 5.5 in. (140
Clearance mm) mm) mm) mm) mm) mm)
Rake (frame)/ 29°/6.1 in. 25°/5.2 in. 25°/5.9 in. 25°/5.9 in. 25°/5.9 in. 25°/5.9 in.
Trail (155 mm) (133 mm) (150 mm) (150 mm) (150 mm) (150 mm)
WEIGHT
Dry Weight Classic / Dark 830 lbs. (376 Chieftain: 783 Limited: 817 864 lbs. (392 912 lbs. (414
(without fuel/ Horse: 745 lbs. kg) lbs. (355 kg) lbs. (371 kg) kg) kg)
fluids) (338 kg) Chieftain Dark Elite: 823 lbs
Vintage: 818 Horse: 802 lbs. (373 kg)
lbs. (371 kg) (364 kg)
Wet Weight Classic / Dark 862 lbs. (391 Chieftain: 815 Limited: 834 896 lbs. (406 944 lbs. (428
(with fuel/ Horse: 777 lbs. kg) lbs. (370 kg) lbs (378 kg) kg) kg)
fluids) (352 kg) Chieftain Dark Elite: 855 lbs
Vintage: 850 Horse 834 lbs. (388 kg)
lbs. (385 kg) (378 kg)
Gross Vehicle 1260 lbs. (573 1385 lbs. (628 1385 lbs. (628 1385 lbs (628 1385 lbs. (630 1385 lbs. (630
Weight Rating kg) kg) kg) kg) kg) kg)
(GVWR)
Gross Axle Front 485 lbs. Front 500 lbs. Front 500 lbs. Front: 500 lbs Front 500 lbs. Front 500 lbs.
Weight Rating (220 kg) (227 kg) (227 kg) (227 kg) Rear: (227 kg) (227 kg)
(GAWR) Rear 775 lbs. Rear 885 lbs. Rear 885 lbs. 885 lbs (401 Rear 885 lbs. Rear 885 lbs.
(352 kg) (401 kg) (401 kg) kg) (403 kg) (403 kg)
Maximum Classic / Dark 523 lbs. (237 Chieftain: 570 Limited: 551 489 lbs. (222 441 lbs. (200
Load Capacity Horse: 483 lbs. kg) lbs. (258 kg) lbs (250 kg) kg) kg)
(riders, cargo, (219 kg) Chieftain Dark Elite: 530 lbs
accessories) Vintage: 410 Horse: 551 lbs. (240 kg)
lbs. (186 kg) (250 kg)

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MODEL YEAR 2018 CHIEF MODELS SPRINGFIELD MODELS / CHIEFTAIN MODELS /

ROADMASTER MODELS
CAPACITIES
Engine Oil 5.5 qts. (5.2 l) with filter at 5.5 qts. (5.2 l) with filter at oil change
oil change
Fuel 5.5 gal. (20.8 l) 5.5 gal. (20.8 l)
Fuel Reserve (fuel light on) 1.0 gal. (3.8 l) 1.0 gal. (3.8 l)
Fork Oil 20.3 oz. (599 cc) 18.8 oz. (557 cc)

MODEL YEAR 2018 ALL MODELS

ENGINE
Engine Type ThunderStroke 111, Air Cooled
Configuration V-Twin
Displacement 111 cu. in. (1811 cc)
Cooling System Air Cooled (CHIEF, SPRINGFIELD)Air/Oil Cooler (CHIEFTAIN DARK HORSE)
Compression Ratio 9.5:1
Valve Train 2 Valves Per Cylinder, Hydraulic Lifters
Bore and Stroke 3.976" x 4.449" (101mm x 113mm)
Fuel System/Throttle Body Closed Loop Fuel Injection/54 mm
Bore
Exhaust System 1 into 2 with Catalytic Converter
Split Dual Exhaust with Cross-over
Rev Limit 5400 RPM
Idle RPM 800 +/- 50 RPM Fully Warm
Lubrication System Semi-Dry Sump
Spark Plug/Gap NGK DCPR8E/.034 inch (0.90 mm)
DRIVETRAIN
Primary Drive Gear Drive Wet Clutch
Crank Gear 55 Teeth
Clutch Gear 86 Teeth
Clutch Type Wet, Multi-Plate
Primary Reduction Ratio 1.564:1
Transmission Type 6 Speed/Constant Mesh/Foot Shift
1st Gear Ratio 2.733:1
2nd Gear Ratio 1.864:1
3rd Gear Ratio 1.385:1
4th Gear Ratio 1.103:1
5th Gear Ratio 0.943:1
6th Gear Ratio 0.811:1
Gear Shift Pattern 1 Down/5 Up
Final Drive Type Belt Drive, 152-Tooth
Transmission 30-Tooth
Rear Wheel 66-Tooth
Ratio 2.2:1
Overall Gear Ratio
1st Gear 9.403:1
2nd Gear 6.411:1
3rd Gear 4.763:1
4th Gear 3.796:1
5th Gear 3.243:1
6th Gear 2.789:1
ELECTRICAL
Stator 710W @ 2000 RPM
610W @2000 RPM (Chief/Chief Dark Horse)
Battery 12 Volt, 18 amp/hour, 310 CCA, Sealed Glass Mat

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MODEL YEAR 2018 ALL MODELS

ENGINE 1
Power Points Front - 10 amp maximum
Rear - 10 amp maximum
(Combined - 10 amp maximum)
Voltage Regulator 14.4 volts/42 amp
Headlight H4 12V 60/55W LL
Roadmaster Classic/Roadmaster/Chieftain Elite: Non-Serviceable LED
Auxiliary Light Chief Vintage/Springfield/Chief Dark Horse/Chieftain/Chieftain Limited: H8 35W
Roadmaster Classic/Roadmaster/Chieftain Elite: Non-Serviceable LED
Tail/Brake Light Non-Serviceable LED
Turn Signal Non-Serviceable LED
License Plate Non-Serviceable LED
Front Fender Light Non-Serviceable LED
Speedometer Non-Serviceable LED
Indicator Lights Non-Serviceable LED

MODEL YEAR 2018 CHIEF MODELS SPRINGFIELD MODELS CHIEFTAIN MODELS /

ROADMASTER MODELS
SUSPENSION
Front Suspension Type/ Telescopic Fork/4.7 in. (119 mm)
Travel
Front Fork Tube Diameter 46 mm
Rear Suspension Type/ Single Shock/3.7 in. Single Shock w/ Air Adjust/4.5 in. (114mm)
Travel (94mm)
Swing-arm Cast Aluminum

MODEL YEAR 2018 CHIEF MODELS SPRINGFIELD CHIEFTAIN ROADMASTER

MODELS MODELS MODELS
WHEELS / BRAKES
Front Wheel Size/ 3.5 in. x 16 in. Cast 3.5 in. x 19 in. Cast
Type Aluminum Aluminum (Dark
3.5 in. x 16 in. 3.5 in. x 19 in. Cast 3.5 in. x 16 in. Cast
Horse)
Spoked (Classic/ Aluminum Aluminum
3.5 in. x 16 in. Cast
Vintage) Aluminum
Rear Wheel Size/ 5 in. x 16 in. Cast
Type Aluminum 5 in. x 16 in. Cast 5 in. x 16 in. Cast 5 in. x 16 in. Cast
5 in. x 16 in. Spoked Aluminum Aluminum Aluminum
(Classic/Vintage)
Front Tire Type/Size 130/90-B16 73H 130/60B19 61H
Dunlop Elite Dunlop American 130/60B19 61H 130/90-B16 73H
130/90-B16 67H Elite (Dark Horse) Dunlop American Dunlop Elite 3
American Elite 130/90-B16 73H Elite
(Classic/Vintage) Dunlop Elite 3
Rear Tire Type/Size 180/65B16 81H
Dunlop American 180/60R16 80H Dunlop Elite 3 Multi-Compound
Elite
Front Brakes Dual / 4 Piston Caliper / Floating Rotor
Rear Brakes Single / 2 Piston Caliper / Floating Rotor

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2 0 1 9 M O D E L S P E C I F I C AT I O N S
MODEL
YEAR PAINT COLOR / CODE MODEL IMAGE
NUMBERS
2019 Chief N19CCDAAAH, Thunder Black Smoke = P-463
Dark Horse BH, CH, EH, XH

2019 Chief N19CVAAAAA, Thunder Black = P-266

Vintage BA, CA, EA, KA, Willow Green / Ivory Cream = P-670
XA, AG, BG, CG, / P-646
EG, KG, XG, AK, Sky Blue / Pearl White = P-737 / P-
BK, CK, EK, KK, 566
XK, AN, BN, CN, Coastal Green / Pearl White = P-753
EN, KN, XN, AY, / P-566
BY, CY, EY, KY, XY, Thunder Black / IMC Yellow = P-266
AP, BP, CP, EP, KP, / P-748
XP
Patriot Red / Pearl White = P-575 / P-
566
2019 N19THDAAAH, Thunder Black Smoke = P-463
Springfield BH, CH, EH, KH, White Smoke = P-675
Dark Horse XH, A6, B6, C6,
E6, K6, X6

2019 N19THAAAAA, Thunder Black = P-266

Springfield BA, CA, EA, KA, Steel Gray / Burgendy Metallic = P-
Limited XA, A5, B5, C5, 692 / P-629
E5, K5, X5, A8, B8, Metallic Jade / Thunder Black = P-
C8, E8, K8, X8 745 / P-266

2019 N19TCBAAAX, Steel Gray = P-692

Chieftain BX, CX, EX, KX,
XX

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2019 N19TFAAAAA, Thunder Black = P-266

Chieftain
Classic
BA, CA, EA, KA,
XA, AN, BN, CN,
Deep Water Metallic / Dirt Track Tan
= P-727 / P-555
1
EN, KN, XN, AY, Thunder Black / Ivory Cream = P-
BY, CY, EY, KY, XY, 266 / P-646
AG, BG, CG, EG, Willow Green / Ivory Cream = P-670
KG, XG, AP, BP, / P-646
CP, EP, KP, XP, A4, Patriot Red Pearl = P-665
B4, C4, E4, K4, X4
Burnished Metallic / Sandstone
Metallic = P-754 / P-755
2019 N19TCDAAAH, Thunder Black Smoke = P-463
Chieftain BH, CH, EH, KH, White Smoke = P-675
Dark Horse XH, A6, B6, C6, Bronze Smoke = P-731
E6, K6, X6, AL, BL,
CL, EL, KL, XL

2019 N19TCAAAA1, B1, Thunder Black Pearl = P-666

Chieftain C1, E1, K1, X1, AJ, Ruby Metallic = P-759
Limited BJ, CJ, EJ, KJ, XJ, Dark Walnut = P-756
AD, BD, CD, ED, Dragon Green = P-740
KD, XD, AT, BT, Burnt Orange Metallic = P-750
CT, ET, KT, XT, AU,
BU, CU, EU, KU,
XU

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2019 N19TRAAAAA, Thunder Black = P-266

Roadmaster BA, CA, EA, KA, Bergundy Metallic = P-629
Limited XA, AV, BV, CV, Polished Bronze / Thunder Black =
EV, KV, XV, A7, B7, P-714 / P-266
C7, E7, K7, X7, Pearl White / Star Silver = P-566 / P-
AU, BU, CU, EU, 354
KU, XU, AK, BK, Steel Gray Smoke / Thunder Black =
CK, EK, KK, XK, P-706 / P-463
AN, BN, CN, EN,
Brilliant Blue / Pearl White = P-620 /
KN, XN, AD, BD, P-566
CD, ED, KD, XD,
Ruby Metallic / Pearl White = P-759 /
A2, B2, C2, E2,
K2, X2, AC, BC, P-566
CC, EC, KC, XC, Deep Water Metallic / Brilliant Blue
AR, BR, CR, ER, = P-727 / P-620
KR, XR Dirt Track Smoke / Thunder Black
Smoke = P-729 / P-463
Ruby Smoke / Thunder Black Smoke
= P-760 / P-463
2019 N19TREAAA0, B0, Candy Red / Black Crystal w/ 23k
Roadmaster C0, E0, X0 Gold Trim = P-1798
Elite

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MODEL YEAR CHIEF SPRINGFIELD / CHIEFTAIN / CHIEFTAIN ROADMASTER

2019 SPRINGFIELD CHIEFTAIN LIMITED
DARK HORSE DARK HORSE 1
DIMENSIONS
Overall Length 103.5 in. (2630 101.7 in. (2583 101.2 in. (2571 98.7 in. (2506 104.6 in. (2656
mm) Dark Horse mm) mm) mm) mm)
103.7 in. (2634 99.1 in. (2634
mm) Vintage mm) Dark Horse
Overall Width 39.4 in. (1000 39 in. (990 mm) 39.4 in. (1000 39.4 in. (1000 39.4 in. (1000
mm) mm) mm) mm)
Overall Height 46.3 in. (1176 56.8 in. (1442 54.6 in. (1388 Limited: 54.6 in. 58.7 in. (1491
mm) Dark Horse mm) mm) (1388 mm) mm)
58.7 in. (1491
mm) Vintage
Seat Height 26 in. (660 mm) 26 in. (660 mm) 26 in. (660 mm) 26 in. (660 mm) 26.5 in. (673 mm)
Wheelbase 68.1 in. (1730 67 in (1701 mm) 65.7 in. (1668 65.7 in. (1668 65.7 in. (1668
mm) mm) mm) mm)
Ground 5.5 in. (140 mm) 5.6 in. (142 mm) 5.6 in. (142 mm) 5.6 in. (142 mm) 5.5 in. (140 mm)
Clearance
Rake (frame)/ 29°/6.1 in. (155 25°/5.2 in. (133 25°/5.9 in. (150 25°/5.9 in. (150 25°/5.9 in. (150
Trail mm) mm) mm) mm) mm)
WEIGHT
Dry Weight Dark Horse: 745 830 lbs. (376 kg) Chieftain: 783 Limited: 817 lbs. 912 lbs. (414 kg)
(without fuel/ lbs. (338 kg) lbs. (355 kg) (371 kg)
fluids) Vintage: 818 lbs. Chieftain Dark
(371 kg) Horse: 802 lbs.
(364 kg)
Wet Weight (with Dark Horse: 777 862 lbs. (391 kg) Chieftain: 815 Limited: 834 lbs 944 lbs. (428 kg)
fuel/fluids) lbs. (352 kg) lbs. (370 kg) (378 kg)
Vintage: 850 lbs. Chieftain Dark
(385 kg) Horse 834 lbs.
(378 kg)
Gross Vehicle 1260 lbs. (573 1385 lbs. (628 1385 lbs. (628 1385 lbs (628 kg) 1385 lbs. (630
Weight Rating kg) kg) kg) kg)
(GVWR)
Gross Axle Front 485 lbs. Front 500 lbs. Front 500 lbs. Front: 500 lbs Front 500 lbs.
Weight Rating (220 kg) (227 kg) (227 kg) (227 kg) (227 kg)
(GAWR) Rear 775 lbs. Rear 885 lbs. Rear 885 lbs. Rear: 885 lbs Rear 885 lbs.
(352 kg) (401 kg) (401 kg) (401 kg) (403 kg)
Maximum Load Classic / Dark 523 lbs. (237 kg) Chieftain: 570 Limited: 551 lbs 441 lbs. (200 kg)
Capacity (riders, Horse: 483 lbs. lbs. (258 kg) (250 kg)
cargo, (219 kg) Chieftain Dark
accessories) Vintage: 410 lbs. Horse: 551 lbs.
(186 kg) (250 kg)

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MODEL YEAR 2019 CHIEF MODELS SPRINGFIELD MODELS / CHIEFTAIN MODELS /

ROADMASTER MODELS
CAPACITIES
5.5 qts. (5.2 l) with filter at oil change = Engines build BEFORE January, 2019
Engine Oil
6.0 qts. (5.7 l) with filter at oil change = Engines build AFTER January, 2019
Fuel 5.5 gal. (20.8 l) 5.5 gal. (20.8 l)
Fuel Reserve (fuel light on) 1.0 gal. (3.8 l) 1.0 gal. (3.8 l)
Fork Oil 20.3 oz. (599 cc) 18.8 oz. (557 cc)

MODEL YEAR 2019 ALL MODELS

ENGINE
Engine Type ThunderStroke 111, Air Cooled
Configuration V-Twin
Displacement 111 cu. in. (1811 cc)
Cooling System Air Cooled (CHIEF, SPRINGFIELD) Air/Oil Cooler (CHIEFTAIN DARK HORSE)
Compression Ratio 9.5:1
Valve Train 2 Valves Per Cylinder, Hydraulic Lifters
Bore and Stroke 3.976" x 4.449" (101mm x 113mm)
Fuel System/Throttle Body Closed Loop Fuel Injection/54 mm
Bore
Exhaust System 1 into 2 with Catalytic Converter
Split Dual Exhaust with Cross-over
Rev Limit 5400 RPM
Idle RPM 800 +/- 50 RPM Fully Warm
Lubrication System Semi-Dry Sump
Spark Plug/Gap NGK DCPR8E/.034 inch (0.90 mm)
DRIVETRAIN
Primary Drive Gear Drive Wet Clutch
Crank Gear 55 Teeth
Clutch Gear 86 Teeth
Clutch Type Wet, Multi-Plate
Primary Reduction Ratio 1.564:1
Transmission Type 6 Speed/Constant Mesh/Foot Shift
1st Gear Ratio 2.733:1
2nd Gear Ratio 1.864:1
3rd Gear Ratio 1.385:1
4th Gear Ratio 1.103:1
5th Gear Ratio 0.943:1
6th Gear Ratio 0.811:1
Gear Shift Pattern 1 Down/5 Up
Final Drive Type Belt Drive, 152-Tooth
Transmission 30-Tooth
Rear Wheel 66-Tooth
Ratio 2.2:1
Overall Gear Ratio
1st Gear 9.403:1
2nd Gear 6.411:1
3rd Gear 4.763:1
4th Gear 3.796:1
5th Gear 3.243:1
6th Gear 2.789:1
ELECTRICAL
Stator 710W @ 2000 RPM
610W @2000 RPM (Chief/Chief Dark Horse)
Battery 12 Volt, 18 amp/hour, 310 CCA, Sealed Glass Mat

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MODEL YEAR 2019 ALL MODELS

ENGINE 1
Power Points Front - 10 amp maximum
Rear - 10 amp maximum
(Combined - 10 amp maximum)
Voltage Regulator 14.4 volts/42 amp
Headlight H4 12V 60/55W LL
Roadmaster: Non-Serviceable LED
Auxiliary Light Chief Vintage/Springfield/Chief Dark Horse/Chieftain/Chieftain Limited: H8 35W
Roadmaster: Non-Serviceable LED
Tail/Brake Light Non-Serviceable LED
Turn Signal Non-Serviceable LED
License Plate Non-Serviceable LED
Front Fender Light Non-Serviceable LED
Speedometer Non-Serviceable LED
Indicator Lights Non-Serviceable LED

MODEL YEAR 2019 CHIEF MODELS SPRINGFIELD MODELS CHIEFTAIN MODELS /

ROADMASTER MODELS
SUSPENSION
Front Suspension Type/ Telescopic Fork/4.7 in. (119 mm)
Travel
Front Fork Tube Diameter 46 mm
Rear Suspension Type/ Single Shock/3.7 in. Single Shock w/ Air Adjust/4.5 in. (114mm)
Travel (94mm)
Swing-arm Cast Aluminum

MODEL YEAR 2019 CHIEF MODELS SPRINGFIELD CHIEFTAIN ROADMASTER

MODELS MODELS MODELS
WHEELS / BRAKES
Front Wheel Size/ 3.5 in. x 16 in. Cast 3.5 in. x 19 in. Cast
Type Aluminum Aluminum (Dark
3.5 in. x 19 in. Cast 3.5 in. x 16 in. Cast
3.5 in. x 16 in. Horse)
Aluminum Aluminum
Spoked (Vintage) 3.5 in. x 16 in. Cast
Aluminum
Rear Wheel Size/ 5 in. x 16 in. Cast
Type Aluminum 5 in. x 16 in. Cast 5 in. x 16 in. Cast 5 in. x 16 in. Cast
5 in. x 16 in. Spoked Aluminum Aluminum Aluminum
(Vintage)
Front Tire Type/Size 130/90-B16 73H 130/60B19 61H
Dunlop Elite Dunlop American 130/60B19 61H 130/90-B16 73H
130/90-B16 67H Elite (Dark Horse) Dunlop American Dunlop Elite 3
American Elite 130/90-B16 73H Elite
(Vintage) Dunlop Elite 3
Rear Tire Type/Size 180/65B16 81H
Dunlop American 180/60R16 80H Dunlop Elite 3 Multi-Compound
Elite
Front Brakes Dual / 4 Piston Caliper / Floating Rotor
Rear Brakes Single / 2 Piston Caliper / Floating Rotor

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2 0 2 0 M O D E L S P E C I F I C AT I O N S
MODEL
YEAR PAINT COLOR / CODE MODEL IMAGE
NUMBERS
2020 Chief N20TEDAAAH, Thunder Black Smoke = P-463
Dark Horse BH, CH, EH, XH

2020 Chief N20TVAAAAA, Thunder Black = P-266

Vintage BA, CA, EA, AG, Willow Green / Ivory Cream = P-670
BG, CG, EG, XG, / P-646
AK, BK, CK, EK, Coastal Green / Pearl White = P-753
XK, AP, BP, CP, EP, / P-566
AD, BD, CD, ED Patriot Red Pearl / Pearl White = P-
575 / P-566
Burnished Metallic / Sandstone
Metal = P-754 / P-755

2020 N20THAAAAA, Thunder Black = P-266

Springfield BA, CA, EA, AB, Bergundy Metallic / Titanium Metal
BB, CB, EB = P-629 / 653

2020 N20TJDBBAH, BH, Thunder Black Smoke = P-463

Springfield CH, EH, XH, AJ, White Smoke = P-675
Dark Horse BJ, CJ, EJ, XJ, AW, Sagebrush Smoke = P-685
BW, CW, EW, XW

2020 N20TCBAAAA, Thunder Black = P-266

Chieftain BA, CA, EA, AT, Titanium Smoke = P-632
BT, CT, ET

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2020 N20TFAAAAA, Thunder Black = P-266

Chieftain
Classic
BA, CA, EA, A2,
B2, C2, E2, AG,
Deep Water Metallic / Dirt Track Tan
= P-727 / P-555
1
BG, CG, EG, A4, Willow Green / Ivory Cream = P-670
B4, C4, E4, AJ, BJ, / P-646
CJ, EJ Burnished Metal / Sandstone Metal =
P-754 / P-755
Metallic Jade / Pearl White = P-745 /
P-566

2020 N20TCDBBAH, Thunder Black Smoke = P-463

Chieftain BH, CH, EH, XH, Ruby Smoke = P-760
Dark Horse AB, BB, CB, EB, Titanium Smoke = P-632
XB, AT, BT, CT, ET, Ghost Grey = P-728
XT

2020 N20TCDBBA7, B7, Black Pearl = P-666

Chieftain C7, E7, A1, B1, Black Pearl w/ grfx = P-666
Limited C1, E1, A3, B3, Radar Blue = P-724
C3, E3, A5, B5, Dragon Green = P-740
C5, E5, AD, BD, Burnt Orange Metallic = P-750
CD, ED, AE, BE,
CE, EE

2020 N20TCEBBA8, B8, Thunder Black Crystal / Wildfire

Chieftain C8, E8, X8 Red Candy = P-794 / P-770
Elite

2020 N20TRABBAA, BA, Thunder Black = P-266

Roadmaster CA, EA, XA, AV, Bergundy Metallic = P-629
BV, CV, EV, XV, Pearl White / Titanium Metallic w/
A5, B5, C5, E5, Black Pin = P-566 / P-653
X5, A6, B6, C6, Titanium Smoke / Thunder Black
E6, X6, Smoke w/ Silver Pin = P-632 / P-463

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2020 N20TKDBBAH, Thunder Black Smoke = P-463

Roadmaster BH, CH, EH, AR, White Smoke = P-675
Dark Horse BR, CR, ER, AW, Ruby Smoke = P-760
BW, CW, EW

2020 N20TRABBA3, B3, Radar Blue / Pearl White w/ Silver

Roadmaster C3, E3, X3, A2, Pin = P-724 / P-566
Limited B2, C2, E2, A1, B1, Ruby Metallic / Pearl White w/ Silver
C1, E1, A9, B9, Pin = P-759 / P-566
C9, E9 Coastal Green / Ivory Cream w/
Black Pin = P-753 / P-646
Dirt Track Smoke / Thunder Black
w/ Gold Pin = P-729 / P-463

2020 N20TREBBAR, BR, Gunmetal / Black Vivid Crystal = P-

Roadmaster CR 1847
Elite

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MODEL YEAR CHIEF / SPRINGFIELD CHIEFTAIN CHIEFTAIN ROADMASTER

2020 VINTAGE / DARK HORSE CLASSIC LIMITED /
SPRINGFIELD ELITE / 1
CHIEFTAIN /
CHIEFTAIN
DARK HORSE
DIMENSIONS
Overall Length 101.7 in. (2583 99.3 in. (2522 101.2 in. (2571 Chieftain Limited Roadmaster:
mm) mm) mm) / Elite: 98.7 in. 104.6 in. (2657
(2506 mm) mm)
Chieftain / Dark Dark Horse:
Horse: 98.7 in. 102.1 in. (2593
(2506 mm) mm)
Elite: 105.4 (2677
mm)
Overall Width 39.4 in. (1000 39.4 in. (1000 39.4 in. (1000 39.4 in. (1000 39.4 in. (1000
mm) mm) mm) mm) mm)
Overall Height Dark Horse: 46.3 49.6 in. (1260 54.7 in. (1389 Chieftain / Dark 58.7 in. (1490
in. (1184 mm) mm) mm) Horse / Limited: mm)
Vintage / 54.5 in. (1384
Springfield: 56.8 mm)
in. (1442 mm) Elite: 56.7 in.
(1440 mm)
Seat Height 26 in. (660 mm) 26 in. (660 mm) 26 in. (660 mm) 25.6 in. (650 mm) 26.5 in. (673 mm)
Wheelbase 67.0 in. (1701 67 in (1701 mm) 65.7 in. (1668 65.7 in. (1668 65.7 in. (1668
mm) mm) mm) mm)
Ground 5.6 in. (142 mm) 5.2 in. (132 mm) 5.1 in. (130 mm) 5.1 in. (130 mm) 5.5 in. (140 mm)
Clearance Dark Horse: 5.1
in. (130 mm)
Rake (frame)/ 25°/5.2 in. (133 25°/5.2 in. (133 25°/5.9 in. (150 25°/5.9 in. (150 25°/5.9 in. (150
Trail mm) mm) mm) mm) mm)
WEIGHT
Dry Weight Dark Horse: 736 758 lbs (344 kg) 789 lbs (358 kg) Chieftain: 789 lbs 893 lbs. (405 kg)
(without fuel/ lbs. (334 kg) (358 kg) Dark Horse: 868
fluids) Vintage: 804 lbs. Dark Horse: 798 lbs (394 kg)
(365 kg) lbs. (362 kg)
Springfield: 803 Limited: 798 lbs.
lbs. (364 kg) (362 kg)
Elite: 804 lbs
(365 kg)
Wet Weight (with Dark Horse: 768 790 lbs (358 kg) 858 lbs (390 kg) Chieftain: 821 lbs 926 lbs. (420 kg)
fuel/fluids) lbs. (348 kg) (372 kg) Dark Horse: 900
Vintage: 836 lbs. Dark Horse: 830 lbs (408 kg)
(379 kg) lbs. (376 kg)
Springfield: 835 Limited: 830 lbs.
lbs. (379 kg) (376 kg)
Elite: 836 lbs
(379 kg)
Gross Vehicle Dark Horse: 1385 1385 lbs. (628 1385 lbs. (628 1385 lbs. (628 1385 lbs. (628
Weight Rating lbs. (628 kg) kg) kg) kg) kg)
(GVWR) Vintage: 1260
lbs. (572 kg)
Springfield: 1385
lbs. (628 kg)

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MODEL YEAR CHIEF / SPRINGFIELD CHIEFTAIN CHIEFTAIN ROADMASTER

2020 VINTAGE / DARK HORSE CLASSIC LIMITED /
SPRINGFIELD ELITE /
CHIEFTAIN /
CHIEFTAIN
DARK HORSE
DIMENSIONS
Gross Axle Dark Horse / Front 500 lbs. Front 500 lbs. Front: 500 lbs Front 500 lbs.
Weight Rating Springfield: Front (227 kg) (227 kg) (227 kg) (227 kg)
(GAWR) 500 lbs. (227 kg) Rear 885 lbs. Rear 885 lbs. Rear: 885 lbs Rear 885 lbs.
Rear 885 lbs. (401 kg) (401 kg) (401 kg) (403 kg)
(401 kg)
Vintage: Front
485 lbs. (220 kg)
Rear 775 lbs.
(352 kg)
Maximum Load Dark Horse: 451 429 lbs. (195 kg) Classic: 361 lbs. Chieftain: 398 294 lbs. (133 kg)
Capacity (riders, lbs. (204 kg) (164 kg) lbs. (180 kg) Dark Horse: 319
cargo, Vintage: 259 lbs. Dark Horse: 389 lbs. (145 kg)
accessories) (117 kg) lbs. (176 kg)
Springfield: 384 Limited: 389 lbs.
lbs. (174 kg) (176 kg)
Elite: 383 lbs.
(174 kg)

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MODEL YEAR 2020 CHIEF MODELS SPRINGFIELD MODELS / CHIEFTAIN MODELS /

ROADMASTER MODELS
CAPACITIES 1
Engine Oil 6.0 qts. (5.7 l) with filter at oil change
Fuel 5.5 gal. (20.8 l)
Fuel Reserve (fuel light on) 1.0 gal. (3.8 l)
Fork Oil 18.8 oz. (557 cc)

MODEL YEAR CHIEF DARK HORSE / CHIEF VINTAGE / SPRINGFIELD DARK HORSE / CHIEFTAIN /
2020 SPRINGFIELD / CHIEFTAIN / CHIEFTAIN CHIEFTAIN DARKHORSE / CHIEFTAIN
CLASSIC LIMITED / CHIEFTAIN ELITE /
ROADMASTER MODELS
ENGINE
Engine Type ThunderStroke 111, Air Cooled ThunderStroke 116, Air Cooled
Configuration V-Twin
Displacement 111 cu. in. (1811 cc) 115 cu. in. (1890 cc)
Cooling
System Air Cooled
Compression
9.5:1 11.0:1
Ratio
Valve Train 2 Valves Per Cylinder, Hydraulic Lifters
Bore and 3.976" x 4.449" (101mm x 113mm) 4.063" x 4.449" (103.2mm x113mm)
Stroke
Fuel System/
Throttle Body Closed Loop Fuel Injection/54 mm
Bore
Exhaust 1 into 2 with Catalytic Converter
System Split Dual Exhaust with Cross-over
Rev Limit 5400 RPM
Idle RPM 800 +/- 50 RPM Fully Warm 900 +/- 50 RPM Fully Warm
Lubrication
Semi-Dry Sump
System
Spark Plug/
NGK DCPR8E/.034 inch (0.90 mm)
Gap
DRIVETRAIN
Primary Drive Gear Drive Wet Clutch
Crank Gear 55 Teeth
Clutch Gear 86 Teeth
Clutch Type Wet, Multi-Plate
Primary
Reduction 1.564:1
Ratio
Transmission
6 Speed/Constant Mesh/Foot Shift
Type
1st Gear Ratio 2.733:1
2nd Gear Ratio 1.864:1
3rd Gear Ratio 1.385:1
4th Gear Ratio 1.103:1
5th Gear Ratio 0.943:1
6th Gear Ratio 0.811:1
Gear Shift 1 Down/5 Up
Pattern
Final Drive
Belt Drive, 152-Tooth
Type
Transmission 30-Tooth
Rear Wheel 66-Tooth

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MODEL YEAR CHIEF DARK HORSE / CHIEF VINTAGE / SPRINGFIELD DARK HORSE / CHIEFTAIN /
2020 SPRINGFIELD / CHIEFTAIN / CHIEFTAIN CHIEFTAIN DARKHORSE / CHIEFTAIN
CLASSIC LIMITED / CHIEFTAIN ELITE /
ROADMASTER MODELS
ENGINE
Ratio 2.2:1
Overall Gear
Ratio
1st Gear 9.403:1
2nd Gear 6.411:1
3rd Gear 4.763:1
4th Gear 3.796:1
5th Gear 3.243:1
6th Gear 2.789:1

MODEL YEAR CHIEF DARKHORSE / VINTAGE /

SPRINGFIELD DARK HORSE
2020 SPRINGFIELD
ELECTRICAL
Stator 710W @ 3500 RPM
Battery 12 Volt, 18 amp/hour, 310 CCA, Sealed Glass Mat
Total Audio
System Output NA
Voltage
14.4 volts/42 amp
Regulator
Headlight H4 12V 60/55W LL
Position Lamp Non-Serviceable LED (Head Dress) W5W 12V in headlight assembly
INT’L = N/A
Auxiliary Light H8 35W
Tail/Brake
Light Non-Serviceable LED
Turn Signal Non-Serviceable LED
License Plate Non-Serviceable LED
Front Fender
Light Non-Serviceable LED
Speedometer Non-Serviceable LED
Indicator
Lights Non-Serviceable LED

MODEL CHIEFTAIN CLASSIC /

YEAR CHIEFTAIN CHIEFTAIN DARK HORSE / CHIEFTAIN ELITE
2020 CHIEFTAIN LIMITED
ELECTRICAL CONTINUED
Stator 710W @ 3500 RPM
Battery 12 Volt, 18 amp/hour, 310 CCA, Sealed Glass Mat
Total
Audio 400 W; 2 x 100 W 5.25" Round, 2
100 W; 2 x 50 W 5.25"
System x 100 W 6.5" Round
Output
Voltage
14.4 volts/42 amp
Regulator
Headlight H4 12V 60/55W LL Non-Serviceable LED
Position Non-Servicable LED integrated into headlight
Lamp INT’L = N/A
Auxiliary
Light Chieftain: H8 35W

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MODEL CHIEFTAIN CLASSIC /

YEAR CHIEFTAIN CHIEFTAIN DARK HORSE / CHIEFTAIN ELITE
2020 CHIEFTAIN LIMITED 1
Tail/Brake
Light Non-Serviceable LED
Turn
Signal Non-Serviceable LED
License
Non-Serviceable LED
Plate
Front
Fender Non-Serviceable LED
Light
Speedom-
Non-Serviceable LED
eter
Indicator
Lights Non-Serviceable LED

MODEL
YEAR ROADMASTER DARK HORSE ROADMASTER ROADMASTER ELITE
2020
ELECTRICAL CONTINUED
Stator 710W @ 3500 RPM
Battery 12 Volt, 18 amp/hour, 310 CCA, Sealed Glass Mat
Total
Audio 600 W; 4 x 100 W 5.25" Round, 2
200 W; 4 x 50 W 5.25 Round"
System x 100 W 6.5" Round
Output
Voltage
14.4 volts/42 amp
Regulator
Headlight Non-Serviceable LED
Position Non-Servicable LED integrated
into headlight Non-Serviceable LED (Head Dress)
Lamp
INT’L = N/A
Auxiliary
Light Non-Serviceable LED
Tail/Brake
Light Non-Serviceable LED
Turn
Signal Non-Serviceable LED
License
Non-Serviceable LED
Plate
Front
Fender Non-Serviceable LED
Light
Speedom-
Non-Serviceable LED
eter
Indicator
Lights Non-Serviceable LED

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MODEL YEAR CHIEF / VINTAGE / SPRINGFIELD / SPRINGFIELD / CHIEFTAIN MODELS

2020 CHIEFTAIN CLASSIC / ROADMASTER
SUSPENSION
Front
Suspension Telescopic Fork/4.7 in. (119 mm)
Type/Travel
Front Fork Tube
46 mm
Diameter
Rear
Suspension Single Shock w/ Air Adjust / 4.5 in. (114mm) / Single Shock w/ Air Adjust / 4.5 in. (114mm) /
Type/Travel 45.7mm ride in 63mm ride in
Swing-arm Cast Aluminum

SPRINGFIELD CHIEFTAIN ROADMASTER

MODEL YEAR 2020 CHIEF MODELS
MODELS MODELS MODELS
WHEELS / BRAKES
Dark Horse: 3.5 in. x 3.5 in. x 17 in. Cast 3.5 in. x 19 in. Cast 3.5 in. x 16 in. Cast
Front Wheel Size/ 17 in. Cast Aluminum Aluminum Aluminum Aluminum
Type Vintage: 3.5 in. x 16 Dark Horse: 3.5 in. x Classic: 3.5 in. x 16 Dark Horse: 3.5 in. x
in. Spoked 19 in. Cast Aluminum in. Cast Aluminum 19 in. Cast Aluminum
Dark Horse: 5 in. x 16
Rear Wheel Size/ in. Cast Aluminum 5 in. x 16 in. Cast 5 in. x 16 in. Cast 5 in. x 16 in. Cast
Type Vintage: 5 in. x 16 in. Aluminum Aluminum Aluminum
Spoked
Dark Horse: 130/80- 130/80B17 65H 130/60B19 61H 130/90-B16 73H
B17 65H America Dunlop American Dunlop American Dunlop Elite 3
Front Tire Type/Size Elite Elite Elite Dark Horse: 130/
Vintage: 130/90-B16 Dark Horse: 130/60- Classic: 130/90B16
60B19 61H Dunlop
67H American Elite B19 61H Dunlop 73H Dunlop Elite 3 American Elite
American Elite
Dark Horse: 180/
60R16 80H Dunlop
Rear Tire Type/Size Elite 3 180/60R16 80H Dunlop Elite 3 Multi-Compound
Vintage: 180/65B16
81H Dunlop
American Elite
Front Brakes Dual / 4 Piston Caliper / Floating Rotor
Rear Brakes Single / 2 Piston Caliper / Floating Rotor

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2 0 2 1 M O D E L S P E C I F I C AT I O N S
YEAR
MODEL
PAINT COLOR / CODE MODEL IMAGE
1
NUMBERS
2021 N21TVACAAB, BB, Crimson Metallic = P-819
Vintage CB, EB, XB Deep Water Metallic / Dirt Track Tan
N21TVACAA2, B2, = P-727 / P-555
C2, E2

2021 N21TVDCAAH, Thunder Black Smoke = P-463

Vintage BH, CH, EH, XH
Dark Horse

2021 N21THAAAAB, Maroon Metallic / Crimson Metallic

Springfield BB, CB, EB = P-711 / 819
N21THAAAAE, Thunder Black / Dirt Track Tan = P-
BE, CE, EE 266 / 555

2021 N21TJDDBAH, BH, Thunder Black Smoke = P-463

Springfield CH, EH, XH White Smoke = P-675
Dark Horse N21TJDDBAJ, BJ, Sagebrush Smoke = P-685
CJ, EJ, XJ
N21TJDDBAW,
BW, CW, EW, XW

2021 N21TCBAAAA, Thunder Black = P-266

Chieftain BA, CA, EA

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2021 N21TCDBBAH, Thunder Black Smoke = P-463

Chieftain BH, CH, EH, XH Ruby Smoke = P-760
Dark Horse N21TCDBBAR, BR, Titanium Smoke = P-632
CR, ER, XR
N21TCDBBAT, BT,
CT, ET, XT

2021 N21TCABBA1, B1, Black Pearl = P-666

Chieftain C1, D1, E1, X1 Radar Blue = P-724
Limited N21TCABBA3, B3,
C3, E3, X3

2021 N21TCDBBAS, BS, Stealth Gray = P-804

Chieftain CS, ES Burnt Orange Metallic Smoke = P-
Icon N21TCDBBAK, BK, 823
CK, EK, XK Crimson Metallic = P-819
N21TCDBBAM,
BM, CM, EM, XM

2021 N21TRABBA1, B1, Thunder Black Pearl = P-666

Roadmaster C1, E1, X1 Maroon Metallic / Crimson Metallic
N21TRABBAB, BB, = P-711 / P-819
CB, EB, XB Alumina Jade / Thunder Black = P-
N21TRABBAC, BC, 822 / P-266
CC, EC, XC

2021 N21TKDBBAH, Thunder Black Smoke = P-463

Roadmaster BH, CH, EH, XH White Smoke = P-675
Dark Horse N21TKDBBAF, BF, Bronze Smoke = P-731
CF, EF, XF
N21TKDBBAW,
BW, CW, EW, XW

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2021 N21TKABBAU, BU, Crimson Metallic = P-819

Roadmaster
Limited
CU, EU, XU
N21TKABBAM,
Thunder Black Azure Crystal = P-809 1
BM, CM, EM, XM

2021 N21TRABBAD, BD, Thunder Black Azure Crystal /

Roadmaster CD, ED, XD Stealth Gray Azure Crystal= P-809 /
Icon N21TRABBAE, BE, P-834
CE, EE, XE Arizona Turquoise / Pearl White = P-
N21TRABBAF, BF, 821 / P-566
CF, EF, XF Blue Slate Smoke / Thunder Black
Smoke = P-826 / P-463

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MODEL YEAR VINTAGE / SPRINGFIELD CHIEFTAIN CHIEFTAIN ROADMASTER

2021 SPRINGFIELD DARK HORSE LIMITED / / LIMITED /
ELITE / DARK DARK HORSE
HORSE
DIMENSIONS
Overall Length 101.7 in. (2583 99.3 in. (2522 98.7 in. (2506 98.7 in. (2506 Roadmaster:
mm) mm) mm) mm) 104.6 in. (2657
mm)
Limited / Dark
Horse: 102.1 in.
(2593 mm)
Overall Width 39.4 in. (1000 mm)
Overall Height 56.8 in. (1442 49.6 in. (1260 54.5 in. (1385 Chieftain / Dark 58.7 in. (1490
mm) mm) mm) Horse / Limited: mm)
54.5 in. (1384
mm)
Elite: 56.7 in.
(1440 mm)
Seat Height 26 in. (660 mm) 25.6 in. (650 mm) 25.6 in. (650 mm) 25.6 in. (650 mm) 26.5 in. (673 mm)
Wheelbase 67.0 in. (1701 67.0 in (1701 65.7 in. (1668 65.7 in. (1668 65.7 in. (1668
mm) mm) mm) mm) mm)
Ground 5.6 in. (142 mm) 5.1 in. (130 mm) 5.1 in. (130 mm) 5.1 in. (130 mm) 5.5 in. (140 mm)
Clearance
Rake (frame)/ 25°/5.2 in. (133 25°/5.2 in. (133 25°/5.9 in. (150 25°/5.9 in. (150 25°/5.9 in. (150
Trail mm) mm) mm) mm) mm)
WEIGHT
Dry Weight Vintage: 798 lbs. 751 lbs. (341 kg) 791 lbs (359 kg) Chieftain / Roadmaster: 877
(without fuel/ (362 kg) Limited / Dark lbs. (398 kg)
fluids) Vintage Dark Horse: 791 lbs Dark Horse /
Horse: 748 lbs. (359 kg) Limited: 858 lbs
(339 kg) Elite: 797 lbs (389 kg)
Springfield: 797 (362 kg)
lbs. (362 kg)
Wet Weight (with Vintage: 830 lbs. Springfield Dark 823 lbs (373 kg) Chieftain / Roadmaster: 909
fuel/fluids) (377 kg) Horse: 783 lbs. Limited / Dark lbs. (412 kg)
Vintage Dark (355 kg) Horse: 823 lbs Dark Horse /
Horse: 780 lbs. (373 kg) Limited: 890 lbs
(354 kg) Elite: 829 lbs (404 kg)
Springfield: 829 (376 kg)
lbs. (376 kg)
Gross Vehicle Vintage: 1260
Weight Rating lbs. (572 kg)
(GVWR) Vintage Dark
1385 lbs. (628 kg)
Horse /
Springfield: 1385
lbs. (628 kg)

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MODEL YEAR VINTAGE / SPRINGFIELD CHIEFTAIN CHIEFTAIN ROADMASTER

2021 SPRINGFIELD DARK HORSE LIMITED / / LIMITED /
ELITE / DARK DARK HORSE 1
HORSE
DIMENSIONS
Gross Axle Vintage: Front
Weight Rating 485 lbs. (220 kg)
(GAWR) Rear 775 lbs.
(352 kg)
Vintage Dark Front 500 lbs. (227 kg)
Horse / Rear 885 lbs. (401 kg)
Springfield: Front
500 lbs. (227 kg)
Rear 885 lbs.
(401 kg)
Maximum Load Vintage: 430 lbs. 602 lbs. (273 kg) 562 lbs. (255 kg) Dark Horse / Roadmaster: 476
Capacity (riders, (195 kg) Limited: 562 lbs. lbs. (216 kg)
cargo, Vintage Dark (255 kg) Dark Horse /
accessories) Horse: 605 lbs. Elite: 556 lbs. Limited: 495 lbs.
(274 kg) (252 kg) (225 kg)
Springfield: 556
lbs. (252 kg)

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MODEL YEAR 2021

CAPACITIES
Engine Oil 6.0 qts. (5.7 l) with filter at oil change
Fuel 5.5 gal. (20.8 l)
Fuel Reserve (fuel light on) 1.0 gal. (3.8 l)
Fork Oil 18.8 oz. (557 cc)

MODEL YEAR VINTAGE / VINTAGE DARK HORSE / SPRINGFIELD DARK HORSE / CHIEFTAIN
2021 SPRINGFIELD / CHIEFTAIN DARKHORSE / CHIEFTAIN LIMITED /
CHIEFTAIN ELITE / ROADMASTER
MODELS
ENGINE
Engine Type ThunderStroke 111, Air Cooled ThunderStroke 116, Air Cooled
Configuration V-Twin
Displacement 111 cu. in. (1811 cc) 115 cu. in. (1890 cc)
Cooling
System Air Cooled
Compression
9.5:1 11.0:1
Ratio
Valve Train 2 Valves Per Cylinder, Hydraulic Lifters
Bore and 3.976" x 4.449" (101mm x 113mm) 4.063" x 4.449" (103.2mm x113mm)
Stroke
Fuel System/
Throttle Body Closed Loop Fuel Injection/54 mm
Bore
Exhaust 1 into 2 with Catalytic Converter
System Split Dual Exhaust with Cross-over
Rev Limit 5400 RPM 5700 RPM
Idle RPM 800 +/- 50 RPM Fully Warm 900 +/- 50 RPM Fully Warm
Lubrication
Semi-Dry Sump
System
Spark Plug/
NGK DCPR8E/.034 inch (0.90 mm)
Gap
DRIVETRAIN
Primary Drive Gear Drive Wet Clutch
Crank Gear 55 Teeth
Clutch Gear 86 Teeth
Clutch Type Wet, Multi-Plate
Primary
Reduction 1.564:1
Ratio
Transmission
6 Speed/Constant Mesh/Foot Shift
Type
1st Gear Ratio 2.733:1
2nd Gear Ratio 1.864:1
3rd Gear Ratio 1.385:1
4th Gear Ratio 1.103:1
5th Gear Ratio 0.943:1
6th Gear Ratio 0.811:1
Gear Shift 1 Down/5 Up
Pattern
Final Drive
Belt Drive, 152-Tooth
Type
Transmission 30-Tooth
Rear Wheel 66-Tooth
Ratio 2.2:1

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MODEL YEAR VINTAGE / VINTAGE DARK HORSE / SPRINGFIELD DARK HORSE / CHIEFTAIN
2021 SPRINGFIELD / CHIEFTAIN DARKHORSE / CHIEFTAIN LIMITED /
CHIEFTAIN ELITE / ROADMASTER 1
MODELS
ENGINE
Overall Gear
Ratio
1st Gear 9.403:1
2nd Gear 6.411:1
3rd Gear 4.763:1
4th Gear 3.796:1
5th Gear 3.243:1
6th Gear 2.789:1

MODEL YEAR VINTAGE / VINTAGE DARK HORSE /

SPRINGFIELD DARK HORSE
2021 SPRINGFIELD
ELECTRICAL
Stator 710W @ 3500 RPM
Battery 12 Volt, 18 amp/hour, 310 CCA, Sealed Glass Mat
Total Audio
System Output NA
Voltage
14.4 volts/42 amp
Regulator
Headlight H4 12V 60/55W LL
Position Lamp Non-Serviceable LED (Head Dress) W5W 12V in headlight assembly
INT’L = N/A
Vintage / Springfield: H8 35W
Auxiliary Light NA
Vintage Dark Horse: NA
Tail/Brake
Light Non-Serviceable LED
Turn Signal Non-Serviceable LED
License Plate Non-Serviceable LED
Front Fender
Light Non-Serviceable LED
Speedometer Non-Serviceable LED
Indicator
Lights Non-Serviceable LED

MODEL CHIEFTAIN DARK HORSE /

CHIEFTAIN CHIEFTAIN ELITE
YEAR 2021 CHIEFTAIN LIMITED
ELECTRICAL CONTINUED
Stator 710W @ 3500 RPM
Battery 12 Volt, 18 amp/hour, 310 CCA, Sealed Glass Mat
Total Audio
System 100 W; 2 x 50 W 5.25" 400 W; 2 x 100 W 5.25" Round, 2
Output x 100 W 6.5" Round
Voltage
14.4 volts/42 amp
Regulator
Headlight H4 12V 60/55W LL Non-Serviceable LED
Position W5W 12V in headlight Non-Servicable LED integrated into headlight
Lamp assembly INT’L = N/A
Auxiliary
Light H8 35W Non-Serviceable LED
Tail/Brake
Light Non-Serviceable LED
Turn Signal Non-Serviceable LED

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MODEL CHIEFTAIN DARK HORSE /

CHIEFTAIN CHIEFTAIN ELITE
YEAR 2021 CHIEFTAIN LIMITED
License Plate Non-Serviceable LED
Front Fender
Light Non-Serviceable LED
Speedome-
Non-Serviceable LED
ter
Indicator
Lights Non-Serviceable LED

MODEL ROADMASTER DARK ROADMASTER

ROADMASTER ROADMASTER ELITE
YEAR 2021 HORSE LIMITED
ELECTRICAL CONTINUED
Stator 710W @ 3500 RPM
Battery 12 Volt, 18 amp/hour, 310 CCA, Sealed Glass Mat
Total Audio 600 W; 4 x 100 W 5.25"
System 200 W; 4 x 50 W 5.25 Round" Round, 2 x 100 W 6.5"
Output Round
Voltage
14.4 volts/42 amp
Regulator
Headlight Non-Serviceable LED
Non-Servicable LED
Position integrated into Non-Serviceable LED Non-Servicable LED integrated into headlight
Lamp headlight (Head Dress) INT’L = N/A
INT’L = N/A
Auxiliary
Light NA Non-Serviceable LED NA
Tail/Brake
Light Non-Serviceable LED
Turn Signal Non-Serviceable LED
License Plate Non-Serviceable LED
Front Fender
Light Non-Serviceable LED
Speedome-
Non-Serviceable LED
ter
Indicator
Lights Non-Serviceable LED

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MODEL YEAR VINTAGE / ROADMASTER MODELS SPRINGFIELD / CHIEFTAIN MODELS

2021
SUSPENSION 1
Front
Suspension Telescopic Fork/4.7 in. (119 mm)
Type/Travel
Front Fork Tube
46 mm
Diameter
Rear
Suspension Single Shock w/ Air Adjust / 4.5 in. (114mm) / Single Shock w/ Air Adjust / 4.5 in. (114mm) /
Type/Travel 45.7mm ride in 63mm ride in
Swing-arm Cast Aluminum

SPRINGFIELD CHIEFTAIN ROADMASTER

MODEL YEAR 2021 VINTAGE MODELS
MODELS MODELS MODELS
WHEELS / BRAKES
Roadmaster: 3.5 in. x
Springfield: 3.5 in. x
Front Wheel Size/ 3.5 in. x 16 in. 17 in. Cast Aluminum
17 in. Cast Aluminum 3.5 in. x 19 in. Cast
Type Spoked Dark Horse / Limited:
Dark Horse: 3.5 in. x Aluminum
3.5 in. x 19 in. Cast
19 in. Cast Aluminum
Aluminum
Rear Wheel Size/ 5 in. x 16 in. Cast 5 in. x 16 in. Cast 5 in. x 16 in. Cast
5 in. x 16 in. Spoked
Type Aluminum Aluminum Aluminum
Springfield: 130/80- Roadmaster: 130/80-
Vintage: 130/90-B16
B17 65H Metzeler B17 65H Metzeler
67H American Elite
Front Tire Type/Size Cruisetec 130/60-B19 66H Cruisetec
Dark Horse: 130/80-
Dark Horse: 130/60- Metzeler Cruisetec Dark Horse/ Limited:
B17 65H Metzeler
B19 66H Metzeler 130/60-B19 66H
Cruisetec
Cruisetec Metzeler Cruisetec
Vintage: 180/65-B16
81H Dunlop
Rear Tire Type/Size American Elite 180/60-R16 80H 180/60-R16 80H 180/60-R16 80H
Dark Horse: 180/60- Metzeler Cruisetec Metzeler Cruisetec Metzeler Cruisetec
R16 80H Metzeler
Cruisetec
Front Brakes Dual / 4 Piston Caliper / Floating Rotor
Rear Brakes Single / 2 Piston Caliper / Floating Rotor

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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

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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 S 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.

SERVICE MANUAL PART OWNER’S MANUAL PART

MODEL YEAR / MARKET MODEL
NUMBERS NUMBERS
Chief
Vintage
Chief Darkhorse
Chieftain /
2017 Indian Motorcycle (U.S.) Limited / Elite 9927618 9927621
Chieftain
Darkhorse
Roadmaster
Springfield
Chief
Vintage
Chief Darkhorse
Chieftain /
2017 Indian Motorcycle (CAN) Limited / Elite 9927618 9927466
Chieftain
Darkhorse
Roadmaster
Springfield
Chief
Vintage
Chief Darkhorse
Chieftain /
2017 Indian Motorcycle (INT’L) Limited / Elite 9927618 9927468
Chieftain
Darkhorse
Roadmaster
Springfield

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SERVICE MANUAL PART OWNER’S MANUAL PART

MODEL YEAR / MARKET MODEL
NUMBERS NUMBERS
Chief / Chief
Classic
Vintage
Chief Dark Horse
Chieftain /
Classic

2018 Indian Motorcycle (U.S. / Chieftain Limited

INT’L) / Elite 9928431 9927873
Chieftain Dark
Horse
Roadmaster /
Classic / Elite
Springfield
Springfield Dark
Horse
Chief / Chief
Classic
Vintage
Chief Dark Horse
Chieftain /
Classic
Chieftain Limited
2018 Indian Motorcycle (CAN) / Elite 9928431 9927876
Chieftain Dark
Horse
Roadmaster /
Classic / Elite
Springfield
Springfield Dark
Horse

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SERVICE MANUAL PART OWNER’S MANUAL PART

MODEL YEAR / MARKET MODEL
NUMBERS NUMBERS 1
Chief
Vintage
Chief Dark Horse
Chieftain
Chieftain Limited
2019 Indian Motorcycle (U.S. /
INT’L) Chieftain Dark 9929389 9929709
Horse
Roadmaster /
Elite
Springfield
Springfield Dark
Horse
Chief
Vintage
Chief Dark Horse
Chieftain
Chieftain Limited
2019 Indian Motorcycle (CAN) Chieftain Dark 9929389 9929710
Horse
Roadmaster /
Elite
Springfield
Springfield Dark
Horse

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SERVICE MANUAL OWNER’S MANUAL

MODEL YEAR / MARKET MODEL
PART NUMBERS PART NUMBERS
Chief Dark Horse
Vintage
Springfield / Dark
Horse
Chieftain Limited /
2020 Indian Motorcycle (U.S. / Elite / Dark Horse
INT’L) 9930568 9930566
Chieftain Classic
Chieftain
Roadmaster / Dark
Horse
Roadmaster Limited
Chief Dark Horse
Vintage
Springfield / Dark
Horse
Chieftain Limited /
2020 Indian Motorcycle (CAN) Elite / Dark Horse 9930568 9930567
Chieftain Classic
Chieftain
Roadmaster / Dark
Horse
Roadmaster Limited

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SERVICE MANUAL OWNER’S MANUAL

MODEL YEAR / MARKET MODEL
PART NUMBERS PART NUMBERS 1
Chief Dark Horse
Vintage
Springfield / Dark
Horse
Chieftain Limited /
2021 Indian Motorcycle (U.S. / Elite / Dark Horse
INT’L) 9850035 9931551
Chieftain Classic
Chieftain
Roadmaster / Dark
Horse
Roadmaster Limited
Chief Dark Horse
Vintage
Springfield / Dark
Horse
Chieftain Limited /
2021 Indian Motorcycle (CAN) Elite / Dark Horse 9850035 99131552
Chieftain Classic
Chieftain
Roadmaster / Dark
Horse
Roadmaster Limited

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E M M I 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
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.

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SPECIAL TOOLS
USING SPECIAL TOOLS How To Use This Book 1
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.

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SPECIAL TOOLS INDEX

ABS Tool (Brake Lever Reserve) Battery Tester Bearing Removal Kit
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

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Crankshaft Rotation Tool Damper Rod Holder Electrical Tester Kit

PF-51239 PV-49453 PV-43526 1

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

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Output Shaft Seal Tool Relay Bypass Tool Shock Air Pump
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

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Cam Installation Tool 1

PF-51455

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REFERENCE
M A S T E R T O R Q U E TA B L E - 9 8 5 0 0 3 5
CHAPTER 2: MAINTENANCE
ITEM TORQUE
Air Filter Fastener 62 in-lbs (7 N·m)

Airbox Filter Cover Fastener 84 in-lbs (10 N·m)

Battery Bracket Fastener 84 in-lbs (10 N·m)

Battery Terminal Fastener 48 in-lbs (5 N·m)

Brake Caliper Cover Acorn Nut 18 in-lbs (2 N·m)

Brake Lever Pivot Fastener 9 in-lbs (1 N·m)

Brake Lever Pivot Nut 53 in-lbs (6 N·m)

Chin Fairing Fastener 36 in-lbs (4 N·m)

Clutch Cable Guide Fastener 84 in-lbs (10 N·m)

Clutch Cable Jam Nut 48 in-lbs (5 N·m)

Oil Drain Plug 15 ft-lbs (20 N·m)

Approximately 3/4 turn after seal has contacted
Oil Filter the filter adapter.
Shift Rod Jam Nut 84 in-lbs (10 N·m)

Sidestand Pivot Fastener 37 ft-lbs (50 N·m)

Sidestand Mount Fastener 45 ft-lbs (61 N·m)

Spark Plug 84 in-lbs (10 N·m)

CHAPTER 3: ENGINE / COOLING / EXHAUST

ITEM TORQUE
ACG Cover Fastener 84 in-lbs (10 N·m)
Battery Box Fastener 18 ft-lbs (24 N·m)

Breather Fastener 84 in-lbs (10 N·m)

Bypass Tube Fastener 84 in-lbs (10 N·m)

Camshaft Chain Tensioner 15 ft-lbs (20 N·m)

Camshaft Sprocket Fastener 159 in-lbs (18 N·m)

Camshaft Thrust Plate Fastener 62 in-lbs (7 N·m)

Chain Guide Fastener (All) 84 in-lbs (10 N·m)

1. Torque to 19 ft-lbs (26 N·m)

Connecting Rod Fastener
2. Torque angle to 105 °

Connecting Rod Fastener (Units that had bulletin I-18-

46 ft-lbs (62 N·m)
06 Completed)

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Camshaft Chain oil Jet Fastener 62 in-lbs (7 N·m)

Coolant Line Fastener 84 in-lbs (10 N·m) 1

Crankcase Fastener 22 ft-lbs (30 N·m)
Cylinder Head Bolt 84 in-lbs (10 N·m)
1. Torque fasteners to 26 ft-lbs (35 N·m)
Cylinder Head Nut 2. Turn additional 50 °
3. Turn additional 90 °
Cylinder Stud 25 ft-lbs (34 N·m)

Dash Closeout Fastener 36 in-lbs (4 N·m)

Detonation Sensor Fastener 15 ft-lbs (20 N·m)

Engine Mount Fastener 45 ft-lbs (61 N·m)

Exhaust Clamp 7 ft-lbs (9 N·m)

Exhaust Manifold Stud 15 ft-lbs (20 N·m)

Fairing Louver Fastener 36 in-lbs (4 N·m)

Filter Adapter 22 ft-lbs (30 N·m)

Flywheel Fastener 112 ft-lbs (152 N·m)

1. Torque front header nuts (starting with lower) to 7

ft-lbs (9 N·m)
2. Torque rear header nuts (starting with lower) to 7
ft-lbs (9 N·m)
Headpipe Nut
3. Torque front header nuts (starting with lower) to
15 ft-lbs (20 N·m)
4. Torque rear header nuts (starting with lower) to 15
ft-lbs (20 N·m)

Heat Shield Clamp 31 in-lbs (3 N·m)

Heat Shield Fasteners, Lower 84 in-lbs (10 N·m)

Intake Manifold Fasteners (left-hand side) 84 in-lbs (10 N·m)
Intake Manifold Fasteners (right-hand side installed
with special tool 5264374) 74 in-lbs (9 N·m)

Input Shaft Feed Tube Fastener 84 in-lbs (10 N·m)

Lower Fairing Bracket Fastener 18 ft-lbs (24 N·m)

Muffler Clamp 40 ft-lbs (54 N·m)

Muffler Fastener 18 ft-lbs (24 N·m)

Oil Filter Adapter Fastener 84 in-lbs (10 N·m)

Oil Pickup Fastener 84 in-lbs (10 N·m)

Oil Pressure Feed tube Fastener 84 in-lbs (10 N·m)

Oil Pressure Switch (2014–2019) 88 in-lbs (10 N·m)

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Oil Pressure Switch (2020+) 11 ft-lbs (15 N·m)

Oil Pump Fastener 84 in-lbs (10 N·m)

Oil Pump Scavenge Tube Fastener 84 in-lbs (10 N·m)

Oil Scavenge Tube Fastener 84 in-lbs (10 N·m)

Oxygen Sensor 14 ft-lbs (19 N·m)

Piston Cooling Jet Fastener 62 in-lbs (7 N·m)

Radiator Mount Fastener 84 in-lbs (10 N·m)

Recovery Bottle Fastener (Lower) 84 in-lbs (10 N·m)

Recovery Bottle Fastener (Upper) 36 in-lbs (4 N·m)

Resonator Mount to Frame Fastener (M8) 18 ft-lbs (24 N·m)

Resonator Mount to Frame Fastener (M6) 84 in-lbs (10 N·m)

Resonator to Resonator Bracket Fastener 18 ft-lbs (24 N·m)

Rocker Shaft Cap Fastener 27 ft-lbs (37 N·m)

Scavenge Oil Inlet Screen Fastener 84 in-lbs (10 N·m)

Sidestand Switch Fastener 43 in-lbs (5 N·m)

Speaker Assembly Fastener 36 in-lbs (4 N·m)

Sprag Clutch Fastener 84 in-lbs (10 N·m)

Stator Fastener 84 in-lbs (10 N·m)

Thermostat Cover Fastener 84 in-lbs (10 N·m)

Thermostat Mounting Bracket Fastener 84 in-lbs (10 N·m)

Transmission Feed Rail Fastener 84 in-lbs (10 N·m)

Valve Cover Fastener 84 in-lbs (10 N·m)

Water Pump Chain Tensioner Fastener 84 in-lbs (10 N·m)
Water Pump Fastener 84 in-lbs (10 N·m)

Water Pump Sprocket Fastener 84 in-lbs (10 N·m)

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CHAPTER 4: FUEL DELIVERY / EFI

ITEM TORQUE 1
Airbox Hatch Cover Fastener 84 in-lbs (10 N·m)

Airbox Filter Cover Fastener 84 in-lbs (10 N·m)

Crankshaft Position Sensor Fastener 84 in-lbs (10 N·m)

Cylinder Head Temperature Sensor 15 ft-lbs (20 N·m)

Fuel Access Plate Fastener (2017+2021) 24 in-lbs (2.7 N·m)

Fuel Access Plate Fastener (2022+) 44 in-lbs (5 N·m)

Fuel Cap Fastener 44 in-lbs (5 N·m)

Fuel Injector Fastener 84 in-lbs (10 N·m)

Fuel Rail Fastener 62 in-lbs (7 N·m)

Fuel Tank Console Fastener 84 in-lbs (10 N·m)

Fuel Tank Mounting Fastener 18 ft-lbs (24 N·m)

Hose Clamp 26 in-lbs (3 N·m)

Ignition Coil Fastener 84 in-lbs (10 N·m)

Ignition Coil Bracket Fastener 84 in-lbs (10 N·m)

Pinion Shaft Retention Fastener 62 in-lbs (7 N·m)

Reed Plate Fastener 62 in-lbs (7 N·m)
Throttle Body Inlet Adapter Fastener 84 in-lbs (10 N·m)

TMAP Sensor Fastener 18 in-lbs (2 N·m)

V-Cover Fastener 84 in-lbs (10 N·m)

V-Cover Bracket Fastener 84 in-lbs (10 N·m)

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CHAPTER 5: CLUTCH / PRIMARY / SHIFT

ITEM TORQUE
Cold Start Cover Fastener 84 in-lbs (10 N·m)

Clutch Stake Nut 125 ft-lbs (170 N·m)

Detent Lever Fastener 84 in-lbs (10 N·m)
Locking Plate Fastener 84 in-lbs (10 N·m)

Primary Cover Fastener (Inner) 84 in-lbs (10 N·m)

Primary Cover Fastener (Outer) 84 in-lbs (10 N·m)

Primary Drive Gear Fastener 83 ft-lbs (112 N·m)

Shift Star Fastener 84 in-lbs (10 N·m)

Stopper Plate Fastener 84 in-lbs (10 N·m)

CHAPTER 6: TRANSMISSION / CRANKSHAFT

ITEM TORQUE
Balance Shaft Gear Fastener 59 ft-lbs (80 N·m)

Balance Shaft Shield Fastener 62 in-lbs (7 N·m)

Balance Shaft Retainer Fastener 84 in-lbs (10 N·m)

Balance Shaft Retainer Plate Fastener 62 in-lbs (7 N·m)

Bearing Retainer Plate Fastener 62 in-lbs (7 N·m)

Crankshaft Blind Plug 15 ft-lbs (20 N·m)

Crankshaft Tone Ring Fastener 18 ft-lbs (24 N·m)

1. Torque to 19 ft-lbs (26 N·m)

Connecting Rod Fastener
2. Torque angle to 105 °

Input Shaft Oil Plug 13 ft-lbs (18 N·m)

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CHAPTER 7: FRAME / BODY

ITEM TORQUE 1
ABS Mount Bracket Fastener (Allen Head) 84 in-lbs (10 N·m)

ABS Mount Bracket Fastener (Hex Head) 84 in-lbs (10 N·m)

Air Deflector Fastener 36 in-lbs (4 N·m)

Cylinder Head Bracket Fastener 75 ft-lbs (102 N·m)

Dash Closeout Fastener 36 in-lbs (4 N·m)

Dash Fastener 25 in-lbs (3 N·m)
Dash Support Fastener 36 in-lbs (4 N·m)

Dash Trim Fastener 36 in-lbs (4 N·m)

Display Bezel Fastener 36 in-lbs (4 N·m)

Enclosure Fastener 36 in-lbs (4 N·m)

Fairing Bracket Nut 18 ft-lbs (24 N·m)

Fairing Support to Downcast Fastener 18 ft-lbs (24 N·m)

Fairing Support to Fairing Bracket Fastener 18 ft-lbs (24 N·m)

Fairing Tray Fastener 36 in-lbs (4 N·m)

Fender Closeout Lower Fastener 84 in-lbs (10 N·m)

Fender Closeout Bracket Fastener 84 in-lbs (10 N·m)

Fender Fastener (Front) 18 ft-lbs (24 N·m)

Fender Fastener (Rear) M6 84 in-lbs (10 N·m)

Fender Fastener (Rear) M8 18 ft-lbs (24 N·m)

Floorboard Base Fastener 18 ft-lbs (24 N·m)

Floorboard Bracket Fastener 35 ft-lbs (47 N·m)

Footpeg Fastener 35 ft-lbs (47 N·m)

Front Downcast Fastener 45 ft-lbs (61 N·m)

Fuel Tank Mount Bracket Fastener 18 ft-lbs (24 N·m)

Fuse Block Mount Bracket Fastener 84 in-lbs (10 N·m)
Grabstrap Fastener 36 in-lbs (4 N·m)

Headlight Bezel Assembly Fastener 36 in-lbs (4 N·m)

Headlight Fastener (Torx) 36 in-lbs (4 N·m)

Headlight Bracket Fastener 36 in-lbs (4 N·m)

Highway Bar Fastener 45 ft-lbs (61 N·m)

Hinge Cover Fastener 36 in-lbs (4 N·m)

Inner Duct Fastener 15 in-lbs (2 N·m)

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Latch Hoop Fastener 36 in-lbs (4 N·m)

Leaf Hinge Fastener 36 in-lbs (4 N·m)

Limiter Fastener 15 in-lbs (2 N·m)

Lower Side Cover Accent Fastener 84 in-lbs (10 N·m)

Midcast Fastener (M12) 75 ft-lbs (102 N·m)

Midcast Fastener (M10) 35 ft-lbs (47 N·m)

Outer Duct Fastener 36 in-lbs (4 N·m)

Outer Fairing Fastener 36 in-lbs (4 N·m)

Pivot Shaft 50 ft-lbs (68 N·m)

Power Supply Fastener 84 in-lbs (10 N·m)

Rear Lower Subframe Fastener 18 ft-lbs (24 N·m)

Ride Command Display Fastener 36 in-lbs (4 N·m)

Saddlebag Fastener 18 ft-lbs (24 N·m)

Saddlebag Lock Fastener 62 in-lbs (7 N·m)

Saddlebag Mount Fastener 84 in-lbs (10 N·m)

Saddlebag Spool Fastener 32 ft-lbs (43 N·m)

Seat Bracket Fastener 52 in-lbs (6 N·m)

Seat Fastener 18 ft-lbs (24 N·m)

Seat Pan Fastener 84 in-lbs (10 N·m)

Shift Linkage Fastener 84 in-lbs (10 N·m)

Sidestand Stop Bracket Fastener 84 in-lbs (10 N·m)

Speaker Fastener 25 in-lbs (3 N·m)

Sprocket Cover Fastener 84 in-lbs (10 N·m)

Storage Door Fastener 36 in-lbs (4 N·m)

Tipover Cover Fastener 18 ft-lbs (24 N·m)

Trunk to Frame Fastener 12 in-lbs (1 N·m)

Trunk to Frame Arm Fastener 12 in-lbs (1 N·m)
Truck Lock Fastener 12 in-lbs (1 N·m)
Trunk Luggage Rack Fastener 88 in-lbs (10 N·m)
Trunk Latch Hoop Fastener 36 in-lbs (4 N·m)

Trunk Bezel Fastener 12 in-lbs (1 N·m)

Trunk Tail light Fastener 12 in-lbs (1 N·m)

Trunk Speaker Fastener 36 in-lbs (4 N·m)

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Turn Signal Bezel Fastener 15 in-lbs (2 N·m)

Turn Signal Fastener 15 in-lbs (2 N·m)

1
Under-Seat Wire Bracket Fastener 84 in-lbs (10 N·m)
Upper Duct Fastener 15 in-lbs (2 N·m)
Visor Top Fastener 36 in-lbs (4 N·m)

VCM2 Fastener 15 in-lbs (2 N·m)

Wire Cover Fastener 15 in-lbs (2 N·m)

Wire Guide Fastener (Lower) 15 in-lbs (2 N·m)

Wire Guide Fastener (Upper) 15 in-lbs (2 N·m)

Windshield Fastener 36 in-lbs (4 N·m)

Windshield Support to Link Fastener 84 in-lbs (10 N·m)

Windshield Support to Motor Fastener 84 in-lbs (10 N·m)

Windshield Link to Pivot Fastener 84 in-lbs (10 N·m)

Windshield Motor Fastener 84 in-lbs (10 N·m)

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CHAPTER 8: STEERING / SUSPENSION

ITEM TORQUE
Axle Nut (Rear) 65 ft-lbs (84 N·m)

Belt Guard Fastener 96 in-lbs (11 N·m)

Cartridge Screw 17 ft-lbs (23 N·m)

Clutch Cable Routing Clip Fastener 84 in-lbs (10 N·m)

Clutch Perch Fastener 96 in-lbs (11 N·m)

Drive Sprocket Lock Washer Fastener 84 in-lbs (10 N·m)

Drive Sprocket Nut 165 ft-lbs (224 N·m)

Fork Cap Nut 12 ft-lbs (16 N·m)

Fork Cap 17 ft-lbs (23 N·m)

Front Axle 52 ft-lbs (70 N·m)

Front Axle Pinch Fastener 19 ft-lbs (26 N·m)

Gusset Plate Fastener 96 ft-lbs (130 N·m)

Handlebar Riser Clamp Fastener 18 ft-lbs (24 N·m)

Handlebar Riser Fastener (M12) 60 ft-lbs (81 N·m)

Lower Fork Clamp Fastener 18 ft-lbs (24 N·m)

P-clamp Fastener 84 in-lbs (10 N·m)

Rocker Fastener 96 ft-lbs (130 N·m)

Seat Fastener 18 ft-lbs (24 N·m)

Shock Air Line Jam Nut 20 ft-lbs (27 N·m)

Shock Adjuster Bracket Mount Fastener M8 18 ft-lbs (24 N·m)

Shock Adjuster Bracket Mount Fastener M6 96 in-lbs (11 N·m)
Shock Adjuster Fastener 18 ft-lbs (24 N·m)
Shock Fastener (2017-2019) 55 ft-lbs (75 N·m)

Shock Fastener (2020+) 96 ft-lbs (130 N·m)

1. Torque to 29 ft-lbs (39 N·m)

2. Turn assembly lock to lock 5 times
Steering Head Nut
3. Loosen 60 °
4. Install Triple clamp and tighten top nut 72 ft-lbs
(98 N·m)

Steering Lock Fastener 18 ft-lbs (24 N·m)

Swing-Arm Pivot Shaft 96 in-lbs (11 N·m)

Swing-Arm Pivot Jam Nut 75 ft-lbs (101 N·m)

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Swing-Arm Pivot Nut (Nylock) 65 ft-lbs (88 N·m)

Switch Cube Cover Fastener 12 in-lbs (1 N·m) 1

Switch Cube Fastener 12 in-lbs (1 N·m)

Tire Pressure Sensor Fastener 72 in-lbs (8 N·m)

Top Triple Clamp Nut 72 ft-lbs (98 N·m)

Upper Fork Clamp Fastener (All except Springfield 18 ft-lbs (24 N·m)

Fork Clamp Fastener (Springfield) 23 ft-lbs (31 N·m)

Valve Stem Nut 53 in-lbs (6 N·m)

CHAPTER 9: BRAKES
ITEM TORQUE
ABS Module Fastener 84 in-lbs (10 N·m)
Banjo Bolt 18 in-lbs (25 N·m)

Bleed Screw 53 in-lbs (6 N·m)

Brake Caliper Fastener (Front) 35 ft-lbs (47 N·m)

Brake Caliper Fastener (Rear) 31 ft-lbs (42 N·m)

Brake Caliper Retainer Fastener (Rear) 20 ft-lbs (27 N·m)

Brake Lever Pivot (Front) 52 in-lbs (6 N·m)

Brake Pad Retaining Pin (Front) 53 in-lbs (6 N·m)

Brake Pad Retaining Pin (Rear) 120 in-lbs (14 N·m)

Brake Rotor Screw 22 ft-lbs (30 N·m)

Junction Block Fastener 84 in-lbs (10 N·m)

Master Cylinder Banjo Bolt 18 ft-lbs (25 N·m)

Master Cylinder Clamp Fastener (Front) 96 in-lbs (11 N·m)

Master Cylinder Cover Fastener (Front) 15 in-lbs (2 N·m)

Master Cylinder Cover Fastener (Rear) 15 in-lbs (2 N·m)

Master Cylinder Fastener (Rear) 18 ft-lbs (24 N·m)

Under-Seat Bracket Fastener 84 in-lbs (10 N·m)

CHAPTER 10: ELECTRICAL

ITEM TORQUE
Battery Box Fastener 18 ft-lbs (24 N·m)

Cell Modem Fastener 36 in-lbs (4 N·m)

Clutch Switch Fastener 6 in-lbs (1 N·m)

Clutch Switch Cover Fastener 6 in-lbs (1 N·m)

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Drive Sprocket Shield Fastener 88 in-lbs (10 N·m)

Gear Position Sensor Fastener 44 in-lbs (5 N·m)

Headlight Carrier Fastener 12 in-lbs (1 N·m)

Headlight Retention Ring Fastener 12 in-lbs (1 N·m)

Headress Fastener 36 in-lbs (4 N·m)

Horn Bracket Fastener 84 in-lbs (10 N·m)
IMU Fastener 84 in-lbs (10 N·m)
J-Case / Voltage Regulator Fastener 84 in-lbs (10 N·m)

License Plate Bracket Fastener 84 in-lbs (10 N·m)

License Plate Light Assembly Fastener 84 in-lbs (10 N·m)

License Plate Light Fastener 16 in-lbs (2 N·m)

Puddle Light Fastener 84 in-lbs (10 N·m)

Stator Cover Fastener 84 in-lbs (10 N·m)

Stator Fastener 84 in-lbs (10 N·m)

Starter Mount Fastener 84 in-lbs (10 N·m)

Starter Solenoid Fastener 84 in-lbs (10 N·m)

Starter Solenoid Terminal Fastener 44 in-lbs (5 N·m)

Starter Terminal Fastener 84 in-lbs (10 N·m)

Tail Light Mount Bracket Fastener 84 in-lbs (10 N·m)

Turn Signal Fastener (Front) 15 in-lbs (2 N·m)

Turn Signal Fastener (Rear) 84 in-lbs (10 N·m)

VCM 1 Fastener 84 in-lbs (10 N·m)

VCM 2 Fastener 15 in-lbs (2 N·m)

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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
THREAD SIZE / DRILL THREAD SIZE / DRILL
DRILL
DECIMAL NEAREST 1
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

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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
3/16 in = .1875 in [5 mm = .1969 in] 25/32 in = .7813 in [20 mm = .7874 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
17/64 in = .2656 in [7 mm = .2756 in] 55/64 in = .8594 in [22 mm = .8661 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
11/32 in = .3438 in [9 mm = .3543 in] 15/16 in = .9375 in [24 mm = .9449 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

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FA H R E N H E I T T O C E L S I U S
oC to oF: 9 (oC + 40) ¸ 5 - 40 = oF 1
oF to oC: 5 (oF + 40) ¸ 9 - 40=oC

DEGREES F DEGREES C
32 0
41 5
50 10
59 15
68 20
77 25
86 30
95 35
104 40
113 45
122 50
131 55
140 60
149 65
158 70
167 75
176 80
185 85
194 90
203 95
212 100

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MEASUREMENT CONVERSION CHART UNIT OF MULTIPLIED

COVERTS TO
MEASURE BY
UNIT OF MULTIPLIED
COVERTS TO
MEASURE BY Pounds force
= Kilo pascals
per square inch x 6.895
ft-lbs x 12 = in-lbs (kPa)
(psi)
in-lbs x.0833 = ft-lbs
= Pounds force
ft-lbs x 1.356 = Nm Kilo pascals
x .145 per square inch
(kPa)
in-lbs x.0115 = kg-m (psi)

Nm x.7376 = ft-lbs Kilo pascals = Kilograms

(kPa) x .01 force per cm2
kg-m x 7.233 = ft-lbs
Kilograms force = Kilo pascals
kg-m x 86.796 = in-lbs per cm2 x 98.1 (kPa)
kg-m x 10 = Nm = Cylinder
p (3.14159) x R2 x H (height)
Volume
in x 25.4 = mm
mm x.03937 = in
in x 2.54 = cm
mile x 1.6 = km
km x.6214 = mile
Ounces (oz) x 28.35 = grams (g)
Fluid Ounce x 29.57 = CCs
grams (g) x.035 = Ounces (oz)
= Fluid Ounces
cc’s x.03381 (oz)

lbs x.454 = kg
kg x 2.2046 = lbs
= Cubic
Cubic Inches x 16.387
Centimeters
Cubic
x.061 = Cubic Inches
Centimeters
Imperial pints x.568 = liters (l)
liters (l) x 1.76 = Imperial pints
Imperial quarts x 1.137 = liters (l)
= Imperial
liters (l) x.88 quarts
Imperial quarts x 1.201 = US quarts
= Imperial
US quarts x.833 quarts
US quarts x.946 = liters
liters x 1.057 = US quarts
US gallon x 3.785 = liter
liter x .264 = US gallon

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CHAPTER 2
MAINTENANCE
2
MAINTENANCE QUICK REFERENCE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
SPECIFICATIONS - MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
INDIAN MOTORCYCLE SERVICE PRODUCTS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
MAINTENANCE INTERVAL CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
BREAK-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
AIR FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
ENGINE OIL & FILTER CHANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
111 C.I. CRANKCASE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
ENGINE OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
IDLE SPEED / FAST IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
TIRE PRESSURE / SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
CLUTCH CABLE INSPECTION / LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29
CLUTCH LEVER LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
CLUTCH LEVER FREE PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
FRONT BRAKE LEVER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
FRONT BRAKE LEVER LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
FRONT BRAKE LEVER REACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
BRAKE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
BRAKE PEDAL LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
SHIFT PEDAL INSPECTION / LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33
SHIFT PEDAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34
BRAKE FLUID LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35
FRONT BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
REAR BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
CRANKCASE VENTILATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
FUEL TANK VENT INSPECTION (49 STATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA AND INTERNATIONAL MODELS) . . . . . .2.38
FUEL SUPPLY HOSE (FUEL RAIL) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39
SPARK PLUG REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.40
SPARK PLUG INSPECTION / GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.40
SPARK PLUG INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.41
ENGINE COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.41
ENGINE COMPRESSION TEST (WET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.42
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.42
BATTERY CHARGING AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.43
BATTERY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.46
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.47

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DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.48

DRIVE BELT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.49
DRIVE BELT TENSION MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.50
DRIVE BELT TENSION - SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.51
DRIVE BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.52
SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.53
FUSE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.54
HEADLIGHT AIM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.55
HEADLIGHT AIM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.56
SIDESTAND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.57
SIDESTAND REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.57
STEERING HEAD / FRONT WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.59
SWINGARM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.59
REAR SHOCK PRELOAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.60
REAR SHOCK PRELOAD ADJUSTMENT - (2017-19) CHIEF MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.61
REAR SHOCK PRELOAD ADJUSTMENT - AIR SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.62
SHOCK ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.65
MAINTENANCE - CHECK WHEEL SPOKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.66

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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
—
2
Battery Type / CCA 12 Volt / 18 AH / 310 CCA
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) 54 psi (372 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: 36 PSI (248 kPa)
REAR: —
Tire Pressure 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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FLUID SPECIFICATIONS

DESCRIPTION FLUID TYPE CAPACITY

Brake Hydraulic Fluid DOT 4 —

5.5 Qts (5.2 L) with filter at oil change

= Engines build BEFORE January, 2019
Engine / Transmission Oil Semi-Synthetic 20W40 Engine Oil
6.0 Qts (5.7 L) with filter at oil change
= Engines build AFTER January, 2019
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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INDIAN MOTORCYCLE SERVICE PRODUCTS AND LUBRICANTS

MAINTENANCE PRODUCT PART NUMBERS

PRODUCT PART NUMBER

All Purpose Grease 14 oz 2872187 2
Anti-Freeze, 50/50 Extended Life (Scout) 1 quart (32 oz) 2880966
Brake Fluid, DOT 4 12 oz 2880016
Carbon Cleaner, Fuel 12 oz 2881911
Crankcase Sealant (Loctite Ultra Black 598) Commercially Available
Fork Oil quart 2880015
Starter Grease 2 oz 2871460
Oil Change Kit (Thunder Stroke Engines) 20W-40 2880067
Oil Change Kit (Scout/Thunder Stroke Engines) 15W-60 2880191

Synthetic 15W-60 Engine Lubricant (Scout/Thunder quart 2880187

Stroke Engines) 55 gal drum 2880188

Semi-Synthetic 20W-40 Engine Lubricant (Thunder quart 2880012

Stroke Engines) 55 gal drum 2880013

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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

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 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 Crankcase Ventilation System Inspect; tighten, clean, adjust

Damper, Cushion Drive

Visual inspection for cracks or deformation is required whenever the rear
wheel is removed. Replace if damage is found.
2
D Drive Belt Inspect; tighten, clean, adjust
E Evaporative Emission Control System Inspect; clean
E Exhaust System Inspect; tighten, adjust
D Fuel System Inspect; clean
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 Cable Freeplay Inspect; adjust if necessary
D Fasteners Inspect; tighten if necessary
D Front Brake Lever Inspect; adjust if necessary, lubricate with proper lubricant as directed
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 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 Inspect; adjust if necessary, 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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5,000 MILES (8,000 KM) SERVICE

CODE ITEM ACTION

XU Air Filter Inspect; clean
D Crankcase Ventilation System 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 Drive Belt Inspect; tighten, clean, 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
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 Inspect; adjust if necessary
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 Replace at specified interval or every 2 years
D Front Forks and Front Axle Inspect; adjust if necessary
D Gear Shift Pedal Inspect; adjust if necessary
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 Inspect; adjust if necessary, 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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10,000 MILES (16,000 KM) SERVICE

CODE ITEM ACTION

XU Air Filter Replace
D Crankcase Ventilation System Inspect; tighten, clean, adjust

Damper, Cushion Drive

Visual inspection for cracks or deformation is required whenever the rear
wheel is removed. Replace if damage is found.
2
D Drive Belt Inspect; tighten, clean, adjust
D Engine Compression Inspect; correct if necessary
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
D Oil Lines / Oil System Inspection Inspect; clean, adjust if necessary
D/E Spark Plugs Inspect; torque to specification
Battery Check terminals; clean; test
D Brake Fluid Replace (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 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 Replace at specified interval or every 2 years
D Front Forks and Front Axle Inspect; adjust if necessary
D Gear Shift Pedal Inspect; adjust if necessary
D Gear Position Switch Inspect; clean. See “GEAR POSITION SWITCH REPLACEMENT”
D Head Light Inspect; adjust if necessary
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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15,000 MILES (24,000 KM) SERVICE

CODE ITEM ACTION

XU Air Filter Inspect; clean
D Crankcase Ventilation System 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 Drive Belt Inspect; tighten, clean, 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
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 Inspect; adjust if necessary
D Clutch Cable Freeplay Inspect; adjust if necessary
D Control Cable Ends Inspect; adjust if necessary
D Fasteners Inspect; tighten if necessary
D Front Brake Lever Adjust if necessary, lubricate with proper lubricant as directed
D Front Fork Oil Replace
D Front Forks and Front Axle Inspect; adjust if necessary
D Gear Shift Pedal Inspect; adjust if necessary
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 Inspect; adjust if necessary, 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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20,000 MILES (32,000 KM) SERVICE

CODE ITEM ACTION

XU Air Filter Replace
D Crankcase Ventilation System Inspect; tighten, clean, adjust

Damper, Cushion Drive

Visual inspection for cracks or deformation is required whenever the rear
wheel is removed. Replace if damage is found.
2
D Drive Belt Inspect; tighten, clean, adjust
D Engine Compression Inspect; correct if necessary
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
D Oil Lines / Oil System Inspection Inspect; clean, adjust if necessary
D/E Spark Plugs Inspect; torque to specification
Battery Check terminals; clean; test
D Brake Fluid Replace (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 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 Gear Position Switch Inspect; clean. See “GEAR POSITION SWITCH REPLACEMENT”
D Head Light Inspect; adjust if necessary
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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25,000 MILES (40,000 KM) SERVICE

CODE ITEM ACTION

XU Air Filter Inspect; clean
D Crankcase Ventilation System 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 Drive Belt Inspect; tighten, clean, 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
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 Inspect; adjust if necessary
D Clutch Cable Freeplay Inspect; adjust if necessary
D Control Cable Ends Inspect; adjust if necessary
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 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 Inspect; adjust if necessary, 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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30,000 MILES (48,000 KM) SERVICE

CODE ITEM ACTION

XU Air Filter Replace
D Crankcase Ventilation System Inspect; tighten, clean, adjust

Damper, Cushion Drive

Visual inspection for cracks or deformation is required whenever the rear
wheel is removed. Replace if damage is found.
2
D Drive Belt Replace
D Engine Compression Inspect; correct if necessary
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
D Oil Lines / Oil System Inspection Inspect; clean, adjust if necessary
D/E Spark Plugs Replace
Battery Check terminals; clean; test
D Brake Fluid Replace (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 Lubricate with proper lubricant as directed
D Fasteners Inspect; tighten if necessary
D Front Brake Lever Lubricate with proper lubricant as directed
D Front Fork Oil Replace
D Front Forks and Front Axle Inspect; adjust if necessary
D Gear Shift Pedal Inspect; adjust if necessary
D Gear Position Switch Inspect; clean. See “GEAR POSITION SWITCH REPLACEMENT”
D Head Light Inspect; adjust if necessary
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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35,000 MILES (52,000 KM) SERVICE

CODE ITEM ACTION

XU Air Filter Inspect; clean
D Crankcase Ventilation System 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 Drive Belt Inspect; tighten, clean, 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
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 Inspect; adjust if necessary
D Clutch Cable Freeplay Inspect; adjust if necessary
D Control Cable Ends Inspect; adjust if necessary
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 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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40,000 MILES (64,000 KM) SERVICE

CODE ITEM ACTION

XU Air Filter Replace
D Crankcase Ventilation System Inspect; tighten, clean, adjust

Damper, Cushion Drive

Visual inspection for cracks or deformation is required whenever the rear
wheel is removed. Replace if damage is found.
2
D Drive Belt Inspect; tighten, clean, adjust
D Engine Compression Inspect; correct if necessary
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
D Oil Lines / Oil System Inspection Inspect; clean, adjust if necessary
D/E Spark Plugs Inspect; torque to specification
Battery Check terminals; clean; test
D Brake Fluid Replace (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 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 Gear Position Switch Inspect; clean. See “GEAR POSITION SWITCH REPLACEMENT”
D Head Light Inspect; adjust if necessary
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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45,000 MILES (72,000 KM) SERVICE

CODE ITEM ACTION

XU Air Filter Inspect; clean
D Crankcase Ventilation System 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 Drive Belt Inspect; tighten, clean, 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
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 Lubricate with proper lubricant as directed
D Front Fork Oil Replace
D Front Forks and Front Axle Inspect; adjust if necessary
D Gear Shift Pedal Inspect; adjust if necessary
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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50,000 MILES (80,000 KM) SERVICE

CODE ITEM ACTION

XU Air Filter Replace
D Crankcase Ventilation System Inspect; tighten, clean, adjust

Damper, Cushion Drive

Visual inspection for cracks or deformation is required whenever the rear
wheel is removed. Replace if damage is found.
2
D Drive Belt Inspect; tighten, clean, adjust
D Engine Compression Inspect; correct if necessary
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
Applies only to fuel pumps built before 11/10/2015.
D Fuel Filter Replacement Fuel pumps built after 11/11/2015 and all 2017 units do not have a
replaceable fuel filter.
D Fuel System Inspect; clean
D Oil Lines / Oil System Inspection Inspect; clean, adjust if necessary
D/E Spark Plugs Inspect; torque to specification
Battery Check terminals; clean; test
D Brake Fluid Replace (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 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 Gear Position Switch Inspect; clean. See “GEAR POSITION SWITCH REPLACEMENT”
D Head Light Inspect; adjust if necessary
D Rear Brake Pedal Inspect; adjust if necessary
D Rear Shock Absorber Replace
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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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- 2
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
NOTICE Change the engine oil at the intervals specified in the
Periodic Maintenance Table beginning on
If the motorcycle is operated in wet or dusty Maintenance Interval Chartpage 2.6. 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.
filter when necessary.
NOTICE
1. Remove air box cover fasteners q and air box Depending on build date, engines will vary in the
cover w. amount of oil to reach the appropriate fill level. To
determine how much oil the engine requires, refer to
the 111 C.I. CRANKCASE INFORMATIONpage 2.22.

NOTICE
Failure to perform frequent oil changes during cold
weather operation can result in condensation
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.

2. Remove three fasteners e securing air filter IMPORTANT

element r to air box backing plate and remove Engine MUST BE WARM while performing the
filter. following procedure.

WARNING
HOT COMPONENTS Wear insulated gloves and/
or allow engine and exhaust to cool before
handling these parts.

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. 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 : 84 in-lbs (10 N·m)

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3. Clean the area around the scavenge area drain 14. Stop the engine and add the additional 1 - 1.5 qts.
plug q and the storage area drain plug w. Place a (0.95 - 1.42 L) of engine oil. Do not add oil if oil
drain pan under both drain plugs. 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 2
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 Checkpage 2.24.

CAUTION
After an oil change, the low oil pressure indicator
may illuminate when the engine is started. If this
4. Remove the drain plugs. Allow the oil to drain occurs, do not increase RPM above idle speed until
completely. the indicator turns off. Operating above idle speed
could result in damage to the engine.
5. Install new sealing washers on the drain plugs. The
sealing surfaces on drain plugs and engine should
be clean and free of burrs, nicks or scratches. 16. Dispose of used filter and oil properly.
6. Reinstall the drain plugs. Torque to specifications. 17. Check for leaks around drain plug and oil filter.

TORQUE NOTICE
Drain Plugs: Recycle used oil and oil filter in accordance with
15 ft-lbs (20 N·m) local regulations.

7. Place oil pan beneath the oil filter. Using an oil 18. CHIEFTAIN MODELS / ROADMASTER: Reset the oil
filter wrench, turn the filter counter-clockwise to change life in the instrument gauge.
remove it.
8. Using a clean dry cloth, clean the filter sealing
surface on the engine.
9. 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.
10. 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.
11. Remove the dipstick. Add only 4.5 qts. (4.25 l) of
the recommended oil at this step. Do not overfill.
12. Reinstall the dipstick securely.
13. With the motorcycle in an upright, centered
position, start the engine and idle for 30 seconds.

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1 1 1 C . I . C R A N K C A S E I N F O R M AT I O N
S E R V I C E PA R T S
Permanent Mold (PM) crankcases will become obsolete once remaining service inventory is depleted. There will
be a new High-Pressure Die cast Version 1 (HPDC v1) service kit (2208414) that should be used to service all 111
C.I. engines MY14–2019. The service kit includes parts and instructions necessary to make the conversion.

ENGINE OIL
VISCOSITY:
Indian Motorcycle engineering has validated the use of 15W60 oil across MY14+ 111 & 116 C.I. engine platforms.
The use of 15W60 has been shown to improve cold-start performance and cold-weather shifting.
SERVICE FILL CAPACITY:
The timeline below identifies oil fill capacity by motorcycle production date. All Permanent Mold (PM) crankcase
engines MY14–19.5 have an service fill volume of 5.5 quarts following oil and filter change. All High-Pressure Die
cast crankcase engines MY19.5+ have a service oil volume of 6.0 quarts following oil and filter change.

REFERENCE
VIN/PIN STICKER DIP STICK THREAD O.D.

Locate the VIN/PIN sticker on the left side of the headtube

and find the DATE MFD.

22 mm (0.87 in) OR 30 mm (1.18 in)

MANUFACTURE DATE
2014 – January 22, 2019 January 23, 2019 – July 28, 2019 July 29, 2019 – Current
High-Pressure Die cast Version 1 High-Pressure Die cast Version 2
Permanent Mold (PM)
(HPDC v1) (HPDC v2)

• Oil Fill Capacity: • Oil Fill Capacity: • Oil Fill Capacity:

5.5 quarts 6.0 quarts 6.0 quarts
• Dip Stick Thread O.D. : • Dip Stick Thread O.D. : • Dip Stick Thread O.D. :
22 mm (0.87 in) 30 mm (1.18 in) 30 mm (1.18 in)
• Gear Position Switch: • Gear Position Switch: • Gear Position Switch:
PN:4014718 PN:4014718 PN:4018619

SELF HELP
For additional details on the oil check, change, and fill processes, visit the Indian Motorcycle Help Center:
www.indianmotorcycle.com/help and search “Oil Change”.

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ENGINE OIL LEVEL CHECK 6. Add the recommended oil as needed to bring the
level between the ADD and FULL marks. Do not
NOTICE
add oil if between the ADD and FULL marks.
Depending on build date, engines will vary in the
amount of oil to reach the appropriate fill level. To NOTICE
determine how much oil the engine requires, refer to The approximate volume between the FULL w and
the 111 C.I. CRANKCASE INFORMATIONpage 2.22. ADD e marks on the dipstick is 32 oz. (.94 L).

With the semi-dry sump lubrication system, the

engine oil level on the dipstick will fluctuate,
depending on the motorcycle’s position and engine
temperature when checked. To ensure a proper
reading of the engine oil level, follow all inspection
procedures closely.

WARNING
Operating with insufficient, deteriorated or
contaminated engine oil will cause accelerated wear
and may result in engine or transmission seizure,
which could result in loss of control and serious
injury or death. Check the oil level frequently.

Always check the oil after running a cold engine at

idle for 30 seconds. The oil fill/dipstick is located on 7. Reinstall the dipstick securely.
the left side of the motorcycle. Always use the
recommended oil. CAUTION
1. Position the motorcycle on level ground in the fully Oil level will NOT be accurate if checked on a cold
upright and centered position. engine. DO NOT ADD oil to bring to FULL mark on a
cold engine, as this can result in overfilling.
2. Start the engine (from cold) and allow it to idle for
30 seconds. Stop the engine.
3. Remove the dipstick q and wipe it clean.
I D L E S P E E D / FA S T I D L E S P E E D
NOTICE
Idle speed is continuously monitored and adjusted
by the ECM.

4. Thread the dipstick until fully seated.

5. Remove the dipstick and view the oil level.
NOTICE
Do not overfill. Overfilling can result in loss of engine
performance and an oil-saturated air filter. Use a
suction device to remove excess oil if overfilled.

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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
WARNING
Indian motorcycles are produced using the
designated tires listed below as original equipment.
This includes field testing to ensure stability and
superior handling. The use of tires other than original 2
equipment may cause instability. See Steering /
Suspension chapter for a review of all tire related
Warnings.

1. Inspect tires for weather checking, cuts, imbedded

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)

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T I R E P R E S S U R E TA B L E ( C O L D ) NOTICE
Also refer to Manufacturing Information label.

2017–18 CHIEF CLASSIC

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

2017–19 CHIEF DARK HORSE

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

2020 CHIEF DARK HORSE

FRONT: Dunlop American Elite (130/80 B17) 36 PSI(248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

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

CHIEF VINTAGE DARK HORSE

FRONT: Metzeler Cruisetec (130/80-B17) 36 PSI (248 kPa)
REAR: Metzeler Cruisetec (180/60-R16) 40 PSI (276 kPa)

2017–19 SPRINGFIELD
FRONT: Dunlop Elite 3 (130/90 B16) 46 PSI (317 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2020 SPRINGFIELD
FRONT: Dunlop American Elite (130/80 B17) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2021 SPRINGFIELD
FRONT: Metzeler Cruisetec (130/80-B17) 36 PSI (248 kPa)
REAR: Metzeler Cruisetec (180/60-R16) 41 PSI (283 kPa)

2018–19 SPRINGFIELD DARK HORSE

FRONT: Dunlop Elite 3 (130/60 B19) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2020 SPRINGFIELD DARK HORSE

FRONT: Dunlop American Elite (130/60 B19) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2021 SPRINGFIELD DARK HORSE

FRONT: Metzeler Cruisetec (130/60-B19) 36 PSI (248 kPa)
REAR: Metzeler Cruisetec (180/60-R16) 41 PSI (283 kPa)

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2015–17 CHIEFTAIN
FRONT: Dunlop Elite 3 (130/60 B19) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2018–20 CHIEFTAIN CLASSIC

FRONT: Dunlop Elite 3 (130/90 B16) 36 PSI (248 kPa) 2
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2018–20 CHIEFTAIN
FRONT: Dunlop American Elite (130/60 B19) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2021 CHIEFTAIN MODELS

FRONT: Metzeler Cruisetec (130/60-B19) 36 PSI (248 kPa)
REAR: Metzeler Cruisetec (180/60-R16) 41 PSI (283 kPa)

2017–19 CHIEFTAIN DARK HORSE

FRONT: Dunlop Elite 3 (130/90 B16) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2020 CHIEFTAIN DARK HORSE

FRONT: Dunlop American Elite (130/60 B19) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

CHIEFTAIN LIMITED / ELITE

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

ROADMASTER
FRONT: Dunlop Elite 3 (130/90 B16) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2021 ROADMASTER
FRONT: Metzeler Cruisetec (130/80-B17) 36 PSI (248 kPa)
REAR: Metzeler Cruisetec (180/60-R16) 41 PSI (283 kPa)

ROADMASTER CLASSIC
FRONT: Dunlop Elite 3 (130/90 B16) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2020 ROADMASTER DARK HORSE

FRONT: Dunlop American Elite (130/60 B19) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2021 ROADMASTER DARK HORSE / LIMITED

FRONT: Metzeler Cruisetec (130/60-B19) 36 PSI (248 kPa)
REAR: Metzeler Cruisetec (180/60-R16) 41 PSI (283 kPa)

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CLUTCH CABLE INSPECTION / 3. Remove lower cable guide fastener w and E-clip
L U B R I C AT I O N 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 Chartpage 2.6.

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 (10 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.

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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 / Lubricationpage
2.29.
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 Playpage 2.30.

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 (5.4 Nm)

7. Slide adjuster boot back over adjuster assembly.

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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 Lubricationpage 2.31.
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
Precautionspage 9.21.

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.

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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
• Pull lever forward (away from hand grip) and hold. Chartpage 2.6.
• 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
Precautionspage 9.21. and inner wave washer from post.

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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 Adjustmentpage
2.34.
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), Installationpage 7.24.
10. Depress brake pedal to verify proper operation
and pedal feel. Bleed brakes if necessary. See
Brake Fluid Replacement & Bleeding
Precautionspage 9.21.

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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:
84 in-lbs (9.5 Nm)

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.

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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 (1.6 Nm)
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.

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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 (0.8 Nm) 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 Replacementpage 9.25 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.

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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 Replacementpage 9.26.

1. Place the motorcycle in an upright position with the

front wheel clamped in a wheel vise.
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.

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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)

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F U E L S U P P LY H O S E ( F U E L R A I L )
INSPECTION
1. The fuel supply 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 2
deterioration, damage, leakage, or kinked areas.
Inspect fuel supply line-to-fuel rail connection e
for signs of leakage.

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.

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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

The front spark plug can be removed without having Removalpage 2.40.
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.

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S PA R K P L U G I N S TA L L AT I O N 3. Remove the LH upper side cover to access the fuse

1. Inspect spark plug gap with a wire gauge. If gap box q.
adjustment is necessary, bend ground electrode
See Side Cover (Upper), Removal /
carefully using a spark plug gap tool.
Installationpage 7.22.
Spark Plug Type: DCPR8E
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:
12.7 ft-lbs (17.2 Nm)

CAUTION
Do not over tighten spark plugs. Damage to the 4. Remove the Fuel Pump Relay w to disable fuel
cylinder head or spark plug may result. pump.

4. Install spark plug wire boots securely over the

plugs.

ENGINE COMPRESSION TEST

1. Warm engine to operating temperature.
IMPORTANT
The 111ci engine is equipped with a decompression
system. Due to this system, cranking speed can
greatly affect compression readings. Indian
Motorcycle strongly recommends using the cylinder
leakdown method to determine how well the
combustion chamber is sealing.
5. Disconnect the ignition coil e to disable ignition
2. Shift transmission into neutral and stop engine. system.

6. Disconnect ignition cables from both spark plugs.

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7. Remove spark plug from cylinder to be tested. ENGINE COMPRESSION TEST (WET)
See Spark Plug Removalpage 2.40. IMPORTANT
8. Install compression tester in the spark plug hole The 111ci engine is equipped with a decompression
following manufacturers instructions. system. Due to this system, cranking speed can
9. Open throttle and crank engine until needle on greatly affect compression readings. Indian
compression gauge stops rising (about 5 seconds). Motorcycle strongly recommends using the cylinder
leakdown method to determine how well the
10. Repeat procedure for other cylinder. combustion chamber is sealing.
Specification - Thunder Stroke 111: All Models
1. Pour 3-5 cc of clean engine oil into each cylinder
STD: 90-110 psi (620-758 kPa) through spark plug hole. Repeat cylinder
SERVICE LIMIT: Below 80 psi (552 kPa) compression test. See Engine Compression
Testpage 2.41.
High engine compression may indicate:
2. If compression increases substantially, inspect
• Carbon deposits in combustion chamber cylinder, piston, and rings.

• Engine modification 3. If compression does not increase, inspect valves

and valve seats.
• Faulty Gauge

Low engine compression may indicate: B AT T E R Y

This motorcycle is equipped with a maintenance free
• Slow starter motor cranking speed battery which is located under the seat. DO NOT
• Carbon or foreign material on valve seat remove cell caps or add distilled water to the battery.
If the battery discharges, refer to Electrical chapter for
• Worn or damaged piston and/or piston rings diagnostic information.
• Leaking exhaust or intake valves
WARNING
• Leaking head gasket
Battery electrolyte is poisonous. It contains sulfuric
• Valve timing incorrect acid. Serious burns can result from contact with skin,
• Non-OEM camshafts or faulty gauge eyes or clothing. Antidote:
External: Flush with water.
If cylinder compression is below specification, Internal: Drink large quantities of water or milk.
perform a cylinder leakage test to determine where Follow with milk of magnesia, beaten egg, or
the leak is occurring. Follow the instructions provided vegetable oil. Call physician immediately.
with the leakdown tester. Eyes: Flush with water for 15 minutes and get prompt
medical attention.
Batteries produce explosive gases. Keep sparks,
flame, cigarettes, etc. away. Ventilate when charging
or using in an enclosed space. Always shield eyes
when working near batteries. KEEP CHILDREN
AWAY FROM BATTERY.

CAUTION
Whenever removing the battery, disconnect the
negative (black) cable first. When reinstalling the
battery, connect the negative (black) cable last.
Do not remove the battery cables while the engine is
running. Doing so may damage the Electronic
Control Module (ECM).
Take great care NOT to reverse the battery leads
when installing the battery.

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B AT T E R Y C H A R G I N G A N D M A I N T E N A N C E A G M B AT T E R Y C H A R G I N G R E C O M M E N D AT I O N S
A G M B AT T E R Y C H A R G E R R E C O M M E N D AT I O N S – LOW CHARGE
The nominal voltage for an Indian Motorcycle battery
Indian Motorcycle recommends using the
is 12.8 Volts when fully charged. The battery will self-
BatteryMINDer® 2012 AGM - 2 AMP battery charger
discharge when disconnected from a vehicle, and will
(PN 2830438) to charge and maintain AGM batteries.
discharge at a faster rate when connected. If the
The charger can be found on the Polaris PG&A website
and ordered in DEX – Item Availability.
battery voltage falls below 12.5V, it should be charged 2
immediately using the recommended battery charger.
Batteries that fall below 12.5V run the risk of sulfation, Listed below are the recommended battery inspection
a condition whereby sulfate crystals form inside the schedules.
battery and significantly reduce performance. AGM
chargers are designed specifically for charging AGM • Batteries which are not connected to a vehicle
type batteries and use high frequency pulses to should be inspected every 60 days. The battery
partially reverse sulfation. must be charged if found to be below 12.5 volts.
• Batteries which are connected to motorcycles
IMPORTANT should be inspected when they arrive at your
The use of non-AGM battery chargers or non-AGM dealership and at least once every month thereafter.
battery tenders may result in a misleading “battery The battery must be charged if found to be below
not found” or “open cell” fault message. Please 12.5 volts.
ensure you are using the recommended AGM
• Showroom bikes used to demonstrate radio, display
charger when charging AGM type batteries.
and infotainment features should be charged daily.
If possible, these bikes should be connected to the
INDIAN MOTORCYCLE RECOMMENDED AGM recommended battery charger continuously.
B AT T E R Y T E S T I N G P R O C E D U R E : Always use the recommended automatic battery
1. Test battery using the battery tester PU-50296. charger, and wait for the charger to complete the
charge cycle before disconnecting it.
2. If the tester indicates a test result other than “Good
Battery,” follow the steps below before replacing
the battery:
a. Connect battery to the recommended battery
charger. If charging sequence begins as
normal, fully charge battery and proceed to
step 3.
The time listed on the PU-50296 battery tester
printout is an estimate. The recommended
automatic charger will indicate when the
battery is fully charged on its display.
b. If charging sequence does not initialize, refer to
AGM Battery Charging Recommendations –
Deeply Discharged (below 3 volts) to attempt
to restore the deeply discharged battery. If
charging sequence will not finish as intended,
the battery needs to be replaced.
3. Re-test battery. If the test results show that battery
failed, proceed with battery replacement.

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A G M B AT T E R Y C H A R G I N G R E C O M M E N D AT I O N S
– D E E P LY D I S C H A R G E D ( B E L O W 3 V O LT S )
AGM batteries discharged to a voltage of 3 volts or
less may not be recognized by the recommended
automatic battery charger. (The minimum voltage
threshold recognized by other battery chargers may
be as high as 10.5 volts). Often times deeply
discharged batteries can be restored by attaching
another, fully-charged, battery to “jump start” the low
battery. Follow the steps below to restore a deeply
discharged battery.
1. Carefully connect the two batteries’ positive
terminals, then the negative terminals using
jumper cables.
2. Connect the recommended battery charger to the
low battery and initiate the charging sequence.

WARNING
Always check to ensure the positive cables are
connected to the positive terminals before powering
the charger on. Reversing polarity when charging
can damage electrical components and risk personal
injury. Be careful not to let battery cable clamps
touch each other.

3. After the charging sequence has initiated,

disconnect the fully-charged battery. Always
disconnect the fully-charged battery positive first,
followed by low battery positive, low battery
negative, and finally fully-charged battery negative
4. Proceed with charging both batteries to full
capacity. Listed in the table below are the
approximate charging times for deeply discharged
batteries. Always use the recommended automatic
battery charger, and wait for the charger to
complete the charge cycle before disconnecting it.
The recommended automatic charger will indicate
when the battery is fully charged on its display.
BATTERY CHARGING BATTERY CHARGING
PN TIME CAPACITY RATE

4011496 11 hours 18 AH 2 amps

4014770 8 hours 12 AH 2 amps

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A G M B AT T E R Y M A I N T E N A N C E T I P S 4. Battery connections should be tightened to the

correct torque during installation. This will reduce
1. If the motorcycle will not be driven for more than 2 voltage drop and ensure a reliable connection
weeks, maintaining the battery with the between the regulator/rectifier and battery.
BatteryMINDer® 2012 AGM - 2 AMP charger (PN
2830438) is recommended. 5. The recommended BatteryMINDer® 2012 charger
comes with the mating connector for easy plug and
2. To help prolong battery life, it is recommended to
remove the battery from vehicles stored ONE
play maintenance. 2
month or longer. To maximize the life of stored • Model year 2017–2020 Indian Motorcycles with
batteries, they should be kept in a cool / dry 111 c.i. engines are conveniently equipped with
location. Batteries will self discharge more rapidly a SAE bullet style connector for quick access to
when stored in extreme temperatures. Batteries charging the battery.
should be maintained using the recommended • Model Year 2021 (except Vintage and
battery charger while in storage. Springfield Dark Horse) Indian Motorcycle 111 ci
3. Batteries will self-discharge more quickly when / 116 ci models come with the connector built
dirty. Periodic cleaning of the battery terminals into the console.
using a terminal brush will help maximize battery
life. Wash terminals with a solution of one
tablespoon baking soda and one cup water. Rinse
well with tap water and dry off with clean shop
towels. Coat the terminals with dielectric grease or
petroleum jelly.

2017–2020 2021+
The connector is located behind the left hand side The connector is located on the dash of the
cover and taped back to the chassis harness. Carefully motorcycle, just to the right of the ride command
remove the tape to expose the connector and length of display screen. Flip the cap up to expose the
wire. Be sure to properly secure the wire and connector. Be sure to close the cap when finished
connector before operating the vehicle. charging.

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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 7.26.
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 /
Installationpage 10.62.
4. Remove negative (-) battery terminal fastener and
cable first q .
5. Remove positive (+) battery terminal fastener and
cable last w .

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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.
2
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
torque to specification.

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 /
Installationpage 10.62.
7. Install seat.
See Seat Removal / Installation - All (except
Roadmaster)page 7.26.

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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 Chartpage 2.6.

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 Chartpage 2.6.

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.

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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 Tensionpage 2.50. 2
Chief Dark Horse
Springfield
Chieftain Dark Horse
Chieftain 1.3“ (34 mm) or 11 notches up on belt guard. See Drive Belt Tensionpage 2.50.
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.

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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 Specificationspage 2.49 for
drive belt deflection specifications.

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8. If belt deflects more than the specified distance D R I V E B E LT T E N S I O N - S P E C I F I C AT I O N S

with 10 lbs. of force, tighten the belt. If deflection is
less than specified loosen the belt.
SPECIFICATIONS: DRIVE BELT
See Drive Belt Adjustmentpage 2.52.
BELT DEFLECTION
NOTICE
New drive systems (new vehicle or when belt and
Model Deflection @ 10 lbs force 2
sprockets are replaced) should be set to the tight Chief / Chief Dark
1.1” (28 mm)
side of the specification and inspected after the first Horse / Vintage
500 miles (800 km).
Springfield /
Chieftain / Chieftain 1.3“ (34 mm)
Dark Horse /
Roadmaster
SONIC TENSION DATA
The following data is provided for use with the Gates
507C Sonic Tension Meter or an equivalent. Follow
Steps 1-4 and the instructions included with your
sonic tension meter.
Required Data For Specification
Sonic Tension Meter
Span 719.10mm
Belt Width 24mm
Belt Mass Constant 8.4 g/mm
2017–19 Models
Tension:
Chief / Chief Dark 23 Hz (± 1 Hz)
Horse / Vintage
Tension:
Springfield /
Chieftain / Chieftain 18 Hz (± 1 Hz)
Dark Horse /
Roadmaster
2020+ Models
Tension: 18 Hz (± 1 Hz)
All Models

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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 (20.3 Nm)

5. Turn the RIGHT SIDE adjuster nut r to achieve

proper belt tension
See Drive Belt Tension Measurementpage 2.50.

1. Place the motorcycle in an upright position with the

front wheel clamped in a wheel vise.
2. Make note of adjuster locations q and w.
3. Raise the rear of the motorcycle so the rear tire can
be freely rotated.

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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 Measurementpage 2.50.
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):
65 ft-lbs (88.0 Nm)
8. Rotate the wheel in the FORWARD direction and
verify that sprocket teeth are still visible on both 13. Pump rear brake pedal several times to reset brake
sides of the drive belt t. 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.

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FUSE REPLACEMENT
Fuses and relays are located in the fuse box under
the Left-Hand upper side cover.
1. Remove Left-Hand upper side cover.
See Side Cover (Upper), Removal /
Installationpage 7.22.
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.

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HEADLIGHT AIM INSPECTION MODELS EQUIPPED WITH LED HEADLIGHTS

Adjust headlight aim when there is a change in load
(rider, cargo, accessories, etc.) or after suspension
adjustment.
To determine what headlight your model uses, refer to
2017 Model Specificationspage 1.4 2
2018 Model Specificationspage 1.10
2019 Model Specificationspage 1.16
2020 Model Specificationspage 1.22
2021 Model Specificationspage 1.31

MODELS EQUIPPED WITH INCANDESCENT

HEADLIGHTS NUM- DESCRIPTION
BER
q 3 in (10 cm) to top cut-off of beam

w Measure distance = 25 ft. (7.62 m)

e Headlight Center

With the headlight switched to LOW beam, the top of

the highest intensity (appears as a diamond shape).

NUM- DESCRIPTION
BER
q 7.5 in (19 cm) to center of highest intensity

w Measure distance = 25 ft. 10 in. (7.62 m)

e Headlight Center

With the headlight switched to HIGH beam, the center

of highest intensity (appears as a diamond shape).

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HEADLIGHT INSPECTION PROCEDURE HEADLIGHT AIM ADJUSTMENT

Follow all steps below to ensure accurate aim NOTICE
inspection.
Chieftain / Roadmaster models:
1. Check and adjust the tire pressure to specification. Access headlight adjustment fasteners by removing
See Tire Pressure / Specificationspage 2.25. the headlight bezel. See Headlight Bulb
Replacement - All Modelspage 10.66.
2. Verify suspension ride height (preload) is set to
Classic / Vintage / Dark Horse / Springfield
specification. See Rear Shock Preload
models:
Inspectionpage 2.60.
Headlight adjustment fasteners can be accessed
3. Move the motorcycle to a clear area with a level directly through the headlight nacelle. It is not
floor and dim lighting, and place it so the top front necessary to remove the nacelle for adjustment.
edge of the headlight housing is 25 ft. (7.6 m) from
the wall.
1. To adjust the headlight vertically, both adjustment
4. With the rider and passenger ( if applicable) on fasteners q must be turned in or out equally. Turn
board, bring the motorcycle to a fully upright fasteners in (clockwise) to lower the beam. Turn
position. Center the handlebars in a straight ahead fasteners out (counter-clockwise) to raise the
position. beam.
5. Start the engine and switch the headlight on to the
specified mode:
• INCANDESCENT = HIGH
• LED = LOW

6. Compare the position of headlight beam on the

wall to the illustration and adjust if necessary. See
Headlight Aim Adjustmentpage 2.56

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.

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S I D E S TA N D I N S P E C T I O N R E M O VA L
1. Support the motorcycle in an upright position with
1. Sidestand will be moved between the UP
the front wheel clamped in a wheel vise.
(retracted) and DOWN (extended) position during
2. Inspect sidestand spring for damage or loss of removal and installation. Be sure vehicle is
tension. Be sure stand returns to fully retracted properly secured.
position.
3. Inspect sidestand for smooth movement.
2. Remove sidestand pivot fastener q using a 6mm
hex wrench while holding the nut with a 15 mm
2
wrench.
4. Inspect sidestand pivot fastener nut for proper
torque. 2017–19 MODELS
TORQUE
Sidestand Pivot Fastener:
37 ft-lbs (50.2 Nm)

5. Replace sidestand if it is bent. Do not attempt to

straighten sidestand.

S I D E S TA N D R E M O VA L / I N S TA L L AT I O N
WARNING
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
secured before you begin.
2020+ MODELS
IMPORTANT
Sidestand fasteners must be replaced any time the
sidestand is removed. The nut is a crushed lock and
therefor it can not be reused.

3. Grasp sidestand firmly and move it to the UP

position.
4. Pull sidestand rearward against spring tension until
mounting flange on sidestand is clear of the
mounting boss on the frame.
5. Relax tension and remove spring.

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I N S TA L L AT I O N
1. Attach spring to sidestand.
2. Lightly grease sidestand mounting boss on frame
and the shouldered portion of the pivot fastener.
3. Place loose end of spring through hole in frame
rail.
4. With sidestand in the retracted position (up), pull
stand rearward against spring tension until the
mounting flange on the sidestand drops onto the
mounting boss on the frame.
5. Swing sidestand to the extended position to align
fastener hole and install NEW fastener and nut.
6. Torque to specification and wipe off any excess
grease.
TORQUE
Sidestand Pivot Fastener:
37 ft-lbs (50.2 Nm)

7. Cycle the sidestand to be sure it moves freely, and

returns to the fully retracted position.

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STEERING HEAD / FRONT WHEEL 3. Inspect for worn swing arm bearings by grasping
INSPECTION the rear wheel and attempting to move wheel side-
to-side q.
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. 2
NOTICE
Be sure control cables, hoses and wiring are not
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, 4. If movement is detected, determine if movement is
feels rough or uneven, or if movement is detected at axle area e or swingarm pivot area r. Refer to
at steering stem, adjust or replace steering head Steering / Suspension chapter for wheel bearing
bearings as necessary. and swingarm bearing replacement.
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.
4. Turn handle bars full right or left and hold against
the fork stop. Attempt to move front wheel side-to-
side. If movement is observed, inspect front axle,
wheel, and bearings. See Steering / Suspension
chapter.

SWINGARM INSPECTION
WARNING
Care should be taken to be sure the motorcycle will
not tip or fall while elevated. Severe personal injury 5. Rotate rear wheel and inspect for smooth rotation
or death may occur if the motorcycle tips or falls. of rear wheel bearings. If roughness or unusual
sounds are detected, inspect rear wheel bearings,
1. Sit astride the motorcycle. Compress the rear belt tension and alignment, and brake pads.
suspension several times and check for smooth
and quiet operation w. 6. Inspect rear shock for leakage and all rear
suspension components for damage or loose
2. Secure motorcycle with rear wheel elevated. fasteners.
7. Inspect suspension pivots and shock mounts for
radial movement in all pivot joints. If a joint has
radial movement, remove rear shock absorber and
inspect suspension pivot linkage. See Steering /
Suspension chapter.
8. Verify axle nut is tight.
9. Replace any worn or damaged parts.

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REAR SHOCK PRELOAD INSPECTION 6. Measure the distance (in millimeters) from the
Periodically inspect rear shock preload. For the most center of the rear axle w to the bottom of the tape
comfortable ride and proper ground clearance, adjust e. Record the results as measurement M1.
preload if ride height is out of specification.

1. Verify that tire pressure is at specification.

See Tire Pressure / Specificationspage 2.25.
2. Place the motorcycle in an upright position with the
front wheel clamped in a wheel vise.
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.

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.

5. 9. Have an assistant measure the same location.

Record the results as measurement M2.
CAUTION
10. Subtract measurement M2 from M1. The result is
For CALIFORNIA and INTERNATIONAL motorcycles, the measured rider sag. (M1–M2=Sag)
the Evaporative Canister must be removed prior to
raising the motorcycle. If the canister is not removed 11. Adjust preload as needed to achieve suspension
and the motorcycle is raised, the fittings will contact sag indicated in the table below.
the swingarm and become damaged.
See
Using a scissor jack or similar tool, raise the • Rear Shock Preload Adjustment - (2017-19)
motorcycle until the rear shock is completely Chief Modelspage 2.61 or
extended. • Rear Shock Preload Adjustment - Air
Shockpage 2.62
for adjustment procedure.

RECOMMENDED SUSPENSION SAG

Chief Classic / Chief
Vintage / Chief Dark 35 mm
Horse
Springfield / Chieftain
Dark Horse / Chieftain /
Roadmaster 45 mm
(All 2020+ Models)

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REAR SHOCK PRELOAD ADJUSTMENT -

(2017-19) CHIEF MODELS
1. Place the motorcycle in an upright position with the
front wheel clamped in a wheel vise.
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.
7. Tighten the lock nut securely against the adjuster
nut.
8. Install the seat as outlined in Frame / Body chapter.

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REAR SHOCK PRELOAD ADJUSTMENT - AIR SHOCK

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.

MODELS EQUIPPED WITH A AIR SHOCK

2017-19 Chieftain, Roadmaster, Springfield All 2020+ Models

CAUTION
Air pressure increases VERY quickly when using pressurized air. Wear eye and face protection.

For riding comfort and to ensure proper ground clearance, adjust rear shock air pressure. 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, in addition to
adjusting shock air pressure.
Follow these guidelines when adjusting:

• Park the motorcycle with the sidestand down on a firm, level surface. Remove all riders and cargo.
• DO NOT exceed 150 PSI (1034 kPa) in the shock.
• Use the INDIAN MOTORCYCLE Air Pump and Gauge (P/N PV-48909). Follow the instructions on the following
pages.

If the recommended air pump is not available, use a gauge and a pressurized air source with a maximum line and
gauge pressure of 150 PSI (1034 kPa). After using the alternate gauge, remove it quickly to minimize leakage.
Expect to lose up to 5 PSI (34 kPa) with each pressure check. Use only a dry air source, such as a system with a
water separator or air line dryer, to prevent moisture from entering the shock.

S TA N D A R D S H O C K ( C H I E F / V I N TA G E ) M O D E L S
AIR SUSPENSION ADJUSTMENT

TOTAL CARGO & AIR PRESSURE (psi)

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

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L O W S H O C K ( C H I E F TA I N / R O A D M A S T E R / S P R I N G F I E L D ) M O D E L S
AIR SUSPENSION ADJUSTMENT

TOTAL CARGO & OCCUPANT AIR PRESSURE (psi)

WEIGHT (lbs) MAX PRESSURE: 150 PSI
NO TRUNK PAINTED TRUNK
0 0 0
150 0 0
2
175 0 10
200 0 17
225 10 24
250 17 45
275 24 65
SELECT PRESSURE CORRESPONDING TO TOTAL
300 32 85 CARGO AND OCCUPANT WEIGHT. REMOVE ALL
PASSENGERS AND CARGO BEFORE SETTING/
325 40 97 CHECKING SHOCK PRESSURE. SET PRESSURE WITH
350 52 110 BIKE ON SIDE STAND.

375 67 119
400 82 127
425 98 136
450 114 145
475 130 N/A
500 145 N/A

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SHOCK AIR PRESSURE ADJUSTMENT PROCEDURE

IMPORTANT
Follow these guidelines when adjusting:
• Park motorcycle with the sidestand down on a firm, level surface.
• Remove all riders and cargo.
• DO NOT exceed 150 psi (1034 kPa) in the shock.
• Use shock air pump (PV-48909) to complete adjustment procedure.

1. 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.

2. Remove the cap from the air fitting q.

3. Refer to the label on the inside of the left-hand 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 Inspectionpage 2.60.

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S H O C K A N A LY S I S
Shock “misting” q or “weepage” w is common and should be present during normal vehicle operation. All
Shock Absorber Seals are designed to allow a thin film of oil to pass into and out of the shock. This thin film of oil
lubricates the Seal to ensure low friction and reduces the corrosion rate of the Piston Rod.

Vehicle operating conditions have a high impact on how much shock oil might be present on the seal and shock
body (i.e. road conditions and operating temperature). It is important to properly identify the difference between
normal operation (weepage or misting) and a shock that has a leak. Below are some images to help determine
what is normal and what could be identified as a bad shock.

MISTING OR WEEPAGE LEAKAGE

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MAINTENANCE - CHECK WHEEL SPOKES

If your motorcycle is equipped with spoked wheels,
inspect both wheels for loose, bent, broken or missing
spokes. To identify loose spokes, grasp each spoke
and try to move it side to side or up and down. All
spokes should be equally tight and have the same
amount of flex. Tighten loose spokes or replace bent,
broken or missing spokes.

Inspect spokes after first 500 miles, then again every

5,000 miles.

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 ENGINE / COOLING / EXHAUST

CHAPTER 3
ENGINE / COOLING / EXHAUST
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
AIR BOX REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
AIR BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 3
ENGINE REMOVAL / INSTALL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11
ENGINE BRACKETS / FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13
PREPARATION FOR ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13
REMOVING ENGINE FROM FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19
LUBRICATION / COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.27
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29
FILTER ADAPTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.30
OIL FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33
OIL PRESSURE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.34
OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.35
OIL PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.36
OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.37
OIL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38
OIL COOLER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40
OIL COOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.41
OIL COOLER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.42
OIL COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.43
CYLINDER HEAD / VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.44
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.44
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.44
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.45
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.46
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.48
CAM CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.48

9850035 R07 - 2017–21 Indian Motorcycle (Full-Size) Service Manual

© Copyright 3.1
ENGINE / COOLING / EXHAUST

CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.49
LIFTERS / PUSHRODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.50
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.51
CAMSHAFT TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.53
CAM CHAIN SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.54
LOCKING THE CRANKSHAFT FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.54
CAM CHAIN COVER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.55
CAM CHAIN TENSIONER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.56
CAM CHAIN TENSIONER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.57
CAM CHAIN TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.58
CAM CHAIN GUIDE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.59
CAM CHAIN GUIDE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.60
CAM CHAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.61
CAM CHAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.62
CAMSHAFT / LIFTER SERVICE - ENGINE OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.63
LIFTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.63
LIFTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.64
CAMSHAFT CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.65
CAMSHAFT CARRIER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.66
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.68
CAMSHAFT CARRIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.69
CAMSHAFT CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.72
CAMSHAFT SERVICE - IN BIKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.73
CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.73
CAMSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.76
CYLINDER HEAD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.77
VALVE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.77
VALVE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.78
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.79
ROCKER ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.80
ROCKER ARM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.81
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.82
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.83
VALVE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.84
VALVE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.85
VALVE GUIDE REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.86
VALVE SEAT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.88
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.89
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.90
TROUBLESHOOTING, CYLINDER HEAD AND VALVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.91
CYLINDER / PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.94
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.94
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.94
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.95
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.96
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.97
CYLINDER / PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.97

9850035 R07 - 2017–21 Indian Motorcycle (Full-Size) Service Manual

3.2 © Copyright
 ENGINE / COOLING / EXHAUST

CYLINDER / PISTON SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.98

PISTON RING PROFILE AND ORIENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.98
CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.99
CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.100
CYLINDER BORE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.101
PISTON TO CYLINDER CLEARANCE WORKSHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.102
CYLINDER WARPAGE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.103
PISTON & PISTON RING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.104
PISTON & PISTON RING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.105
PISTON PIN / PIN BORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.106 3
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.107
PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.108
CYLINDER STUD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.109
CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.110
TROUBLESHOOTING, CYLINDER / PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.111
EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.113
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.113
EXHAUST SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.115
MUFFLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.115
CROSS OVER PIPE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.116
HEAD PIPE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.118
HEAD PIPE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.119
CROSS OVER PIPE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.120
MUFFLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.122

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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.

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6. Using a 5 mm hex wrench, remove the four

fasteners t securing the throttle body to the
mounting plate and remove throttle body assembly.

7. Using an 8 mm socket, remove the lower fastener

y securing the air box to the mounting plate.

8. Push the rubber harness seal through to the back

side of the air box and remove the air box from the
motorcycle.

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A I R B O X I N S TA L L AT I O N 5. Install air box retainer fastener r and torque to

specification.
1. Install the four fasteners q securing the air box
mounting bracket to the engine and torque to
specification.

TORQUE TORQUE

Air Box Bracket Fasteners: Baffle Plate Fasteners:

88.5 in-lbs (10.0 Nm) 31 in-lbs (3.5 Nm)
Air Box Retainer Fastener:
88.5 in-lbs (10.0 Nm)
2. Feed the throttle body electrical connector through
the hole in the air box and install the rubber
harness seal in the rectangular cutout. 6. Install throttle body o-ring and throttle body.
Torque throttle body fasteners t to specification.
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.

TORQUE
Throttle Body Fasteners:
88.5 in-lbs (10.0 Nm)

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.

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9. Install the three air filter adapter plate fasteners y 11. Install air box gasket and cover. Torque fasteners
and torque to specification. i to specification.

TORQUE
Air Filter Adapter Plate Fasteners:
31 in-lbs (3.5 Nm) TORQUE
Air Box Cover Fasteners:
10. Install the air filter element and torque fasteners u 84 in-lbs (9.5 Nm)
to specification.

TORQUE
Air Filter Fasteners:
62 in-lbs (7.0 Nm)

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E N G I N E R E M O VA L / I N S TA L L
G E N E R A L I N F O R M AT I O N
SERVICE NOTES
A floor jack or commercially available motorcycle
engine lift or hoist is required for engine removal.
Arrange for assistance when removing and installing
the engine.
Once the engine is removed from frame, an engine
stand is recommended for engine disassembly and
assembly.
Engine removal and installation methods may differ
slightly depending on available equipment, but
always be sure the engine and chassis are securely
supported at all times.

REQUIRES ENGINE CAN BE SERVICED

REMOVAL FOR WITH ENGINE IN
SERVICE FRAME
Camshaft(s) / Bearings Airbox Removal
Crankshaft & Crankshaft Camshaft Chain / Guide
Component Service / Tensioner Assembly
Cylinder Heads Fuel Injectors / Throttle
Body / Fuel Rail
Cylinders Voltage Regulator,
Stator, Rotor (Flywheel)
Lifters Clutch
Oil Pump Gearshift Linkage
(External)
Balance Shaft Ignition System
Piston/Cylinder Oil Pump Drive
Pushrods Output Shaft Seal
Transmission/All Torque Compensator
Internal Transmission Assembly
Parts
Valve Covers
Starter, Starter One-Way
Clutch, Starter Torque
Limit Clutch
Crankshaft Position
Sensor Timing Wheel

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S E R V I C E S P E C I F I C AT I O N S
ITEM SPECIFICATIONS
Approximately 293 lbs
Engine Dry Weight
(133 kg)
Approximately 6.0
Oil Capacity (Dry Fill)
Quarts (5.7 Liters)

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SPECIAL TOOLS
TOOL DESCRIPTION PART NUMBER
Engine Stand Adapter PF-51240
Motorcycle Table Lift / Commercially Available
Wheel Vise
12"x12" Platform Jack Commercially Available
Engine Hoist (Cherry Commercially Available
Picker)
Engine Stand Commercially Available

Bosch Automotive Service Solutions: 1–800–328–

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

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A S S E M B LY V I E W S
E N G I N E B R A C K E T S / FA S T E N E R S
LEFT SIDE BRACKETS / FASTENERS

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Fastener, Engine Mount — M12 x 1.75 x 50 (QTY.2) 75 ft-lbs (101.6 Nm)

w Fastener, Engine Mount — M10 x 1.5 x 25 (QTY.1) 45 ft-lbs (60.0 Nm)

e Fastener, Engine Mount — M10 x 1.5 x 60 (QTY.2) 45 ft-lbs (60.0 Nm)

r Fastener, Frame Down Tube — M10 x 1.5 x 100 (QTY.2) 45 ft-lbs (60.0 Nm)

t Fastener, Front Engine Mount — M8 x 1.25 x 20 (QTY.2) 18 ft-lbs (24.4 Nm)

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RIGHT SIDE BRACKETS / FASTENERS

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Fastener, Engine Mount — M12 x 1.75 x 50 (QTY.1) 75 ft-lbs (101.6 Nm)

w Fastener, Engine Mount — M12 x 1.75 x 120 (QTY.1) 75 ft-lbs (101.6 Nm)

e Fastener, Engine Mount — M10 x 1.5 x 60 (QTY.2) 45 ft-lbs (60.0 Nm)

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E N G I N E R E M O VA L 13. Loosen axle nut q and loosen belt tension

adjustment nuts w and remove belt from drive
P R E PA R AT I O N F O R E N G I N E R E M O VA L sprocket.
Remove the front fender with the motorcycle rest-
ing on it’s side stand, prior to placing the front tire
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. 3
1. With the motorcycle resting on it’s side stand,
remove the front fender. See Front Fender
Removalpage 7.33.
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 Removalpage 3.4.
(Upper), Removal / Installationpage 7.22.
15. Remove the knock sensor e.
4. Remove lower side covers. See Side Cover
(Lower), Removal / Installationpage 7.22. 16. Disconnect the TMAP sensor r.
5. Remove the seat. See Seat, Removal / Installation - 17. Disconnect the CHT sensor t.
Classic / Vintage / Chieftainpage 7.26.
6. Remove the battery. See Battery Removalpage
2.46.
7. Remove the fuel tank. See Fuel Tank Removalpage
4.17.
8. Remove the complete exhaust system. See
EXHAUST SERVICE.
9. Remove the sprocket cover. See Drive Sprocket
Cover, Removal / Installationpage 8.58.
10. Remove the ignition coil assembly. See Ignition
Coil Removal / Installationpage 10.53.
11. Remove the RH and LH floorboard assemblies. See
Floorboard (Driver), Removalpage 7.23.
18. Remove both ends of the breather hose y from the
12. Remove highway bars, if equipped. See Highway valve covers.
Bar Removalpage 7.29.

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19. Disconnect electrical connectors from both fuel

injectors and feed the electrical harness and all
plugs up through the fuel rail (distribution line)
and move out of the way.
20. Using a 10 mm socket, remove the top oil cooler
fastener u and release the oil cooler from the
lower mounting tabs i.

21. Disconnect the oil pressure switch. See Sensors —

Powertrain Managementpage 4.13.
22. Disconnect the gear position switch. See Sensors
— Powertrain Managementpage 4.13.
23. Using a 4 mm hex wrench, remove the two
fasteners securing the sidestand switch and move
switch out of the way. See Sensors — Powertrain
Managementpage 4.13.

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REMOVING ENGINE FROM FRAME • Using a 5 mm hex wrench, remove the two
1. Perform the preliminary engine removal steps fasteners s securing the charcoal canister to the
outlined in this chapter. See Preparation For Engine bracket. Remove canister.
Removalpage 3.13.
•
NOTICE
APPLICABLE TO CA AND INTERNATIONAL
MODELS ONLY.

• Noting position, disconnect hoses a from the 3

charcoal canister.

• Remove the two fasteners d securing the

charcoal canister mounting bracket to the ABS
bracket.

2. Place a platform jack beneath the engine and raise

enough to support crankcase (Jack should just be
touching the crankcase).

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3. Using a 5 mm hex wrench, remove the fastener q 9.

securing the clutch cable clip to the bottom of the
NOTICE
LH 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.

4. Remove the E-clip from the end of the clutch cable,

rotate the clutch arm by hand and release the
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
e r t securing the LH front down tube to the
frame top tube and lower engine boss. 10. Remove the three regulator mounting bracket
fasteners u securing the regulator bracket to the
7. Remove the LH frame down tube and side stand as engine case and move bracket out of the way.
an assembly.

11. Remove the starter motor. See Starter Motor,

8. Disconnect the stator from the regulator.
Removal / Installationpage 10.31.
12. Remove CPS. See Sensors — Powertrain
Managementpage 4.13.

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13. Using a 5 mm hex wrench, remove the four 16.

fasteners i securing the hard hydraulic lines to the NOTICE
RH frame down tube and 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.

14. Using an 8 mm hex wrench, remove the remaining

two fasteners o from the RH frame down tube and
remove.
17. Remove the two fasteners g securing the starter
solenoid to the ABS bracket.

15. Disconnect the main ABS electrical connector and

two brake switch connectors from the ABS Module.
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.

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19. Remove the two fasteners h securing the battery 22. Working from the LH side of the motorcycle,
tray to the engine and the grounding fastener j remove the two fasteners 1( securing the rear of the
from the engine case. engine to the LH frame panel.

20. Working from the RH side, using a 16 mm socket, 23. Push engine slightly to the RH side to free up from
remove the two fasteners k securing the rear of the alignment dowels. With an assistant, lower the
motor to the frame side panel. engine from the frame and remove from vehicle.
21. Using a pick tool, remove the two spacers l from
the RH side of the engine between the frame panel
and engine mounts.

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E N G I N E I N S TA L L AT I O N 4. Slide the engine back until the rear mounting ears

The following procedure is written assuming the en- are aligned with the mounting holes in the frame
gine has been assembled and is resting on an engine side panels. Adjust height of engine as needed to
stand, ready for installation. align rear mounts and dowel pins.
Refer toEngine Brackets / Fastenerspage 3.11 in this
5. Slide the engine towards the left-hand frame panel
chapter for torque values and assembly views.
until the dowel pins are fully seated.
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
3
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.

1. Clean mating surfaces of frame and engine

crankcase. Install alignment dowels q.
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.
2. Place motorcycle in an upright position with the
front wheel clamped in a wheel vise. 8. Working on the right-hand side of the engine,
slide the spacers w into position between the
3. Position the engine on a platform jack to the left of right-hand frame panel and the engine crankcase.
the motorcycle and slide into position so the
engine is orientated correctly front to back.

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9. Install the two engine mounting fasteners e into 12. Install the four fasteners y securing the ABS
the right-hand frame panel, through the spacers module bracket to the rear of the engine and
and torque to specification. See Engine Brackets / torque to specification.
Fastenerspage 3.11.

TORQUE
10. Torque the left hand rear engine mounting
fasteners to specification. ABS Module Bracket Fasteners:
84 in-lbs (9.5 Nm)
TORQUE
Rear Engine Mounting Fasteners: 13. Reconnect the main connector and brake switch
75 ft-lbs (101.7 Nm) connectors to the ABS module.
14. Install the two fasteners u securing the starter
11. Install the two fasteners r securing the battery solenoid to the ABS bracket and torque to
box to the engine and the grounding wire fastener specification.
t and torque to specification.

TORQUE
TORQUE
Starter Solenoid Mounting Fasteners:
Battery Box Fasteners: 84 in-lbs (9.5 Nm)
84 in-lbs (9.5 Nm)
15. If applicable, install the mounting bracket and
TORQUE charcoal canister to the back of the ABS module
bracket and reconnect vapor hoses.
Grounding Wire Fastener:
84 in-lbs (9.5 Nm)

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16. 19. Install the regulator / rectifier mounting bracket

and the regulator / rectifier. See Rectifier /
NOTE
Regulator Replacementpage 10.40
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
3
Brackets / Fastenerspage 3.11.

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 / Fastenerspage 3.11.

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 (9.5 Nm)

18. Install the starter motor. See Starter Motor,

Removal / Installationpage 10.31.

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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 / Installationpage 10.53.
specification.
33. Install the sprocket cover. See Drive Sprocket
Cover, Removal / Installationpage 8.58.
34. Install the complete exhaust system. See EXHAUST
SERVICE.
35. Install the lower side covers. See Side Cover
(Lower), Removal / Installationpage 7.22.
36. Install the battery. See Battery Installationpage
2.47.
37. Install the fuel tank. See Fuel Tank Installationpage
4.24.
38. Install the seat. See Seat, Removal / Installation -
Classic / Vintage / Chieftainpage 7.26.
39. Install the upper side covers. See Side Cover
(Upper), Removal / Installationpage 7.22.
TORQUE
40. Install new oil filter and fill engine to proper level
Side Stand Bumper Fastener: with Indian Motorcycle engine oil.
84 in-lbs (9.5 Nm)
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 (4.9 Nm)
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 Managementpage 4.13. brake system if necessary.

24. Install the oil cooler to the frame. See Oil Cooler 45. Test ride motorcycle and check all systems for
Installationpage 3.43. 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
Managementpage 4.13.
26. Install the air cleaner assembly and throttle body.
See Air Box Installationpage 3.6.
27. Fit the drive belt over the drive sprocket and set
belt tension / wheel alignment. See Drive Belt
Adjustmentpage 2.52.
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 Installationpage 7.29.
30. Install front fender. See Front Fender
Installationpage 7.34.
31. Install the left-hand and right-hand floorboard
assemblies. See Floorboard (Driver),
Installationpage 7.24.

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L U B R I C AT I O N / C O O L I N G
G E N E R A L I N F O R M AT I O N

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SERVICE NOTES
The Thunderstroke 111 uses a semi-dry sump
lubrication system. The engine oil is housed in a
separate chamber within the engine cases q as shown
in the image below.

The oil pump has two sets of internal gerotors. One set
provides lubrication pressure and the second set
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,
review the troubleshooting charts located in this
chapter.
If the engine is making irregular noises that appear to
be coming from rotating parts, check the lubrication
side oil pressure. Check the oil pressure before
engine disassembly, and recheck the oil pressure after
a repair.

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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 3
stuck open
Damaged engine Pressure relief valve stuck
bearings/excessive closed
engine wear.
Restricted oil filter, oil
filter screen or
passages

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SPECIAL TOOLS
TOOL DESCRIPTION PART NUMBER
Oil Pressure Gauge PV-43531

Bosch Automotive Service Solutions: 1-800-328-

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

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S E R V I C E S P E C I F I C AT I O N S
NOTICE
Depending on build date, engines will vary in the amount of oil to reach the appropriate fill level. Engines
produced up to January, 2019 will require 5.5 U.S. qts. Engines produced after January, 2019 will require 6.0 U.S.
qts.

IMPORTANT
Always follow the engine oil level check procedure for accurate readings of the engine oil. DO NOT
OVERFILL!
3
ITEM STANDARD LIMIT
Engine Oil Capacity (After Disassembly) 5.8 U.S. qts (5.5 Liters) Not Applicable
5.5 U.S. qts (5.2 Liters) = Engines Not Applicable
Engine Oil Capacity (At Change with Filter) Follow build BEFORE January, 2019
the oil change procedure outlined in the
Maintenance chapter. 6.0 U.S. qts (5.7 Liters ) = Engines Not Applicable
build AFTER January, 2019
5.4 U.S. qts (5.1 Liters) = Engines Not Applicable
Engine Oil Capacity (At Change without Filter) build BEFORE January, 2019
Follow the oil change procedure outlined in the
Maintenance chapter. 5.9 U.S. qts (5.6 Liters ) = Engines Not Applicable
build AFTER January, 2019
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)
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)

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A S S E M B LY V I E W S

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OIL COOLER

NOTICE
This system only applies to certain models. See Oil Flow Diagrampage 3.31 for list of affected models.

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Oil Filter (Apply oil to filter seal) Approximately 3/4 turn after sealing ring has
contacted the filter adapter.

w Fastener, Oil Cooler Pipes - M6 x 1.0 x 12 1 in-lbs (8.0 Nm)

(QTY.2)

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 Fastener, Oil Filter Adapter - M6 x 1.0 x 40 88 in-lbs (10.0 Nm)

(QTY.3)

i Oil Filter Adapter Assembly –

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F I LT E R A D A P T E R

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Fastener, Oil Filter Adapter - M6 x 1.0 x 40 88 in-lbs (10.0 Nm)

(QTY.3)

w Oil Filter Adapter Assembly –

e O-ring, Oil Cooler –

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OIL FLOW DIAGRAM

OIL COOLER FILTER ADAPTER INTERNAL BYPASS

• Chieftain Dark Horse • Chief Classic

• Chieftain • Chief Vintage
• Roadmaster • Chief Dark Horse
• Springfield

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L U B R I C AT I O N S Y S T E M

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

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 –

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OIL PRESSURE INSPECTION

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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. 3
2. Turn the engine OFF.
3. Remove oil pressure switch q.

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 sectionpage 3.25.
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 (2014-19):
88 in-lbs (10 N·m)

TORQUE
Oil Pressure Switch (2020+):
11 ft-lbs (15 N·m)

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OIL PUMP SERVICE

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O I L P U M P R E M O VA L 6. Remove the oil pump / snorkel tube assembly

1. Remove engine from frame. See Removing Engine from the LH crankcase.
From Framepage 3.15.
2. Separate engine cases. See Crankcase
Separationpage 6.23.
3. Remove external snap-ring q, flat washer w, oil
pump drive gear e, and drive pin r from oil
pump input shaft.

4. Remove the oil pump snorkel tube fasteners t.

5. Remove the three fasteners y from the oil pump

assembly.

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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.

TORQUE
3. Install the oil pump / snorkel tube assembly into Oil Pump Fasteners:
the crankcase and loosely install fastener w 88.5 in-lbs (10.0 Nm)
securing the snorkel tube to the left-hand
crankcase. 5. Torque snorkel tube fasteners to specification.
TORQUE
Snorkel Tube Fasteners:
88.5 in-lbs (10.0 Nm)

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

Assemblypage 6.40.

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9. Install engine in frame. See Engine

Installationpage 3.19.
10. Verify engine oil pressure after assembly. See Oil
Pressurepage .

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OIL COOLER SERVICE

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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.

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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.

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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
and torque to specification.

TORQUE
Oil Cooler Mounting Fastener:
84 in-lbs (9.5 Nm)

3. Install the oil cooler lines into the oil filter adapter
and torque flange fasteners w to specification.

TORQUE
Oil Cooler Line Fasteners:
71 in-lbs (8.0 Nm)

4. Run the engine to cycle oil through the oil cooler

and check oil level. Top off if necessary.

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C Y L I N D E R H E A D / VA LV E S
G E N E R A L I N F O R M AT I O N
The Thunder Stroke 111 / 116 engines use a single
cam chain system to drive a centrally located camshaft
(intake). The central camshaft uses a gear drive to turn
two outer camshafts (exhaust). Each cylinder is
equipped with two valves that are opened and closed
via self-adjusting hydraulic lifters and pushrods.

SERVICE NOTES
• This chapter covers service of the cylinder heads,
camshafts, cam chain and tensioner, cam chain
guide and roller / rocker arms.
• Refer to Engine / Cooling / Exhaust chapter for
engine removal and installation.
• If cylinder heads are removed the cylinder base
gasket must be replaced also.
• Mark and store all mating parts for correct engine
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.
• 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.

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SPECIAL TOOLS
TOOL DESCRIPTION PART NUMBER
Valve Spring Compressor PV-1253
Crankshaft Locking Tool PF-51235
Crankshaft Rotation Tool PF-51239
Seal and Bearing Driver Set PV-43558
Camshaft Service Tool PF-51455
Camshaft Holding Tool PF-52544
3
*Special Tool PF-51455-A includes both PF-51455 AND
PF-52544
Bosch Automotive Service Solutions: 1-800-328-
6657 or https://polaris.service-solutions.com/

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S E R V I C E S P E C I F I C AT I O N S

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
Intake Valve Closes At
43.0° ABDC 44° ABDC
1 mm Lift
Exhaust Valve Opens
44° BBDC 48° BBDC
CAMSHAFT At 1 mm Lift
DATA
Exhaust Valve Closes
4° ATDC 10° ATDC
At 1 mm Lift
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)

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CYLINDER HEAD & VALVE TRAIN DATA

ITEM STANDARD SERVICE LIMIT

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)
3
.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)

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A S S E M B LY V I E W S
CAM CHAIN

NUMBER PART DESCRIPTION TORQUE SPECIFICATIONS (IF

APPLICABLE)
q Fastener - M6 x 1.0 x 65 (QTY.6) / Fastener - M6 x 1.0 x 40 88 in-lbs (10.0 Nm)
(QTY.4)

w Cam Cover -

e Cam Cover Gasket -

r Fastener, Timing Chain Tensioner - M8 x 1.25 x 40 (QTY.1) 5 ft-lbs (20.3 Nm)

t Tensioner, Timing Chain -

y Snap Ring, Tensioner Arm -

u Tensioner Arm, Timing Chain -

i Fastener, Timing Chain Guide - M6 x 1.0 x 40 (QTY.2) 71 in-lbs (8.0 Nm)

o Pivot, Tensioner Arm 15 ft-lbs (20.3 Nm)

a Guide, Timing Chain -

s Fastener, Timing Gear - M10 x 1.5 x 40 (QTY.2) 52 ft-lbs(70.0 Nm)

d Washer, Timing Gear -

f Timing Gear, Crankshaft -

g Timing Gear, Camshaft (Intake) -

h Timing Chain -

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CAMSHAFTS

NUMBER PART DESCRIPTION TORQUE SPECIFICATIONS (IF

APPLICABLE)
q Fastener, Bearing Retainer Plate - M5 x 0.8 x 12 (QTY.6) 62 in-lbs (7.0 Nm)
w Retaining Plate, Cam Bearings -

e Fastener, Timing Gear - M10 x 1.5 x 40 (QTY.2) (Exhaust Camshafts) 52 ft-lbs(70.0 Nm)
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) 18 ft-lbs (20.0 Nm)

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) -

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LIFTERS / PUSHRODS

NUMBER PART DESCRIPTION TORQUE SPECIFICATIONS (IF

APPLICABLE)

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 (10.0 Nm)

t Lifter Block -

y Gasket, Lifter Block -

u Fastener, Retaining Plate - M5 x 0.8 x 12 (QTY.1 per cylinder) 62 in-lbs (7.0 Nm)

i Dowel, Lifter Guide -

o Lifter -

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CYLINDER HEAD

NUMBER PART DESCRIPTION TORQUE SPECIFICATIONS (IF

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 / Rocker Arm Nut 22 ft-lbs (30.0 Nm)

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 (10.0 Nm)

j Outer Valve Cover -

k Fastener, Outer Valve Cover - M6 x 12 x 15 (QTY.3) 88 in-lbs (10.0 Nm)

l Cylinder Head Temperature Sensor (CHT) 70 in-lbs (8.0 Nm)

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CAMSHAFT TIMING

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CAM CHAIN SERVICE

LOCKING THE CRANKSHAFT FOR SERVICE
This procedure describes how to lock the crankshaft in
the Top Dead Center (TDC) position using
commercially available hand tools.
1. Remove the spark plugs. See Spark Plug
Removalpage 2.40.
2. Remove the stator. See Stator Removalpage 10.37.
3. Using special service tool PF– 51239, rotate the
crankshaft counterclockwise (primary side) until
the front piston is at TDC. See Cylinder Headpage
3.51.
4. Lock the crankshaft by inserting a 5/16” pin punch
(or equivalent) into the locking hole q.

NOTICE
It may be necessary to rotate the crankshaft slight
forward or back to properly align holes.

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C A M C H A I N C O V E R R E M O VA L / I N S TA L L AT I O N
1. Remove the right-hand floorboard / master
cylinder assembly and move out of the way. See
Floorboard (Driver), Removalpage 7.23
NOTICE
The right-hand floorboard and rear brake master
cylinder can be removed as an assembly. It is not
necessary to disconnect the brake line from the
master cylinder while performing this procedure.

2. Remove the ten fasteners q securing the cam 3

chain cover to the inner timing cover.

3. Remove the cam chain cover and gasket.

4. INSTALLATION is performed by reversing the
removal procedure.
5. Clean gasket mating surfaces and install cam
chain cover using a new gasket.
6. Torque cam chain cover fasteners following the
specified torque sequence.

TORQUE
Cam Chain Cover Fasteners:
88.5 in-lbs (10.0 Nm)

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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.

1. Remove the cam chain cover. See Cam Chain

Cover, Removal / Installationpage 3.55.
2. Remove cam chain tensioner fastener q and
remove the cam chain tensioner.

3. Remove the external snap ring w from the

tensioner arm and remove arm and spring as an
assembly.

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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
3
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.

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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
Headpage 3.51.
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 (20.0 Nm)

6. With a new gasket and both mating surfaces clean,

install the cam chain cover. See Cam Chain Cover,
Removal / Installationpage 3.55.

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C A M C H A I N G U I D E R E M O VA L
1. Remove the cam chain cover. See Cam Chain
Cover, Removal / Installationpage 3.55
2. Remove the two fasteners q securing the cam
chain guide to the engine and remove the guide
and spacers.

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C A M C H A I N G U I D E I N S TA L L AT I O N
1. If removed, install the cam chain. See Cam Chain
Installationpage .
2. Install cam chain guide q and fasteners w .
Torque to specification.

TORQUE
Cam Chain Guide:
71 in-lbs (8.0 Nm)

3. Install the cam cover. See Cam Chain Cover,

Removal / Installationpage 3.55.

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C A M C H A I N R E M O VA L
1. Place motorcycle in an upright position with the
front wheel clamped in a wheel vise.
2. Drain the engine oil. See Engine Oil & Filter
Change in the Maintenance Chapter.
3. Remove spark plugs. See Spark Plug Removalpage
2.40.
4. Place an oil drain pan beneath the engine to catch
any residual oil when primary and cam chain
covers are removed. 3
5. Remove the cam chain cover. See Cam Chain
Cover, Removal / Installationpage 3.55.
6. Perform the crankshaft locking procedure. See
Locking the Crankshaft for Servicepage 3.54.
7. Remove the cam chain tensioner and tensioner
arm assemblies. See Cam Chain Tensioner
Removalpage 3.56.
8. Remove the cam chain guide. See Cam Chain
Guide Removalpage 3.59
9. Remove the camshaft and crankshaft sprocket
fasteners q .

10. Pull the camshaft sprocket, crankshaft sprocket

and cam chain off as an assembly.
11. Collect the woodruff key from the crankshaft.

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C A M C H A I N I N S TA L L AT I O N • Align timing marks r .

CAUTION • Position the chain on the sprockets so that the

dark chain links line up with sprocket
The Thunder Stroke 111 / 116 is an INTERFERENCE hashmarks.
ENGINE. If the camshafts and crankshaft must be
turned independently of each other to set valve
timing, the camshafts must be set to TDC prior to
rotating the crankshaft. Failure to do this may cause
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.
TORQUE
Camshaft / Crankshaft Sprocket Fasteners:
52 ft-lbs (70.0 Nm)
2. Perform METHOD 1 of the crankshaft locking
procedure. This will ensure the crankshaft is locked
in the TDC position. See Locking the Crankshaft for 8. Install the cam chain guide. See Cam Chain Guide
Servicepage 3.54. Installationpage 3.60
3. Place the woodruff key in the end of the crankshaft. 9. Install the cam chain tensioner and tensioner arm
assemblies. See Cam Chain Tensioner
4. Working on a flat surface, assemble the timing Installationpage 3.58
chain onto the crankshaft and camshaft sprockets
as shown. 10. Install the cam chain cover. See Cam Chain Cover,
Removal / Installationpage 3.55
11. Remove the crankshaft locking pin installed during
the crankshaft locking procedure in step 2.
12. Install stator. See Stator Installationpage 10.38
13. Install flywheel. See Flywheel Installationpage 5.25
14. Install clutch assembly and clutch rack. See Clutch
Installationpage 5.21
15. If applicable, Install torque compensator. See
Torque Compensator Installationpage 5.23
16. Install primary cover. See Primary Cover
Installationpage 5.14

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CAMSHAFT / LIFTER SERVICE - ENGINE 4. Using a T25 Torx, remove the fastener e securing
OUT the lifter retaining plate to the inner cam chain
cover and remove plate.
L I F T E R R E M O VA L
IMPORTANT
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 Removalpage 3.79. 3
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.

6. Repeat steps 3–5 to remove the rear lifters.

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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 88.5 in-lbs (10.0 Nm)
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 Installationpage 3.90.
fastener relief facing up. 11. Install inner and outer valve cover gaskets. See
Valve Cover Installationpage 3.78.
5. Install retaining plate fastener r and torque to
specification.

TORQUE
Lifter Retaining Plate Fastener:
62 in-lbs (7.0 Nm)

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.

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C A M S H A F T C A R R I E R R E M O VA L
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. Keep mated parts together.

1. Remove the engine from the frame and place on

an engine stand. See Removing Engine From
Framepage 3.15.
2. Remove lifters. See Lifter Removalpage 3.63.
3
3. Remove cam chain, cam chain tensioner and
guide. See Cam Chain Removalpage 3.61.
4. Remove the three remaining camshaft carrier
fasteners q .

5. Grasp the camshaft carrier w and pull straight out

to remove the three camshafts, outer bearings and
carrier as an assembly.
NOTICE
The camshaft ends are slip-fit to the inner bearings
and should come out by hand.

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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 6. Noting position in the carrier for reassembly,

IMPORTANT remove the camshafts and sprockets r from the
carrier bearings.
Camshafts are slip-fit to carrier bearings. Once the
carrier assembly has been removed from the engine,
the intake (center) camshaft will be held in place by
gear preload only. Use caution while working on the
carrier assembly so that camshafts do not fall from
carrier and become damaged.

1. Remove the camshaft carrier assembly. See

Camshaft Carrier Removalpage 3.65.
2. Remove the six fasteners and the bearing retainer
plate q from the carrier assembly.

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.

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
locking the camshafts.
4. Loosen, do not remove, the exhaust camshaft
fasteners e .

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.

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8.
NOTICE
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 . 3
9. Separate components of gear as shown.

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CAMSHAFT INSPECTION
For the following camshaft inspection procedure,
refer to the camshaft service specifications sec-
tion. See Service Specificationspage 3.46.

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
lobes q and intake cam lobes w.
3. Measure O. D. of each camshaft journal. Exhaust
journals e and Intake journals r .

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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.
3
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 (7.0 Nm)

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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.

Install the LH and RH exhaust camshafts so the

timing marks line up as shown.

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11. Install exhaust camshaft fasteners f and washers

g into carrier assembly so they are finger tight.

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.

13. Torque exhaust camshaft fasteners to specification.

TORQUE
Exhaust Camshaft Fasteners:
52 ft-lbs (70.0 Nm)

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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 4. Install cam chain, cam chain tensioner and guide.

See Cam Chain Installationpage .
NOTICE
Base and head gasket seal is released when 5. Install lifters. See Lifter Installationpage 3.64.
removing camshaft carrier. Replacement of both 6. Install engine in frame. See Engine
head and base gasket is recommended to prevent oil Installationpage 3.19.
leaks.

1. Lift the camshaft carrier assembly q into position

so that each of the camshaft ends fits into the inner
bearings.

2.
NOTICE
The camshaft ends are slip-fit to the inner bearings
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
specification.

TORQUE
Camshaft Carrier Fasteners:
15 ft-lbs (20.0 Nm)

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CAMSHAFT SERVICE - IN BIKE 4. Remove the remaining camshaft carrier fasteners

C A M S H A F T R E M O VA L w.
IMPORTANT
Camshaft removal with the engine installed in the
frame requires Special Tools #: PF-51455 and PF-
52544.

NOTICE
Secure the woodruff keys or place a shop towel
under camshaft drive gears to ensure keys don’t fall
3
into the engine.

1. Remove the cam chain, guide and tensioner

assemblies. See Cam Chain Cover Removal /
Installationpage 3.55.
5. Remove the camshaft bearing carrier assembly e.
2. Remove the exhaust camshaft fasteners q.

6. On Special Tool PF-51455, loosely assemble the

lower camshaft retainer plate y to the main plate
using two fasteners u.
3. Install Special Tool PF-52544 as shown.

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7. Install the camshaft special tool assembly onto the 10. With the flat side of the retaining pin s aligned
camshafts and tighten fasteners i until they are perpendicular to the rear exhaust camshaft push-
hand-tight. rod tube, slide the pin in hole marked “B” d until it
stops.
NOTICE
The lower camshaft retainer plate should be tight NOTICE
enough to support the outboard camshaft bearing It will be necessary to rotate the camshaft
journal. (clockwise) with a wrench to seat the pin.

8. Install special tool spacer o (has dowel hole) onto 11. Rotate the camshaft using a suitable wrench while
the intake camshaft and spacers a onto the pressing on the retaining pin until it seats.
exhaust camshafts. 12. Use the second etched line (marked “B”) to
9. Install camshaft gear washers and fasteners until determine when the shaft is fully seated in the hole
they are hand-tight. 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.

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13. Repeat steps 10-12 for the forward exhaust 17. Rotate the camshaft using a suitable wrench while
camshaft. pressing on the retaining pin until it seats at the
line marked “B”.
NOTICE
For the forward exhaust camshaft you will use the
hole marked “A” and the line marked “A”.

14. Slide the third retaining pin into the front cylinder
intake camshaft position (hole marked “A”) until it
stops.
NOTICE 3
It will be necessary to rotate the camshaft
(clockwise) with a wrench to seat the pin.

15. Rotate the camshaft using a suitable wrench while

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

18. Remove fasteners f and lower camshaft retaining

plate g.

16. Slide the fourth retaining pin into the rear cylinder
intake camshaft position (hole marked “B”) until it
stops.
NOTICE
19. Carefully pull each of the camshafts out from its
It will be necessary to rotate the camshaft respective bore.
(clockwise) with a wrench to seat the pin.
NOTICE
It may be necessary to rotate the camshaft by hand
during removal so the camshaft lobes can clear the
retaining plate.

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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. Install the camshaft carrier, timing components and
ti ming chain cover as outlined in this chapter.

2. Assemble the lower camshaft retaining plate e to

the main plate and tighten fasteners r until the are
hand-tight.

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CYLINDER HEAD SERVICE

VA LV E C O V E R R E M O VA L
1. Remove engine from frame and place on an
engine stand. See Removing Engine From
Framepage 3.15.
2. Using a T40 Torx Plus, remove the three fasteners
q from each of the outer valve covers and remove
covers.

3. Using an 8mm socket, remove the fasteners w

securing the inner valve covers to the cylinder
head.

4. Remove inner valve covers and gaskets.

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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

1. Using new gaskets, install the inner valve covers 3. Install the outer valve covers and torque fasteners
and thread fasteners q in finger tight. to specification.
TORQUE
Outer Valve Cover Fasteners:
88.5 in-lbs (10.0 Nm)

2. Reference the torque sequence at the beginning of

this section and torque inner valve cover fasteners
to specification.
TORQUE
Inner Valve Cover Fasteners:
88.5 in-lbs (10.0 Nm)

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C Y L I N D E R H E A D R E M O VA L
CAUTION
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
Framepage 3.15. 3
2. Remove inner and outer valve covers. See Valve
Cover Removalpage 3.77.
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 .

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R O C K E R A R M R E M O VA L
1. Remove rocker arm fasteners q and remove
rocker arms as an assembly.

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ROCKER ARM INSPECTION

NOTICE
Rocker arms are non-serviceable and must be
replaced as an assembly.

1. Visually inspect rocker arms and needle bearings

for scoring or damage.
2. Inspect oil passage q at the push rod cup and
clean thoroughly. Use only clean solvent.
3

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
cup show signs of wear, cracks, nicks or burrs.

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C Y L I N D E R H E A D D I S A S S E M B LY 4. Remove and discard the spring seat / valve stem

seal assemblies t .
CAUTION
Wear eye protection while removing valve springs.

NOTICE
Keep mated parts together for assembly.

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 .

5. Clean carbon deposits from combustion chamber.

6. Clean gasket surfaces.

3. Remove the valves r .

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CYLINDER HEAD INSPECTION

1. Visually inspect cylinder head for cracks or
damage. Pay close attention to the areas around
spark plug q and valve seats w .

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
Specificationspage 3.46.

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VA LV E I N S P E C T I O N 6. Measure valve stem deflection for each valve to

determine if valve or valve guide requires
NOTICE
replacement.
Valve service specifications can be found at the
beginning of this chapter. See Service
Specificationspage 3.46.

1. Place valves on V-blocks as shown and measure

valve stem runout q using a runout gauge or
similar tool..

A. Raise valve 10mm (0.400") off of seat.

B. Position dial indicator as shown. Measure
deflection in two directions perpendicular to each
other (X & Y axis).
C. If valve deflection exceeds service limit
measure valve stem diameter.
2. Inspect the valve face for damage from burning,
pitting or uneven contact. 7. Replace valve and repeat step 6 if valve stem O.D.
measures outside standard range. If valve stem
3. Place valves on V-block as shown and inspect deflection exceeds service limits with a new valve
valve head radial runout w . 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.

4. Insert valves into their original locations in

cylinder head.
5. Inspect that each valve moves up and down
smoothly without binding in guide.

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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 3

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.

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VA LV E G U I D E R E M O VA L / I N S TA L L AT I O N
CAUTION
Replacement of valve guides requires an oven,
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
competent machinist. Valve seat reconditioning is
required when valve guides are replaced.

1. Support cylinder head and place valve guide

remover into valve guide from the combustion
chamber side.
2. Drive or press old valve guides out of cylinder
head.

CAUTION
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

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.
8. Inspect and recondition valve seats.

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VA LV E S E AT I N S P E C T I O N
NOTICE
Valves cannot be ground. If valve face is burned or
badly worn, replace the valve.

1. Remove carbon deposits from valves and seats.

2. Inspect valve face for burning, pitting or uneven
contact.
3. Apply a light coating of machinist’s layout fluid or
paste to valve face. 3
4. Install valve into valve guide.
5. Tap valve several times to make a clear impression
on the valve face. Do not rotate valve.
6. Remove valve and measure contact area (valve
seat width). See Service Specificationspage 3.46.

7. If valve seat is incorrect, recondition as needed.

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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.

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C Y L I N D E R H E A D A S S E M B LY
CAUTION
Wear eye protection during assembly.

1. Lubricate valve stems with assembly lube.

2. Install valve in head before installing seal. Hold
valve against seat wipe off the portion that extends
above the guide.
3. Apply Indian Motorcycle engine oil to valve guide
seal and install seal on valve, rotating the seal as
3
you install it.
4. Press seal firmly in place on top of guide. Be
careful not to dislodge spring from seal.
5. Install valve spring and upper retainer.

CAUTION
Do not compress valve springs more than necessary
to install keepers.
Support cylinder head so valves will not be
damaged.

6. Compress valve springs using a valve spring

compressor and adapter.
7. Apply a small amount of grease to both sides of a
valve keeper.
8. Insert both valve keepers in place on valve.
9. Remove spring compressor.
10. Repeat previous steps for remaining valves.
11. Be sure all keepers are fully seated in groove.

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C Y L I N D E R H E A D I N S TA L L AT I O N 8. Install washers and nuts on cylinder studs. Tighten

finger tight.
NOTICE
The base gasket seal is broken when the cylinder
head is removed and must be replaced. See Cylinder
Installationpage 3.110.
Rocker arms must be removed from cylinder head
prior to installation.

1. If previously removed, lubricate push rod tube o-

rings with a small amount of engine oil and press
them into the lifter blocks until fully seated.
2. Verify that locating dowels q are in position on the
cylinder deck.
3. Thoroughly clean cylinder and cylinder head
mating surfaces.
NOTICE 9. Fully torque cylinder head following the procedure
Gaskets and gasket sealing surfaces must be free of below to ensure accurate final torque:
oil and grease during assembly.

4. Slide push rods through push rod tubes until seated

in lifters.
NOTICE
All push rods and rocker arms are identical, although
an effort should be made to put parts back into the
same location from which they were removed.

5. Install a new head gasket w .

TORQUE
Cylinder Head Nuts:
1. Torque fasteners to 26 ft-lbs (35 N·m) 2. Turn
additional 50 ° 3. Turn additional 90 °

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.

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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 3
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
Collapsed Hydraulic Lifter Bleed Air from Lifter(s) /
(s) Run at high idle for 10
Low Compression minutes
Poor Seating of Valve(s) Repair or Replace
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
Collapsed Hydraulic Lifter Bleed Air from Lifter(s) /
(s) Run at high idle for 10
Engine Noise Valve Train Area minutes
Broken or Weak Valve Replace
Spring(s)

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PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR

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
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

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CYLINDER / PISTON
G E N E R A L I N F O R M AT I O N
SERVICE NOTES
NOTICE
Clean the machine thoroughly before removing
engine from frame.

• This section covers service of the cylinder, piston

and rings. The engine must be removed from the
frame to perform the procedures in this section.
Refer to Engine / Cooling / Exhaust chapter for
engine removal and installation.
• Mark and store all mated parts for assembly.
Assemble engine by putting used parts that pass
inspection back in the same location.
• Machined mating surfaces are very delicate. Handle
and store all parts in such a way that the mating
surfaces will not be damaged.
• Many parts require assembly lubrication. Follow the
assembly lubrication procedures carefully.
• 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.
• Cleanliness of parts is critical to engine life and
proper parts inspection. Use clean solvent and hot,
soapy water to clean parts. Dry with compressed air
before inspection and engine assembly. Coat parts
with fresh lubricant to prevent oxidation after
cleaning.

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SPECIAL TOOLS
TOOL DESCRIPTION PART NUMBER
Piston Ring Compressor PV-43570-A
Clutch Shaft Holding Tool PF-51232
Cylinder Bore Gauge PV-3017
Crankshaft Rotation Tool PF-51239
Crankshaft Locking Pin PF-52135
Engine Case Splitting Tool PF-51234
3
Straightedge, Feeler Commercially
Gauge Available
Protective Sleeves For Commercially
Pistons / Studs Available

Bosch Automotive Service Solutions: 1-800-328-

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

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S E R V I C E S P E C I F I C AT I O N S
ITEM STANDARD SERVICE LIMIT
111 c.i. 116 c.i.
100.987 - 101.013 103.187 - 103.213 Check taper and
I.D. (3.9759" - 3.9769”) (4.0625" - 4.0635”) out-of-round
Cylinder Out of Round 0.05 mm (0.002")
Measure 66 mm up from base gasket
Taper surface 0.05 mm (0.002")
Gasket Surface 0.1 mm max.
-
Warpage (0.0039")
Piston Mark Piston orientation is determined by arrow on piston crown.
Direction Position BOTH pistons so arrows point to front of engine.
Piston O.D. (Measured 12 mm up (Measured 21 mm up Replace if piston-to-
(Nominal) from bottom of skirt, from bottom of skirt, cylinder clearance is
90 degrees to pin) 90 degrees to pin) excessive with good
cylinder
100.932 - 100.946 103.132 - 103.146
mm mm
(3.9737 - 3.9743") (4.0603 - 4.0609”)
Piston
Piston Pin Hole I.D. 22.006 - 22.012 mm 22.004-22.010 mm 22.047 mm
(0.8664 - 0.8666") (0.8663 - 0.8665”) (0.8680")
Piston Pin O.D. 21.995 - 22.000 mm 21.96 mm
(0.8659 - 0.8661") (0.864")
Piston to Cylinder 0.041 - 0.081 mm 0.15 mm
(0.0016 - 0.0032") (0.006")
Piston to Piston Pin 0.006 - 0.017 mm 0.004 - 0.015 mm 0.035 mm
(0.0002 - 0.0007") (0.0002 - 0.0006”) (0.0014")
Ring End Gap - Top 0.15 - 0.40 mm .80 mm
(Installed) (0.006 - 0.016") (0.031")
Ring End Gap - 2nd 0.33 - 0.53 mm 1.11 mm
(Installed)Ring End (0.013 - 0.021") (0.043")
Piston Ring Gap - 3rd (Oil 0.15 - 0.35 mm 0.80 mm
Clearances Control Rails) (0.006 - 0.014") (0.031")
(Installed)
Piston Ring Marks “CTOP” mark must
-
face UP on all rings.
Top Ring
0.02 - 0.060 mm
(1.2mm ring 0.11 mm (0.0043")
(0.0008 - 0.0024")
thickness)
Piston Ring to 2nd Ring
0.02 - 0.060 mm
Ring Land (1.2 mm ring 0.11 mm (0.0043")
(0.0008 - 0.0024")
thickness)
0.03 - 0.17 mm
Oil Control Ring 0.26 mm (0.010")
(0.001 - 0.0067")

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A S S E M B LY V I E W S
CYLINDER / PISTON

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Fastener, Connecting Rod Bearing Cap Reference Connecting Rod Installationpage

6.34.
w Bearing Cap, Connecting Rod -

e Bearing, Connecting Rod (52 mm) -

r Circlip, Wristpin -

t Wristpin -

y Piston (101 mm) -

u Ring, Oil Control -

i Ring, Compression (top 2 rings) -

o Gasket, Cylinder Base -

a Cylinder -

s Gasket, Cylinder Head -

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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

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C Y L I N D E R R E M O VA L
1. Remove cylinder head (s). See Cylinder Head
Removalpage 3.79.
2. Remove cylinder (s). Support pistons to prevent
damage. Place a section of hose over the cylinder
studs to prevent damage to the piston rings.

3. Remove cylinder base gasket q .

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.

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CYLINDER INSPECTION
1. Visually inspect cylinder bores for scratches and
wear.
2. Inspect gasket surfaces for scratches or other
damage that may cause an oil leak.

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CYLINDER BORE MEASUREMENT

1. Measure each cylinder bore in 6 places to
determine:

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.

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PISTON TO CYLINDER CLEARANCE WORKSHEET

Front 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” 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")

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.

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C Y L I N D E R WA R PA G E M E A S U R E M E N T
1. Inspect cylinder for warpage at cylinder head
surface and base gasket surface.
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.

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P I S T O N & P I S T O N R I N G R E M O VA L
1. Cover crankcase with a clean shop towel to
prevent piston circlip from falling into the
crankcase.
2. Remove the left piston pin circlip q .

3. Push piston pin w out to left side of engine and

remove the piston e .

4. Rotate rings in piston grooves. Rings should rotate

freely in grooves.
5. Clean carbon deposits from piston.
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.

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PISTON & PISTON RING INSPECTION 6. Measure installed ring end gap with a feeler gauge
and compare to specifications. See Service
1. Visually inspect piston for cracks, excessive wear,
Specificationspage
scoring, etc.
7. Install rings onto a clean piston. Push rings in until
2. Measure piston skirt O.D. (see table below).
they are flush with piston. Using a feeler gauge,
Replace piston if worn beyond the service limit. measure side clearances for the 1st & 2nd rings.
See Service Specificationspage .

111 C.I. 116 C.I. 8. Replace parts that exceed service limit.

90° to pin and 12 mm 90° to pin and 21 mm

from bottom of piston from bottom of piston
skirt skirt

3. Calculate Piston to Cylinder Clearance. Subtract

piston O.D. from cylinder bore I.D. and compare to
specifications. See Service Specificationspage
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.

5. Use a piston to push each ring squarely into

cylinder bore from bottom (push rings 25-50 mm
into cylinder).

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PISTON PIN / PIN BORE INSPECTION 5. Calculate connecting rod-to-piston pin clearance
1. Measure piston pin hole I. D. top to bottom (as by subtracting pin O.D from rod hole I.D.
shown) and as close to the circlip groove as
possible with a telescoping gauge. Record the 6. Compare measurements to specifications and
smallest measurement. replace any worn parts. See Service
Specificationspage .

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.

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P I S T O N R I N G I N S TA L L AT I O N
CAUTION
The rings may be damaged if they are over
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
Orientationpage 3.98.
3. Install top and bottom rails with end gap located
3
as shown. See Piston Ring Profile And
Orientationpage 3.98
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
Orientationpage 3.98.

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P I S T O N I N S TA L L AT I O N
The pistons are marked with an arrow on the crown.
Install pistons on connecting rods with arrow q facing
the FRONT of the engine.

1. Place a clean shop towel over crankcase to prevent

foreign material from entering crankcase.
2. Install a new circlip on one side of the piston with
end gap facing UP (12:00 position).
IMPORTANT
Never reuse piston pin circlips.

3. Lubricate piston pin and I. D. of connecting rod

small end with engine oil or moly lube.
4. Install piston over connecting rod with arrow on
piston crown facing FRONT of engine.
5. Push piston pin w through rod and piston pin hole
until it is stopped by circlip.
6. Install remaining circlip e with end gap facing up
(12:00 position.)

7. Make sure both piston circlips are seated properly

in the groove.

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CYLINDER STUD REPLACEMENT

1. Use a stud extractor to remove 10 mm studs q .

2. Clean threads in cases thoroughly.

3. Apply engine oil to stud threads.
4. Install studs and torque them to specification.
TORQUE
Cylinder Studs:
25 ft-lbs (34.0 Nm)

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C Y L I N D E R I N S TA L L AT I O N 8. Install piston ring compressor over rings and

compress rings into ring grooves.
NOTICE
Be sure all top end parts are ready for assembly. CAUTION
Sealant on crankcase parting line must not be
allowed to dry before top end is assembled and Be sure compressor band end gap does not align
torqued. with any ring end gap when compressing the rings.

1. First wash cylinders with clean solvent, then with NOTICE

hot soapy water.
Install cylinders in their original locations. Cylinder
2. Rinse the cylinders with clear water and with Knock Sensor is the front cylinder.
immediately dry with compressed air. Cylinder
bore should be wiped with a clean white shop 9. Remove protective covering from crankcase.
towel and engine oil.
10. Carefully install cylinder (s) over piston/ring
3. Apply a light coat of engine oil to piston and rings. assembly. Do not force cylinder over piston.
4. Ensure cylinder alignment dowel pins are in place Monitor rings carefully. If a piston ring becomes
and gasket surfaces are clean and oil-free. dislodged from the ring compressor; remove
cylinder, inspect ring carefully for damage.
5. Apply a small amount of crankcase sealant to the
crankcase parting lines on base gasket surface as
shown.

11. Remove piston ring compressor when rings are

fully captive in cylinder.
6. Install new cylinder base gaskets onto crankcase. 12. Slide cylinder down over piston until seated to
base gasket and crankcase surface.
IMPORTANT
13. Repeat for other cylinder.
Inspect all sealing surfaces carefully for scratches or
imperfections. DO NOT allow oil or grease to contact 14. Install cylinder head (s). See Cylinder Head
gaskets or sealing surfaces during the assembly Installationpage 3.90.
process.

7. Apply a small amount of engine oil to inside

surfaces of a piston ring compressor band.

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TROUBLESHOOTING, CYLINDER / PISTON

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
3
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
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 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
Collapsed Hydraulic Lifter Bleed Air from Lifter(s) /
(s) Run at high idle for 10
Low Compression minutes
Poor Seating of Valve(s) Repair or Replace
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
Collapsed Hydraulic Lifter Bleed Air from Lifter(s) /
(s) Run at high idle for 10
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

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PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR

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

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EXHAUST
EXHAUST SYSTEM *Includes 2021 Vintage / Vintage Dark Horse /
2017–2020 Springfield Dark Horse*

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

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)

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2021+ *All 2021 models excepts Vintage / Vintage Dark

Horse / Springfield Dark Horse*

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

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)

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

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EXHAUST SERVICE 3. Remove the four fasteners e securing each

muffler to the rear hanger.
M U F F L E R R E M O VA L
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.

1. Using a flat head screwdriver, loosen (do not 3

remove) the rear heat shield clamps q.

4. Slide the muffler assemblies rearward to remove

from the head pipe and cross over pipe.

2. Loosen the forward muffler clamps w between the

head pipe / cross over pipe and muffler.

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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
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.

1. Remove saddlebags, if equipped.

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
support fasteners t.

3. Remove left and right muffler assembliespage

3.115.
4. Remove cross over pipe support fastener w from
left hand side of the motorcycle.

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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.
3

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.

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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
hot for a period of time after the engine is stopped.
Heat sink edges are extremely sharp and could
Wear insulated protective clothing or wait for
cause personal injury. Wear gloves while removing
components to cool sufficiently before working on
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 3.116 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.

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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 (9.5 Nm)

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 pipepage

3.120 assembly.
4. Tighten front and rear head pipe flange nuts to
specification.
TORQUE
Head Pipe Flange Nuts: TORQUE
15 ft-lbs (20.3 Nm) Floorboard Support Fasteners:
35 ft-lbs (47.5 Nm)

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ENGINE / COOLING / EXHAUST

C R O S S O V E R P I P E I N S TA L L AT I O N 6. Tighten cross over pipe support fastener w and

Front head pipe must be installed before cross over rear head pipe support fasteners w to
pipe / rear head pipe assembly can be installed. specification.
1. Slide cross over pipe onto rear head pipe. Do not TORQUE
tighten clamp q at this time.
Cross Over / Head Pipe Support Fasteners:
18 ft-lbs (24.4 Nm)

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
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:
31 ft-lbs (42.0 Nm)

8. Reconnect rear oxygen sensor.

9. Install left and right heat shields r and torque
front clamps to specification.

4. Tighten head pipe flange nuts to specification.

TORQUE
Head Pipe Flange Nuts:
15 ft-lbs (20.3 Nm)

5. Install heat sink trim covers and torque fasteners

to specification.
NOTICE
TORQUE Rear heat shield clamps should not be tightened until
Heat Sink Trim Cover Fasteners: the mufflers have been installed.
84 in-lbs (9.5 Nm)
TORQUE
Heat Shield Clamps:
31 in-lbs (3.5 Nm)

10. Install left and right muffler assembliespage 3.122.

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ENGINE / COOLING / EXHAUST

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 4. Torque rear muffler support fasteners q to
rear support fasteners can be installed. specification.
TORQUE
Muffler Support Fasteners:
18 ft-lbs (24.4 Nm)

5. Torque rear heat shield clamps e to specification.

2. Install rear muffler support fasteners q into left

and right muffler assemblies finger tight.

TORQUE
Heat Shield Clamps:
31 in-lbs (3.5 Nm)

6. Start engine and listen for exhaust leaks.

3. Tighten left and right muffler clamps w to

specification.

TORQUE
Muffler Clamps:
31 ft-lbs (42.0 Nm)

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 FUEL DELIVERY / EFI

CHAPTER 4
FUEL DELIVERY / EFI
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
SERVICE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
EFI SYSTEM PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 4
FUEL LINE ROUTING (49 STATE MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
FUEL LINE ROUTING (CA & INTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.11
AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.12
SENSORS — POWERTRAIN MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13
FUEL DELIVERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.14
INTAKE MANIFOLD, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.14
FUEL PUMP PRESSURE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.15
FUEL SYSTEM DEPRESSURIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16
FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.17
FUEL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.19
FUEL TANK VENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.20
FUEL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.21
FUEL TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.24
FUEL LEVEL SENSOR RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.25
FUEL PUMP SUPPLY VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.26
FUEL PUMP CURRENT DRAW TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.27
PRIMING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.28
EFI SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.29
FUEL INJECTION SYSTEM - OVERVIEW OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.29
ECM CONNECTOR MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.30
TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.32
SENSOR DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.39
ECM PINOUT TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.40
ECM CONNECTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.41
ECM REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.41
TEMPERATURE & MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) REPLACEMENT . . . . . . . . . . . . . . .4.42
CYLINDER HEAD TEMPERATURE SENSOR, TEST / REPLACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.43
FUEL RAIL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.44
FUEL INJECTOR, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.49
FUEL INJECTOR RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.49
FUEL RAIL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.50
CRANKSHAFT POSITION SENSOR, TEST / REPLACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.57

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DETONATION SENSOR TEST / REPLACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.58

THROTTLE BODY (ETC) REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.59
CYLINDER MISFIRE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.60
REAR CYLINDER DEACTIVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.61
CAN DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.62
CAN (CONTROLLER AREA NETWORK) DIAGNOSTIC OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.62
DIGITAL WRENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.63
DIGITAL WRENCH DIAGNOSTIC SOFTWARE OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.63
DIAGNOSTIC SOFTWARE VERSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.63
ECM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.63
GUIDED DIAGNOSTIC AVAILABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.63
DIGITAL WRENCH COMMUNICATION ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.63
DIGITAL WRENCH DIAGNOSTIC CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.64
DIGITAL WRENCH SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.64
DIGITAL WRENCH VERSION AND UPDATE ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.64
DIGITAL WRENCH UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.65
DIGITAL WRENCH FEATURE MAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.66
ENGINE CONTROLLER REPROGRAMMING (REFLASH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.67
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.69
FUEL SYSTEM TROUBLESHOOTING, PART 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.69
FUEL SYSTEM TROUBLESHOOTING, PART 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.70
FUEL SYSTEM TROUBLESHOOTING, PART 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.71
FUEL SYSTEM TROUBLESHOOTING, PART 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.72

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 FUEL DELIVERY / EFI

G E N E R A L I N F O R M AT I O N
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.
4
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
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.

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FUEL DELIVERY / EFI

SPECIAL TOOLS
TOOL DESCRIPTION PART NUMBER
Electrical Tester Kit PV-43536
Fuel Line Plug Tool 2521832
Fuel Rail Fastener 2564374
Torquing Tool
Fuel Pressure Adapter PV-48656
Fuel Pressure Gauge PU-43506–A
Relay Bypass PU-49466
Smartlink Module Kit PU-47471
USB to Serial Adapter PU-50621

Bosch Automotive Service Solutions: 1-800-328-

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

S E R V I C E S P E C I F I C AT I O N S
ITEM SPECIFICATIONS
Fuel Pump Pressure
4.0 BAR (400 kPa) (58 psi)
(Normal Operation)
Idle Speed 800 rpm ± 50 rpm
Fuel Pump Amp Draw
3–5 Amps
(Normal Operation)
Recommended
91 Octane Minimum
Octane
Injector Resistance 11.4 - 12.6 Ohms

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 FUEL DELIVERY / EFI

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.
4
When connecting and disconnecting the battery
cables refer to Electrical chapter for complete battery
connection and charging information. See Battery
Installationpage 2.47. Static electricity can damage the electronic controllers
beyond repair. The human body can easily store
Make sure that the ignition is powered down before 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
larger value fuse or “jumper” the fuse with wire,
aluminum foil or any other means. Always investigate
the cause of the problem and repair before replacing
the fuse.

Do not touch ECM connector pins

Anti-static wrist strap PV-43541

NOTICE
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.

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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.

Use proper test adapters on connector pins

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.

"SNAP"

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.

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A S S E M B LY V I E W S
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 )

NUMBER PART DESCRIPTION

q Fuel Line (Pump to Fuel Rail)

w Fuel Vent Line, Upper (from tank)

e Fuel Vent Line, Lower (to atmosphere)

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FUEL LINE ROUTING (CA & INTL)

NUMBER PART DESCRIPTION

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)

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FUEL SYSTEM
2017–2020

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2021+

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

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 —

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F U E L TA N K

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Fastener, 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 Seal, Access Panel –

u Fuel Pump –

i Fastener, Fuel Tank — M8 x 1.25 x 35 (QTY.2) 18 ft-lbs (24.5 Nm)

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AIR BOX

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Fastener, Air Box Cover — M6 x 1.0 x 10 (QTY.3) 84 in-lbs (9.5 Nm)

w Cover, Air Box –

e Fastener, Air Filter Element — M5 x 0.8 x 10 62 in-lbs (7.0 Nm)

(QTY.3)

r Gasket, Air Box Cover –

t Air Filter Element –

y Fastener, Air Filter Retainer Plate — 10 x 5/8 31 in-lbs (3.5 Nm)

(QTY.3)

u Retainer Plate, Air Filter –

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SENSORS — POWERTRAIN MANAGEMENT

TORQUE (IF
NUMBER SENSOR / LOCATION APPLICABLE)
q TPMS (Tire Pressure Monitoring System) — Sensor located 180° from valve 44 in-lbs (5.0 Nm)
stem
w Wheel Speed Sensor, Rear — Located at the rear caliper carrier 96 in-lbs (10.8
Nm)
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 88 in-lbs (10.0
Nm)
i Gear Position Switch — Located inside the drive sprocket cover, below the 43 in-lbs (4.9 Nm)
drive sprocket
o Oxygen Sensor, Rear — Located on the rear head pipe 14 ft-lbs (19.0
Nm)
a Side Stand Switch — Located behind the side stand hinge 43 in-lbs (4.9 Nm)
s CPS (Crank Position Sensor) — Located on the front of the engine by the oil 88.5 in-lbs (10.0
filter Nm)
d Oxygen Sensor, Front — Located on the front head pipe 14 ft-lbs (19.0
Nm)
f Detonation “Knock” Sensor — Located on the rear face of the front cylinder 14.7 ft-lbs (20.0
heat sink Nm)
g CHT (Cylinder Head Temperature) Sensor — Located on the rear face of the 70 in-lbs (8.0 Nm)
front cylinder head
h Fuel Injectors — Located at the cylinder head intake ports —

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TORQUE (IF
NUMBER SENSOR / LOCATION APPLICABLE)
j Ignition coil — Located behind the horn assembly on the RH side of the engine 84 in-lbs (9.5 Nm)
k TMAP — (Temperature / Manifold Absolute Pressure) Sensor — Located on the 62 in-lbs (7.0 Nm)
back side of the intake manifold

FUEL DELIVERY SERVICE

I N TA K E M A N I F O L D , R E M O VA L / 7. Rotate the air box mounting flange up as shown
I N S TA L L AT I O N and remove the intake manifold from the engine.
1. Place motorcycle in an upright position with the
front wheel clamped in a wheel vise.
2. Remove the fuel tank. See Fuel Tank Removalpage
4.17.
3. Remove the air box / throttle body assembly. See
Air Box Removalpage 3.4.
4. Remove the fuel injectors. See Fuel Injector,
Removal / Installationpage 4.49.
5. Loosen the two clamps q securing the intake
manifold to the rubber boots at the front and rear
cylinders.

8. INSTALLATION is performed by reversing the

removal procedure.
9. Torque the intake manifold clamps and boots to
specification.
TORQUE
Intake Manifold Clamps:
20 in-lbs (2.3 Nm)

TORQUE
Intake Manifold Boots:
6. Remove the four fasteners securing the intake 88.5 in-lbs (10.0 Nm)
boots to the cylinder head.

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FUEL PUMP PRESSURE INSPECTION 4. Turn ignition switch off. Disconnect gauge adapter
and re-connect fuel line (Fuel Tank
WARNING Installationpage 4.24).
Gasoline is extremely flammable. Work in a well
FUEL PRESSURE TROUBLESHOOTING
ventilated area. Open flames, sparks and cigarettes
must be kept away from gasoline. KEEP GASOLINE FUEL PRESSURE TOO FUEL PRESSURE TOO
OUT OF THE REACH OF CHILDREN! LOW: INSPECT HIGH: INSPECT
* Low fuel level (add * Plugged fuel return
fuel) (in tank on pressure
CAUTION
* Pump not running regulator)
Wear safety glasses or a face shield when working (Fuel pump or circuit * Pressure regulator
around the fuel system to protect your eyes. malfunction) malfunction (located
* Restricted fitting, fuel on pump).
1. Depressurize fuel system and disconnect fuel line supply line, or gauge
at fuel rail. SeeFuel System Depressurizationpage adapter hose
4.16 . * Fuel line kinked or 4
restricted (from tank
2. Install fuel pressure gauge PU-43506– A and fuel fitting to rail)
pressure gauge adapter PV-48656. * Fuel line leaking
3. Start engine and record fuel pressure (or press the (leaking air in or fuel
power switch ON and cycle the Engine Stop switch out)
to read pressure when pump cycles for 2-3 * Vent restriction
seconds). * Plugged fuel pickup
filter (located in fuel
Minimum Fuel pressure 3.51 BAR (351 kPa) (51 tank)
psi) * Pressure regulator
malfunction (located on
pump)
*Fuel pump malfunction
(Pump should run for
about 2 seconds the
instant that the key
switch and Engine Stop
switch are turned ON.

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

fitting) and hold. Gently slide fitting straight off fuel
CAUTION rail.
Fuel lines remain under pressure at all times. Use 7. Cover fuel fittings to keep debris out.
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. See Electrical >

Chassis Electrical > Fuse Box.
3. Pull the fuel pump relay and crank the engine over
for 5 seconds to release pressure.
4. Remove the horn. See Horn Removal /
Installationpage 10.75.
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.

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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.

4
6. Lift the rear of the tank and slide back
approximately 2” to expose the front console cover
fastener.

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
Depressurizationpage 4.16
4. 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.

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8. Disconnect electrical connectors at the security

light, central locking and system power buttons
and remove console cover.
9. Disconnect the fuel pump electrical connector r,
and the fuel vent line t.
10. Wrap a clean shop towel around fuel line fitting y
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.

11. Squeeze both release buttons (one on each side of

fitting) and hold. Gently slide fitting straight off fuel
pump.
12. Cover fuel fittings to keep debris out.
13. Lift the rear of the fuel tank and slide rearward to
release from the front isolators.

14. Lift the tank off of the motorcycle and store safely.

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F U E L P U M P R E M O VA L 4. With a shop rag wrapped around the fuel fitting,

squeeze both release buttons from the fuel line
WARNING connector w (one on each side of fitting) and hold.
Replace all mounting fasteners and pump seal O-ring Pull straight up to remove.
any time pump is removed for service. Do not kink or
bend fuel pickup hose upon removal. Review
gasoline warnings outlined in the beginning of this
chapter. See EFI System Precautionspage 4.5.

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. 4
1. Remove the console cover from the fuel tank. See
STEPS 1–5 of Fuel Tank Removalpage 4.17. CAUTION
2. Disconnect the fuel pump electrical connector and Do not use anything other than fingers to remove the
move out of the way. quick connection. The use of tools can damage the
connection.
3. Disconnect the fuel tank vent line q by sliding the
rubber elbow off of the fitting.
5. Remove fuel pump access panel nuts e in an
alternating or “star” pattern.

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6. Raise the fuel pump access panel enough to 9. Reach in through the fuel pump access panel and
disconnect the fuel line r. Squeeze both release gently press the fuel pump retaining tab t toward
buttons, on the fuel quick connector (one on each the right-hand side of the fuel tank.
side of fitting), and hold. Gently slide fitting
straight off the fuel pump access panel.

10. Lift the fuel pump assembly out of the retaining

7. Cover fuel tank to keep debris out. bracket and carefully lift out of the fuel tank.
8. To disengage the electrical connector tab, gently
insert a flat-blade screwdriver between the
connector tab and access panel as shown. Once the F U E L TA N K V E N T I N S P E C T I O N
tab is released, gently pull the fuel pump electrical 1. Refer to Maintenance chapter for tank vent
connector to remove. inspection and hose routing information. See Fuel
Tank Vent Inspection (49 State)page 2.38.

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F U E L P U M P I N S TA L L AT I O N 3. Slide the pump into position until the retaining tab

engages and you hear an audible “click”. Gently
1. Lower the fuel pump assembly into the access hole
pull straight up on the pump to ensure it is locked
with the level arm facing forward and the jet pipe
in place.
resting on the left side of the tunnel.

IMPORTANT
2. Once the pump body is inside the tank, line up the
guide rails and retaining tab with the bracket q. Make sure the jet pump pickup tube is captured in
fuel tank bracket on opposite side of tank tunnel.

4. Verify that the float arm moves freely through it’s

full range of motion.
5. Press a new sealing gasket w into the bottom of the
fuel pump access panel.

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6. Lower the fuel pump access panel into position and 7. Install fuel pump access panel nuts r and tighten
connect the electrical connector and supply line e. to specification following the torque sequence
shown.

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.

TORQUE
Fuel Pump Access Panel (2017-2021):
24 in-lbs (2.7 N·m)

TORQUE
Fuel Pump Access Panel (2022+):
44 in-lbs (5 N·m)

8. Connect the fuel supply line, vent line and fuel

pump electrical connector to the top of the access
panel.
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.

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10. Prime the fuel system, check for leaks, and verify
fuel pump operation. See Priming The Fuel
Systempage 4.28

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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
Console Cover Fasteners:
84 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.

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9. Install the outer isolators and washers onto the 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

rear tank mount and install mounting fasteners y. OVERVIEW OF OPERATION: Fuel level readings are
measured by a variable resistance fuel level sensor q.
The fuel level sensor is located inside the fuel tank on
the fuel pump.

4
10. Verify that the fuel tank vent line is routed
properly and torque the fuel tank mounting
fasteners to specification.
TORQUE If fuel level readings are inaccurate when the
motorcycle is powered up, or if the fuel gauge isn’t
Fuel Tank Mounting Fasteners:
indicating fuel level at all, perform the following test
18 ft-lbs (24 N·m) and refer to resistance values located at the end of this
procedure.
11. Install seat and side covers.
1. Remove the fuel pump. See Fuel Pump
12. Prime the fuel system and verify fuel pump Removalpage 4.19.
operation. See Priming The Fuel Systempage 4.28
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 (terminals A &C) and
compare to the table.

LEVEL SENSOR ARM APPROXIMATE

POSITION RESISTANCE LIMITS
Full (Top of Range) 97–103 Ω
Empty (Bottom of
Range) 445–455 Ω

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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 Removalpage 4.19 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.

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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.
4
5. Read fuel pump current draw on meter and
compare to specification.
6. Inspect fuel pump circuit wiring or replace fuel
pump if current draw exceeds specification.
SPECIFICATION: Fuel Pump Current Draw
Maximum: 6 DC Amps

2. Remove fuel pump relay w by pulling straight

upward.

3. Set meter to DC Amps. Be sure red meter lead is in

the 10A jack, and black meter lead is in common
(-) jack.

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PRIMING THE FUEL SYSTEM

Prime procedure should be performed:
• If a new fuel pump is installed or if tank is run
completely dry.
• Whenever fuel system is serviced (fuel line is
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.
9. Repeat Steps 4-8 about 4 times to complete the
priming procedure.
NOTICE
Fuel level in tank must be high enough to submerge
pickup screen on fuel pump.

10. Once system is pressurized, carefully check all

fuel connections, joints and lines for leaks.

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EFI SERVICE
FUEL INJECTION SYSTEM - OVERVIEW OF
O P E R AT I O N
The Electronic Fuel Injection (EFI) system functions to
provide the engine with precisely metered fuel under
varying loads and conditions.
The Engine Control Module or “ECM”, is located
beneath the battery box. It is programmed to provide
the correct fuel/air mixture and ignition timing based
on several sensor input signals (engine load, temp,
altitude, manifold pressure etc.). The ECM also
provides grounds or voltage to other EFI related
circuits of the electrical and fuel delivery systems.
An Electronic Throttle Control (ETC) system takes the
place of a conventional, cable-operated throttle body. 4
The ETC controls throttle blade angle and provides
rate-of-change feedback to the ECM.
The ETC also serves as a plausibility check for the
TMAP sensor. The MAP portion of the TMAP sensor is
the primary air flow and load sensing device.
An electric fuel pump, mounted inside the fuel tank
supplies fuel pressure to the injectors continuously
when the engine is running or cranking. A pressure
regulator incorporated on the pump keeps fuel
pressure steady at approximately 3.51 Bar (350 kPa /
51 PSI). The fuel pump cycles “ON” for 2-3 seconds
when the motorcycle is powered up and the Engine
Stop switch is turned ON to pressurize the system for
start-up.
The fuel injectors inject fuel when they are grounded
by drivers inside the ECM. The duration of an injector
pulse (length of time the injector circuit is grounded)
is controlled by the ECM. Pulse duration determines
the amount of fuel delivered to the engine (longer
cycles = more fuel). The ECM selects the correct fuel
injector pulse by calculating the airflow from the MAP
sensor measurement and referencing a three
dimensional “map” for the desired air-to-fuel ratio
(AFR). The ECM calculates an injection time based on
the measured airflow and desired AFR.
Although TMAP and engine RPM are the most
influential inputs for selecting a map reference point,
the ECM also evaluates feedback from minor sensors
in the system, to obtain a more accurate “picture” of
the fuel needs at any given moment.
The fuel control system is closed loop. When the
engine is at a warm idle and typical cruising engine
speeds and loads, the ECM will operate in “closed
loop fuel control” mode. The oxygen sensors in each
headpipe will provide feedback to the ECM and the
injection time will be adjusted for each cylinder to
achieve the target AFR.
The locations of sensors and other EFI system related
components are outlined in this chapter. See Sensors
— Powertrain Managementpage 4.13.

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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 FRONT 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 FRONT O2 SNR RETURN

6 WH/BK PPS 1 RETURN 6 BK/BU FUEL SENDER GROUND

7 - NOT USED 7 BG REAR 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

14 - NOT USED 14 - NOT USED

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

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PIN ECM COLOR FUNCTION PIN ECM COLOR FUNCTION

1 2

21 WH/GN PPS 1 OUTPUT 21 - NOT USED

22 - NOT USED 22 - 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

28 - NOT USED 28 - NOT USED

29 - NOT USED 29 - NOT USED

30 - NOT USED 30 GY/RD REAR O2 SENSOR OUTPUT

31 - NOT USED 31 - NOT USED 4

32 YE CAN HIGH 32 - NOT USED

33 - NOT USED 33 - 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 FRONT 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

45 - NOT USED 45 - NOT USED

46 - NOT USED 46 GY/WH REAR O2 SENSOR CONTROL

47 BG/BK SIDESTAND SWT SIGNAL 47 BK/WH ECM GROUND

48 - NOT USED 48 DB/RD RIGHT REAR TS OUTPUT

49 - NOT USED 49 - NOT USED

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

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TROUBLE CODES
SPN FMI COMPONENT CONDITION MIL P-CODE
3 Voltage Too High ON P1228

29 4 Accelerator Position 2 Voltage Too Low ON P1227

2 Not Plausible ON P1225

3 Voltage Too High ON P0123

4 Voltage Too Low ON P0122

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

ON P0503
2 Data Erratic or Intermittent (or Missing)
84 Vehicle Speed Signal ON C1058

8 Sensor Frequency Outside Normal Range ON P0501

9 Abnormal Update Rate ON P160A

ON C1069
19 Received Vehicle Speed has error
ON P106B
3 Voltage Too High ON P0228

91 4 Accelerator Position 1 Voltage Too Low ON P0227

2 Not Plausible ON P0225

3 Voltage Too High ON P0463

4 Voltage Too Low ON P0462

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
3 Voltage Too High ON P0108

4 Voltage Too Low ON P0107

Manifold Absolute Pressure
102 2 Signal Out of Range ON P0106
Sensor
10 Abnormal Rate of Change ON P0109

7 Pneumatic Fault ON P1106

3 Voltage Too High ON P0113
105 Intake Air Temperature Sensor
4 Voltage Too Low ON P0112

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SPN FMI COMPONENT CONDITION MIL P-CODE

10 Abnormal Rate of Change ON P0114

2 Signal Out of Range ON P0111

3 Voltage Too High ON P0118

4 Voltage Too Low ON P0117

2 Signal Out of Range ON P0116

10 Abnormal Rate of Change ON P0119

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 4

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

3 Voltage Too High ON P0917

4 Voltage Too Low ON P0916

523 Gear Sensor Signal
9 Abnormal Update Rate ON P1914

2 Signal Fault ON P0914

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

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SPN FMI COMPONENT CONDITION MIL P-CODE

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 Driver Circuit Open/Grounded ON P0264

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

4 Driver Circuit Grounded ON P1265
5 Driver Circuit Open/Grounded ON P0615

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

4 Driver Circuit Grounded ON P0616

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

14 Incorrect Sensor / Improper Mounting ON C143D

1023 5 Trip Sudden Decelerations Open / Short ON C1045

5 Driver Circuit Open/Grounded ON P1481

1071 3 Fan Relay Driver Driver Circuit Short to B+ ON P1482

4 Driver Circuit Grounded ON P1483
5 Driver Circuit Open/Grounded ON P1351

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

4 Driver Circuit Grounded ON P1361
5 Driver Circuit Open/Grounded ON P1352

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

4 Driver Circuit Grounded ON P1362
5 Driver Circuit Open/Grounded ON P0230

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

4 Driver Circuit Grounded ON P0231
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 Right Turn Indicator Driver Driver Circuit Open/Grounded OFF P1710
2369
Circuit

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SPN FMI COMPONENT CONDITION MIL P-CODE

3 Driver Circuit Short to B+ OFF P1711
4 Driver Circuit Grounded OFF P1712
2 Signal Fault ON P0130

12 Bad Component ON P113A

3056 Oxygen Sensor 1 (Front)
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
4
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

3598 ECU Output Supply Voltage 2
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

3599 ECU Output Supply Voltage 3
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

3 Voltage Too High ON P0223

4 Voltage Too Low ON P0222

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

10 Abnormal Rate of Change ON P0220

13 Calibration / Adaption Failure ON P1220

Condition Exists (engine disabled due to extended

520267 31 Kickstand Switch kickstand) ON P181C

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SPN FMI COMPONENT CONDITION MIL P-CODE

2 Signal Fault ON P1501

3 Voltage High ON P1503

520200 Tipover Sensor
4 Voltage Low ON P1502

14 Condition Exists (tip over condition detected) ON P1504

5 Driver Circuit Open/Grounded ON P0444

520202 3 Canister Purge Valve Driver Circuit Short to B+ ON P0443

4 Driver Circuit Grounded ON P0445
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

5 Driver Circuit Open/Grounded ON P1611

520208 3 Chassis/Acc Relay Driver Circuit Short to B+ ON P1614

4 Driver Circuit Grounded ON P1613
2 Plausibility Fault ON P0135

5 Oxygen Sensor Heater 1 (pre) Driver Circuit Open/Grounded ON P0030

520209 (front)
3 Driver Circuit Short to B+ ON P0032
4 Driver Circuit Grounded ON P0031
2 Plausibility Fault ON P0141

5 Oxygen Sensor Heater 2 (post) Driver Circuit Open/Grounded ON P0036

520210 (rear)
3 Driver Circuit Short to B+ ON P0038
4 Driver Circuit Grounded ON P0037

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

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SPN FMI COMPONENT CONDITION MIL P-CODE

520263 31 ABS Tire Irregular Tire Size ON C1040

520264 12 ABS ECU ECU Error ON C1041

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 4
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
5 Open Circuit / Short to B+ ON C1078
520292 Right Fog Lamp
6 Grounded Circuit ON C1079
5 Open Circuit / Short to B+ ON C122A
520293 Horn
6 Grounded Circuit ON C122B

520294 5 Windshield Motor Driver Open Circuit / Short to B+ ON C1222

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SPN FMI COMPONENT CONDITION MIL P-CODE

6 Grounded Circuit ON C1223

520295 2 Windshield Motor Switch Both inputs are closed ON C1225

520296 12 Accelerometer Bad Component ON C1125

520297 31 System On Button Switch Stuck ON C1530

5 Open Circuit / Short to B+ ON C1047

520298 Heated Grips
6 Grounded Circuit ON C1048
5 Open Circuit / Short to B+ ON C1226
520299 Power Lock Motor
6 Grounded Circuit ON C1227
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

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

5 Open Circuit ON P1596

520321 3 Tail Light Shorted to Battery ON P1597

4 Shorted to Ground ON P1598

3 Voltage Too High ON P1599

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 3 Knock Sensor Positive Line Voltage Too High ON P1327

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SPN FMI COMPONENT CONDITION MIL P-CODE

4 Voltage Too Low ON P1328

3 Voltage Too High ON P132A

520332 Knock Sensor Negative Line
4 Voltage Too Low ON P132B

2 Signal Fault ON P1136

12 Bad Component ON P1139

520333 Oxygen Sensor (Pre) (BANK 2)
3 Voltage High ON P1137

4 Voltage Low ON P1138

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
4
31 Cruise Control Input Message Counter not incremented ON U1405
524080
Counter
5 Open Circuit ON P1075

524083 3 Secondary Air Control Valve Shorted to Battery ON P1076

4 Shorted to Ground ON P1077

SENSOR DIAGNOSTICS Many sensor tests described in this section are

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

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ECM PINOUT TESTING

NOTICE
Tests in this section may require reading resistance
and voltages at ECM connector. Once ECM
connector has been removed from the ECM:

• Do not touch pins on ECM. Static electricity from

your body can damage the ECM.
• Do not attempt to perform tests on the ECM unit.
• Always use the appropriate test connector from the
Electrical Connector Test Adapter Kit (PV-43526) or
an appropriate test probe that will not damage
(expand) the connector pin socket.
• DO NOT attempt to use standard meter probes or
other devices to probe connector pin sockets. this
could expand a terminal socket or damage the
connector, create a problem where none existed
before, and complicate the diagnostic process.
• Sensor tests on the following pages can often be
performed at the sensor connector itself or at the
ECM connector based on accessibility of the
connector or wiring.
• If a sensor tests within the specified range (OK),
then test the circuit wiring. This usually originates at
the ECM connectors, but may include other
connections.

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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 / Installationpage 7.22. Connector Removalpage 4.41.
2. Remove the RH lower side cover. See Side Cover 2. Remove the battery box. See Battery Box
(Lower), Removal / Installationpage 7.22. Removalpage 10.14.
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 (4.1 Nm)
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.

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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 /
Installationpage 10.53.
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

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 62 in-lbs (7.0 Nm)
IMPORTANT
This sensor should only be tested using Digital
Wrench Diagnostic Software.

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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 Removalpage 4.41.

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 Mappage 4.30. 4
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

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F U E L R A I L R E M O VA L 1. Remove upper side covers.

Remove Saddlebags (if equipped).
Remove Trunk (if equipped). See Trunk Removal,
Roadmasterpage 7.36

NOTICE
The fuel rail design will vary by year. The torque for
the fuel rail fasteners is the same for both designs.
See the images below for model year variations.

2017–19

2. Remove the two fasteners y retaining the driver

seat to the frame. Remove seat.

2020+

NOTICE
For models with a passenger seat, remove passenger
seat fastener.

3. Depressurize the fuel system. See Fuel System

Depressurizationpage 4.16
4. Disconnect the vent / EVAP line from the fuel tank.

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5. Remove fuel tank fasteners u. 7. Remove the three fasteners i securing the air
cleaner cover to the air box.

4
NOTICE
To provide access to fuel rail, lift the rear of the fuel 8. Remove the three fasteners o securing the air filter
tank high enough to insert a small 2x4 piece of wood to the adapter plate and remove air filter.
beneath the fuel tank rear mount.

6. Using compressed air, blow any debris away from

base of fuel injectors.

NOTICE
Accessory intakes may require a different removal
process.

CAUTION
Always wear eye protection

NOTICE
Cleaning the area with compressed air prevents
sand, grit, and dirt from entering the intake runner as
the injector is removed.

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9. Remove the three fasteners a securing the air filter 11. Remove the lower fastener d securing the air box
adapter plate to the air box assembly and remove housing to the mounting plate.
adapter plate.

12. Disconnect the multi-plug f from the throttle body.

NOTICE
When removing the adapter plate, start by applying
more pressure to the forward (left-hand) edge and
pull outward to release the valve cover vent hose
from the back side of the adapter plate.

10. Remove the upper two fasteners s securing the

baffle plate to the intake.

13. Remove four throttle body fasteners g and remove

throttle body.

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14. Push the rubber multi-plug seal through the back 17. Squeeze both release buttons, on the quick fuel
of the air box housing. Disconnect intake hose and connector (one on each side of fitting), and hold.
remove air box housing. Gently slide fitting straight off the fuel rail.

15. Cover intake h to prevent debris from entering the CAUTION

engine.
Always wear eye protection

18. Insert FUEL LINE PLUG TOOL (2521832) into fuel

line to prevent fuel from leaking.

16. Wrap a clean shop towel around fuel line fitting.

NOTICE
Listen for an audible “click” to confirm the Fuel Line
Plug Tool is fully engaged.

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19. Using a 'L' shaped allen wrench remove the two 21. Remove o-rings from the top and bottom of the
fasteners k securing the fuel rail to the intake injectors and discard o-rings.
manifold. Carefully remove fuel rail from the right-
hand side of the motorcycle.

NOTICE
When removing fuel rail from injectors, wrap a rag
around both ends of the fuel rail to collect fuel.

20. Leave electrical connector in place, remove fuel

injectors from intake.

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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 Installationpage

1. Remove fuel rail from injectors. See Fuel Rail
Removalpage .
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
2. Disconnect electrical connector from fuel injector.
Discard fuel injector AND injector o-rings. IMPORTANT
Take note of front and rear fuel injector harness
3. Lubricate NEW injector o-rings with clean, connectors before disconnecting them.
silicone-free motor oil.
NOTICE The fuel injectors are non-serviceable. If diagnosis
Apply oil sparingly and avoid contaminating the indicates a problem with either injector, test the
pintle valve / jet surface and upper inlet port. 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

4

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.

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F U E L R A I L I N S TA L L AT I O N 1. Lubricate NEW injector o-rings with clean,

silicone-free motor oil.
NOTICE
The fuel rail design will vary by year. The torque for
the fuel rail fasteners is the same for both designs.
See the images below for model year variations.

2017–19

NOTICE
Apply oil sparingly and avoid contaminating the
pintle valve / jet surface and upper inlet port.

2. Install NEW o-rings onto top and bottom of

injectors
2020+
PART NUMBER POSITION
1500198 TOP OF INJECTOR
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.

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3. Install fuel injectors by carefully pressing into 6. Install the FUEL RAIL TORQUE TOOL (5264374)
intake manifold. onto a ¼ in drive torque wrench. Install a 5 mm
allen bit to the hex end of the torque tool as shown.

4
CAUTION
IMPORTANT
Use care not to fold or displace lower o-ring from
seating surface. Alignment of the special tool is critical to achieve the
correct torque. Make sure the FUEL RAIL TORQUE
TOOL remains in-line with the torque wrench while
4. Install replacement fuel rail from the right-hand torquing fasteners.
side of motorcycle.

CAUTION
Use care not to fold or displace upper o-ring from
seating surface.

5. Install fuel rail fasteners k into the intake manifold

until finger tight.

NOTICE
For ease of installation, install the front cylinder fuel
rail fastener first.

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7. Torque fuel rail fasteners to specification. 9. Connect fuel line to fuel rail.

IMPORTANT IMPORTANT
Make sure the FUEL RAIL TORQUE TOOL and the Verify fuel supply line is properly seated and locked
torque wrench remain in-line while torquing in place by listening for audible "click" when
fasteners. pressing into place. Pull gently on quick connector
once seated to ensure a proper connection has been
made.
TORQUE
Fuel Rail Fasteners: IMPORTANT
62 in-lbs (7 N·m)
Prime the fuel system by turning the run/stop switch
on and then off. Once system is pressurized, carefully
8. Squeeze the quick connect buttons (one on each check all fuel connections, joints and lines for leaks.
side) and hold. Remove special tool from fuel line. See Priming The Fuel Systempage 4.28

CAUTION 10. Uncover the intake h.

Do not use anything other than fingers to remove the
quick connection. The use of tools can damage the
connection.

NOTICE
Use a rag to contain the small amount of fuel that may
drain from the fuel line after the special tool is
removed.

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11. 13. Install four throttle body fasteners g. Torque

fasteners to specification.

4
IMPORTANT
Verify that BOTH air box o-ring seals are correctly in TORQUE
position before installing the throttle body. Throttle Body Fasteners:
84 in-lbs (10 N·m)
12. Feed the throttle body multi-plug connector
through the hole in the air box. Connect intake
14. Connect the multi-plug f to the throttle body.
hose to the air box housing.

NOTICE
Use a small amount of lubricant around the outside of
the breather hose when installing to the air box
housing.

NOTICE
Make sure that the harness seal is fully seated in the
air box cutout.

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15. Install the lower fastener d securing the air box to 17. Install the three air filter adapter plate fasteners a.
the mounting plate. Torque fastener to Torque fasteners to specification.
specification.

18. Install the three fasteners o securing the air filter

TORQUE to the adapter plate. Torque fasteners to
specification.
Air Box Fastener:
84 in-lbs (10 N·m)

16. Install the upper two fasteners s securing the

baffle plate to the intake. Torque fasteners to
specification.

TORQUE
Air Filter Fasteners:
62 in-lbs (7 N·m)

TORQUE
Upper Intake Fasteners:
15 in-lbs (2 N·m)

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19. Install the three fasteners i securing the air 22. Remove the small 2x4 piece of wood beneath the
cleaner cover to the air box. Torque fasteners to fuel tank rear mount and lower fuel tank into
specification. position. Install fuel tank fasteners u. Torque
fasteners to specification.

TORQUE
TORQUE
Air Box Cover Fasteners:
84 in-lbs (10 N·m) Fuel Tank Fasteners:
18 ft-lbs (24 N·m)
20. Install the fuel tank vent line to the chassis vent line
at rear of tank. 23. Slide front of seat into seat retaining bracket. Install
the two fasteners y retaining the driver seat to the
frame. Torque seat fasteners to specification

21. Verify that both fuel tank isolators are assembled

correctly as shown.
TORQUE
Seat Fasteners:
18 ft-lbs (24 N·m)

NOTICE
For models with a passenger seat, install and torque
passenger seat fastener.

24. Connect the motorcycle to Digital Wrench. Verify

no fail codes and no MIL lights are present. Field
Test the motorcycle to verify proper operation.

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25. Install the upper side covers.

26. Install Trunk (if equipped). See Trunk Installation,

Roadmasterpage 7.37
27. Install Saddlebags (if equipped).

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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. Installationpage 10.31.
2. Remove regulator / rectifier assembly and bracket.
See Rectifier / Regulator Replacementpage 10.40.
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.

5. Installation is performed by reversing the

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 88.5 in-lbs (10.0 Nm)
not been damaged and is securely mounted to the
crankshaft assembly.

Crankshaft Position Sensor: 860 Ohms @ 20°C (68°F)

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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
520332
P132B 4 Negative Line: Voltage too low

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
Removalpage 2.46. continuity). See ECM Connector Mappage for
2. With the RH upper side cover removed, locate the 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 / sensor with a rubber mallet or other non-metallic
Installationpage 4.41. 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

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14. Remove the ignition coil assembly and mounting T H R O T T L E B O D Y ( E T C ) R E M O VA L

bracket. See Ignition Coil Removal / 1. To remove the Electronic Throttle Control
Installationpage 10.53. assembly, see Air Box Removalpage 3.4.
15. Remove the fuel tank. See Fuel Tank Removalpage
4.17.
16. Remove the fastener w securing the detonation
sensor to the forward cylinder.

17. Noting how the detonation sensor harness is

routed, remove the sensor from the motorcycle.
18. INSTALLATION is performed by reversing the
removal procedure.
19. Torque the detonation sensor fastener to
specification.
TORQUE
Detonation Sensor Fastener:
14.7 ft-lbs (20.0 Nm)

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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.

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.

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R E A R C Y L I N D E R D E A C T I VAT I O N
Designed as an aid to reduce engine and exhaust heat
to the rider, Rear Cylinder Deactivation turns off the
rear cylinder when the engine gets hot.
The following condition must be met for Rear Cylinder
Deactivation to be enabled.
• Engine must be up to operating temperature
• Ambient Temperature must exceed 15 C
• Engine speed must remain below 1000 rpm
• Gear position must be 1, 2, or N
• Throttle must be in the closed position (0% throttle)

For models equipped with Ride Command, Rear 4

Cylinder Deactivation can be turned off by accessing
the settings menu in the drop-down from the top of the
screen. Cylinder Deactivation controls are in the
Vehicle menu. When Rear Cylinder Deactivation is
functioning, an icon will illuminate at the top of the
Ride Command display screen.
For models not equipped with Ride Command, do the
following to disable Rear Cylinder Deactivation:
1. Press the right-hand trigger until “CYLdeAC”
displays.
2. Hold down the right-hand trigger. “CD ON” or “CD
OFF” will display.
3. Toggle to turn cylinder deactivation on or off. Press
and hold hand right-hand trigger to save settings.
• CYLdeAC ON: rear cylinder can deactivate
• CYLdeAC OFF: rear cylinder cannot deactivate

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CAN DIAGNOSTICS
CAN (CONTROLLER AREA NETWORK)
DIAGNOSTIC OVERVIEW
Overview
The speedometer and Engine Control Module (ECM)
have integrated 120Ω termination resistors. With the
speedometer unplugged, check resistance between
the CAN terminals at the speedometer connector. The
resistance should be 120Ω. With the speedometer
connector plugged in, and the ECM connector
unplugged the resistance will be 120Ω. With
speedometer and ECM connectors plugged in, the
resistance will be 60Ω

Baseline CAN Resistance Values

Checking resistance between Yellow CAN High wire
and Green CAN Low wire at the specified module
connectors below (while unplugged):

• VCM = 60Ω
• ECM = 120Ω
• Speedometer = 120Ω
• ABS Module = 60Ω
• Diagnostic Connector = 60Ω

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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
4
• 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
available, see Digital Wrench Version and Update
IDpage 4.64.

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.
In addition, guided diagnostics are also available for
many other electrical sub systems.

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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 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
The diagnostic connector q is located under the LH Knowing what Digital Wrench version and update is
upper side cover, below the fuse box. installed will help determine which updates are
required.
NOTICE
Versions and updates are subject to change.

1. Open the Digital Wrench software. Locate the

version ID shown on the lower right side of the
Digital Wrench start-up screen.

Follow these steps to connect the diagnostic interface

cable to the vehicle:
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.
3. Connect the Vehicle Interface Cable to the Digital
Wrench diagnostic connector. 2. Proceed to http://polaris. diagsys. com to see if a
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
Always operate with the latest update.

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D I G I TA L W R E N C H U P D AT E S 6. If the update file date listed is newer than your

Updates are released for Digital Wrench via the current version and update, download the file.
Internet at: http://polaris.diagsys.com. The Digital
Wrench website can also be accessed through the
dealer website at: www.polarisdealers.com.
NOTICE
Only authorized Indian Motorcycle dealers and
distributors can access the dealer website.

1. Log on to www.polarisdealers.com.
2. Locate the Service and Warranty drop-down
menu.
3. Click on Digital Wrench Updates.
4
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.
4. The Digital Wrench portal website should appear
in a new web browser.
5. Click on Digital Wrench Version Updates.

NOTICE
Versions and updates are subject to change.

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.

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

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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 4
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.

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9. Go to www. polarisdealers. com and click on

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

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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
Open wiring / connector
Inspect / Repair
Inspect / Repair
4
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

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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 2
PROBLEM POSSIBLE CAUSE AFFECTED PART(S) REPAIR RECOMMENDED
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 Test / Replace
Rotor Inspect / Install correctly
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

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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 3
PROBLEM POSSIBLE CAUSE AFFECTED PART(S) REPAIR RECOMMENDED
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
4
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

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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 4
PROBLEM POSSIBLE CAUSE AFFECTED PART(S) REPAIR RECOMMENDED
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 Repair
Air leak at throttle body to Test / Repair
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

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CHAPTER 5
CLUTCH / PRIMARY / SHIFT
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
PRIMARY COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
CLUTCH PINION SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
TORQUE COMPENSATOR - 2017 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
PRIMARY DRIVE GEAR - 2018+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5
PRIMARY COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
CLUTCH PINION SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
CLUTCH PINION SHAFT BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
CLUTCH PINION SHAFT SEAL REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
CLUTCH PINION SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.11
SHIFT RATCHET REMOVAL & INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.11
SHIFT RATCHET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.13
SHIFT SHAFT BEARING & SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.14
PRIMARY COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.14
CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.16
CLUTCH RACK, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.16
CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.16
CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.17
CLUTCH INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.19
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20
CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21
TORQUE COMPENSATOR SERVICE - 2017 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22
TORQUE COMPENSATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22
TORQUE COMPENSATOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22
TORQUE COMPENSATOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23
PRIMARY DRIVE GEAR SERVICE - 2018+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
PRIMARY DRIVE GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
PRIMARY DRIVE GEAR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.25
FLYWHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.25
TROUBLESHOOTING, CLUTCH / PRIMARY / SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.26

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G E N E R A L I N F O R M AT I O N
S E R V I C E I N F O R M AT I O N SPECIAL TOOLS
• Clutch and external transmission shift linkage TOOL DESCRIPTION PART NUMBER
service can be accomplished with the engine in the
Case Splitting / Assembly PF-51234
frame.
Tool
• Internal transmission or internal shifting mechanism
service requires engine removal and crankcase Clutch Shaft Holder PF-51232
separation. Crankshaft Locking Pin PF-52135
• Oil additives of any kind are not recommended by Crankshaft Rotation Socket PF-51239
Indian Motorcycle. Using oil additives or oil of the
wrong viscosity can have a detrimental affect on Engine Stand Adapter PF-51240
clutch performance, operation, and service life.
Moly Assembly Paste 2871460
• Burnt clutch plates are not an indication of defective
clutch plates. Burnt clutch plates indicate that a Bosch Automotive Service Solutions: 1–800–328–
problem exists within the clutch system, the clutch 6657 or https://polaris.service-solutions.com/
has been used improperly, or plates were
contaminated by improper oil or additives.
• Indian Motorcycle 20W/40 motorcycle oil is
recommended for all operating temperatures. If
Indian Motorcycle 20W/40 oil is not available, a high
quality JASO MA compliant/rated, 20W/40
motorcycle oil suitable for use in wet clutch
transmissions can be used.
• Lubricate parts during assembly as described in the
procedures.
• Corroded or sticking shift linkage pivot points can
cause abnormal shifting. Replace any linkage
components that are damaged or do not move
freely, and lubricate at regular intervals.

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S E R V I C E S P E C I F I C AT I O N S
ITEM SPECIFICATIONS
Clutch Type Wet, Multi-Disk
Clutch Operating Mechanism Manual / Cable Operated
Torque Compensator Belleville Spring Loaded Cam
Assembly
Primary Reduction Ratio 1.56 : 1
Clutch / Gear Shift / Linkage
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
Clutch Lever Free Play (Cable) .50-1.50 mm (.020-.060")

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A S S E M B LY V I E W S
PRIMARY COVER

NUM- PART DESCRIPTION TORQUE (IF APPLICABLE)

BER
q Fastener, Primary Cover - M8 x 1.25 x 35 (QTY.7) 15 ft-lbs (20.0 Nm)

w Fastener, Primary Cover - M8 x 1.25 x 75 (QTY.7) 15 ft-lbs (20.0 Nm)

e Primary Cover -

r Gasket, Primary Cover -

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CLUTCH PINION SHAFT

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

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 -

u Lever, Clutch -

i Fastener, Clutch Lever - M6 x 1.0 x 25 (QTY.1) 88 in-lbs (10.0 Nm)

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T O R Q U E C O M P E N S AT O R - 2 0 1 7

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Compensator Fastener (QTY.1) 83 ft-lbs (112.0 Nm)

w Locking Plate Fasteners (QTY.2) 88.5 in-lbs (10.0 Nm)

e Locking Plate -

r Compensator Spring Retainer -

t Compensator Spring Cup -

y Compensator Spring -

u Compensator Slider -

i Compensator Gear -

o Washer -

a Compensator Sleeve -

s Stator Rotor -

d Stator Fastener (QTY.3) 88.5 in-lbs (10.0 Nm)

f Stator -

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PRIMARY DRIVE GEAR - 2018+

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Primary Drive Gear Fastener (QTY.1) 83 ft-lbs (112.0 Nm)

w Locking Plate Fasteners (QTY.2) 88.5 in-lbs (10.0 Nm)

e Locking Plate -

r Adapter -

t Primary Drive Gear -

y Stator Rotor -

u Stator Fasteners (QTY.3) 88.5 in-lbs (10.0 Nm)

i Stator -

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CLUTCH

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

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) -
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 -

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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 .
1. Place motorcycle in an upright position with the
front wheel clamped in a wheel vise.
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),
Removalpage 7.23
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.
5
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.

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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
Removalpage 5.9. 1. Remove clutch pinion shaft. See Clutch Pinion
2. Remove the E-clip q and washer from the end of Shaft Removalpage 5.10.
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.

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.

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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
Removalpage 5.9.
4. Remove clutch assembly. See Clutch Removalpage
5.16.
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 .

5

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.

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CLUTCH / PRIMARY / SHIFT

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
mechanism to keep it engaged with the shift star.

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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:
5
NOTICE
84 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
Installationpage 5.21.
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
Installationpage 5.14.
spring. Torque fastener to specification.

TORQUE
Detent Roller Fastener:
84 in-lbs (10 N·m)

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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.
1. Remove primary cover. See Primary Cover
Removalpage 5.9. 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.

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.
8. Install primary cover. See Primary Cover
Installationpage 5.14.
9. After installing primary cover, be sure shift shaft
returns freely to the centered position after
rotating up or down.

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6. Torque the primary cover fasteners to specification

following the torque sequence.

TORQUE
Primary Cover Fasteners:
15 ft-lbs (20.0 Nm)

Primary Cover Torque Sequence

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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 2. INSTALLATION: Reverse the removal procedure
to install.
1. Using an internal snap ring pliers, remove snap
ring q and clutch rack w. CAUTION
The clutch rack is to be installed with the snap ring
facing outward on 2021 models only. 2014–2020
models will have the snap ring facing inward. Failure
to correctly install the clutch rack will cause
improper operation.

2021 MODELS
CORRECT
Snap ring q is facing outward.

INCORRECT
Snap ring is facing inward.

C L U T C H R E M O VA L
1. Remove primary cover. See Primary Cover
Removalpage 5.9.
2. Remove clutch rack. See Clutch Rack, Removal /
Installationpage .

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3. Perform the crankshaft locking procedure. See 3. With the clutch assembly resting on a clean, flat
Locking the Crankshaft for Servicepage 3.54. work surface, alternately loosen the five pressure
plate fasteners e in a star pattern until spring
4. Remove clutch nut q , Belleville washer w , and tension has relaxed. Remove fasteners and
flat washer e. Discard the stake nut. springs.

5. Remove clutch assembly from clutch shaft.

4. Remove pressure plate r.
5
6. A new stake nut must be installed upon assembly.

C L U T C H D I S A S S E M B LY
CAUTION
Clutch is under spring pressure. WEAR EYE
PROTECTION.

1. Remove the clutch. See Clutch Removalpage 5.16.

2. Remove the sleeve q and needle bearing w from
the back side of the clutch assembly.

5. Lift the clutch assembly t out of the basket and

set aside.

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6. Remove thrust washer y. 8. Alternately remove Friction Plates C a and

Seperator Plates B s .

NOTE
9. Remove Friction Plate Bd , Judder Spring f and
The clutch assembly consists of three different Judder Spring Seat g .
types of friction plates and two different types of
seperator plates. See Clutchpage 5.8.

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 .

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CLUTCH INSPECTION 8. Inspect surface of steel plate guides t on outer

1. Clean clutch plates, inner hub, and outer basket. edge of hub for wear, grooves, or damage. Check
Clutch Basket all posts y for cracks or damage.
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. 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.
5
10. Replace steel plates if grooved, distorted or
discolored. Inspect plates for distortion by placing
4. Replace parts that fail inspection
each plate on a precision flat surface. Insert a
5. Rotate hub bearing. Check for smooth rotation. feeler gauge between plate and flat surface in
Inner race should have no detectable radial several places.
movement.
Clutch Steel Plate Warp Service Limit:
6. Lubricate bearing e with engine oil. .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
Clutch Hub
NOTICE
7. Inspect spline teeth r for wear, cracks or damage.
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.

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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
Clutchpage 5.8.

Apply engine oil to Friction Plate B t and install.

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.

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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. 5

TORQUE
Clutch Spring Fasteners:
88.5 in-lbs (10.0 Nm)

3. Lock the crankshaft. See Locking the Crankshaft

for Servicepage 3.54.
4. Torque the stake nut to specification.
TORQUE
Clutch Stake Nut: 125 ft-lbs (170.0 Nm)

5. Install clutch rack assembly. See Clutch Rack,

Removal / Installationpage .
6. Install primary cover. See Primary Cover
Installationpage 5.14.
7. Check engine oil and fill to proper level.

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T O R Q U E C O M P E N S AT O R S E R V I C E - 2 0 1 7
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.
Removalpage 5.9.
NOTICE
2. Perform crankshaft locking procedure. See
Locking the Crankshaft for Servicepage 3.54. 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)

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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 Servicepage 3.54.
over the crankshaft followed by thrust washer w . 7. Apply Loctite 262 to compensator fastener and
torque to specification.
TORQUE
Compensator Fastener:
83 ft-lbs (112.0 Nm)

8. Install compensator locking plate and fasteners i

and torque to specification.

5
3. Install the torque compensator gear e and upper
ramp r .

TORQUE
Compensator Fastener Locking Plate:
88.5 in-lbs (10.0 Nm)

9. Install primary cover. See Primary Cover

Installationpage 5.14.
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.

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PRIMARY DRIVE GEAR SERVICE - 2018+

P R I M A R Y D R I V E G E A R R E M O VA L P R I M A R Y D R I V E G E A R I N S TA L L AT I O N
1. Remove primary cover. See Primary Cover 1. Apply engine oil to shaft splines before installation.
Removalpage 5.9.
2. Install the primary drive gear t to the crankshaft.
2. Perform crankshaft locking procedure. See Locking
the Crankshaft for Servicepage 3.54.
3. Remove the primary drive gear fastener q ,
locking plate fasteners w , and locking plate e
from the crankshaft.

3. Install adapter r.
4. Lock the crankshaft for service. See Locking the
Crankshaft for Servicepage 3.54.
5. Install locking plate e, fasteners w and torque
4. Remove the adapter r and primary drive gear t fasteners to specification.
from the crankshaft.
TORQUE
Locking Plate Fasteners:
88.5 in-lbs (10.0 Nm)

6. Apply Loctite 262 to primary drive gear fastener q

and torque to specification.
TORQUE
Primary Drive Gear Fastener:
83 ft-lbs (112.0 Nm)

7. Install primary cover. See Primary Cover

Installationpage 5.14.
8. Fill engine oil to proper level.

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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.
Removalpage 5.9.
2. Thread two primary cover fasteners q into the
2. Remove clutch assembly. See Clutch Removalpage flywheel w and install onto crankshaft.
5.16.
3. Remove torque compensator assembly (2017
models). See Torque Compensator Removalpage
5.22.
Remove Primary Drive Gear (2018+ models). See
Primary Drive Gear Removalpage 5.24
4. Remove thrust washer q and compensator sleeve
w (2017 models). 5

3. Install Torque Compensator (2017 models). See

Torque Compensator Installationpage 5.23 .
Install Primary Drive Gear (2018 models). See
Primary Drive Gear Installationpage 5.24.
4. Install clutch assembly. See Clutch Installationpage
5.21.
5. Install primary cover. See Primary Cover
Installationpage 5.14.
5. Thread two primary cover fasteners e into 6. Check engine oil and add as necessary.
threaded holes on flywheel r.

6. Grasp the two fasteners and lift the flywheel off of

the stator.

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TROUBLESHOOTING, CLUTCH / PRIMARY

/ SHIFT
PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR
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

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PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR

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
5
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
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

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NOTES

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CHAPTER 6
TRANSMISSION / CRANKSHAFT
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
CRANKCASE FASTENER LENGTH AND TORQUE PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
SHIFT DRUM / SHIFT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.11
BALANCE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.12
GEAR TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.13
BALANCE SHAFT SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.16
INNER CAM CHAIN COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.16 6
BALANCE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.16
BALANCE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.17
INNER CAM CHAIN COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.19
STARTER DRIVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.20
STARTER DRIVE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.20
STARTER DRIVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.20
STARTER DRIVE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.21
CRANKSHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.23
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.23
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.26
TRANSMISSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.27
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.29
CONNECTING ROD SIDE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.30
CONNECTING ROD REMOVAL / IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.30
CONNECTING ROD INSPECTION (BIG END) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.31
CONNECTING ROD BEARING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.31
CONNECTING ROD BEARING CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.32
CONNECTING ROD BEARING SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.33
CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.34
CONNECTING ROD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.34
CRANKSHAFT CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.36
MAIN BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.36
MAIN BEARING OIL CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.36
LEFT CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.37
RIGHT CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.37
CRANKSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.38
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.39

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CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.40

STAKE NUT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.43
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.44

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G E N E R A L I N F O R M AT I O N
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
6
• 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
TOOL DESCRIPTION PART NUMBER
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
Engine Stand Adapter PF-51240

Bosch Automotive Service Solutions: 1-800-328-

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

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S E R V I C E S P E C I F I C AT I O N S

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")
Crankshaft End Play (2017– .05 - .30 mm
-
2018 ONLY) (.0019 - .0118")
Crankshaft End Play (2019 0.080–0.450 mm
ONLY) (0.003–0.018”)
Balance Shaft Journal O.D., Left (Primary 24.980 - 24.992 mm /
Side) / Journal O.D., Right 24.969 - 24.979 mm -
(Cam Side)

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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 6
Gear Ratio: 4th Gear 1.10: 1
Gear Ratio: 5th Gear 0.94: 1
Gear Ratio: 6th Gear (Overdrive) 0.81: 1

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A S S E M B LY V I E W S
CRANKCASE

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Fastener, Crankcase — M8 x 1.25 x 100 (QTY.12) 22 ft-lbs (30.0 Nm)
w Fastener, Crankcase — M8 x 1.25 x 110 (QTY.6) 22 ft-lbs (30.0 Nm)
e Bearing, Camshaft —

r Fastener, Bearing Retainer – M5 x 0.8 x 12 (QTY.16) 62 in-lbs (7.0 Nm)

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 (7.0 Nm)

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 —

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CRANKSHAFT

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Bearing, Crankshaft Main (RH) — Non-Serviceable —

w Fastener, Connecting Rod Bearing Cap (QTY.4) Reference Connecting Rod

Installationpage 6.34.

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) —

i Bearing, Crankshaft Main (LH) — Non-Serviceable —

o Wrist Pin, Piston —

a Circlip, Wrist Pin —

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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 (30.0 Nm)

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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

o Gear, 2nd — Drive

a Snap Ring (not used on 2019-2020 engines)

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Output Shaft

NUMBER DESCRIPTION
q Snap Ring (not used on 2019-2020 engines)

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

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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

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BALANCE SHAFT

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Fastener, Balance Shaft Gear — M10 x 1.5 x 40 59 ft-lbs (80.0 Nm)

(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 (7.0 Nm)

(QTY.3)

i Bearings, Balance Shaft -

o Balance Shaft -

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GEAR TRAIN
1st Gear

2nd Gear

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3rd Gear

4th Gear

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5th Gear

6th Gear

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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 Removalpage 3.65. Cover Removalpage 6.16.
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

Separationpage 6.23.
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.

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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
Assemblypage 6.40.
4. Lock the crankshaft for service using Method 1.
See Locking the Crankshaft for Servicepage 3.54. 6
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 (80.0 Nm)

11. Install the starter drive. See Starter Drive

TORQUE Installationpage 6.21.
Balance Shaft Drive Gear:
10 ft-lbs (14.0 Nm)

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.

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12. Install the spacer y onto the crankshaft.

13. Install the inner cam cover. See Inner Cam Chain
Cover Installationpage 6.19.

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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

6
1. Clean inner cam chain cover and crankcase
mating surfaces with a residue-free degreaser.
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 (20.0 Nm)

5. Install the camshaft carrier assembly. See

Camshaft Carrier Installationpage 3.72.

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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 Removalpage 6.16. 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.

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.

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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
crankcase bore followed by the reduction gear y .
6
one-way clutch bearing until fully seated.
The raised shoulder on the reduction gear
should face the crankcase.

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5. Install spacer u onto the crankshaft.

6. Install inner cam chain cover. See Inner Cam

Chain Cover Installationpage 6.19.
7. Check engine oil and fill to proper level.

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CRANKSHAFT SERVICE
C R A N K C A S E S E PA R AT I O N 19. Remove engine case fasteners.
1. Drain the engine oil. See Engine Oil & Filter
Change in the Maintenance Chapter.
2. Remove engine from frame. See Preparation For
Engine Removalpage 3.13.
3. Mount engine securely on an engine stand using
Engine Stand Adapter tool PF-51240.
4. Remove cylinder heads. See Cylinder Head
Removalpage 3.79.
5. Remove cylinders. See Cylinder Removalpage
3.99.
6. Remove lifters. See Lifter Removalpage 3.63.
7. Remove primary cover. See Primary Cover
Removalpage 5.9.
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 Removalpage 5.22. threaded spacers q and M12 threaded spacer w
9. Remove clutch assembly. See Clutch Removalpage into the main plate e as shown. Use only holes
5.16. marked with the letter A.
10. Remove flywheel. See Flywheel Installationpage
5.25. 6
11. Remove stator. See Stator Removalpage 10.37.
12. Remove the cam chain. See Cam Chain
Removalpage 3.61.
13. Remove camshaft carrier assembly. See Camshaft
Carrier Removalpage 3.65.
14. Remove the inner cam chain cover. See Inner Cam
Chain Cover Removalpage 6.16.
15. Remove the starter drive. See Starter Drive
Removalpage 6.20.
16. Remove the balance shaft driven gear and drive
gear. See Balance Shaft Removalpage 6.16. 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
Removalpage 8.58.
18. Remove the gear position switch. See Gear
Position Switch Replacementpage 10.113.
NOTICE
If applicable, collect the two switch contact pins and
springs from the end of the shift drum so they do not
get lost.

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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.

TORQUE
Main Plate Mounting Fasteners (All):
88.5 in-lbs (10.0 Nm)

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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.
6

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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 & Inspectionpage 5.11.
2. Remove the balance shaft. See Balance Shaft
Removalpage 6.16.
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.

4. Lift the shift drum w out of the bearing.

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TRANSMISSION INSPECTION
Input Shaft

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

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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

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

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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 Crankcasepage 6.6. 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 Specificationspage 6.4.
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 Separationpage 6.23.
• Measurement outside of specification 2. Rotate balance shaft q until counterweights are
clear of crankshaft.
Gears
2. Visually inspect:
• Gear internal splines
6
• 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.

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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
Specificationspage 6.4.

3. Remove connecting rod fasteners and connecting

rod bearing caps.
NOTICE
It may be necessary to lightly tap the caps with a
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 Inspectionpage 6.34. mating surfaces will be damaged. Replace the
connecting rod assembly if mating surfaces are
damaged.

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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 Inspectionpage 3.106
for connecting rod small end inspection. 1. Torque to 19 ft-lbs (26 N·m)
2. Torque angle to 105 °
CAUTION
Be sure to match connecting rod caps with their 6
respective rod and orient the cap properly before TORQUE
installing the cap. Secure the big end of rods in a vise
I-18-06 Connecting Rod Fasteners:
equipped with soft, protective jaws before torquing
rod fasteners. 46 ft-lbs (62 N·m)

4. Measure I. D. of connecting rod big end for size

and out of round and compare to specification. See
Service Specificationspage 6.4.

2. Remove bearings and install caps on connecting

rods. Be sure mating surfaces q of rod and cap are
clean. 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 Selectionpage 6.33.

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CONNECTING ROD BEARING CLEARANCE

INSPECTION
1. Assemble the connecting rod cap with bearings
and torque to specification.
TORQUE
Connecting Rod Fasteners:
1. Torque to 19 ft-lbs (26 N·m)
2. Torque angle to 105 °

TORQUE
I-18-06 Connecting Rod Fasteners:
46 ft-lbs (62 N·m)

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
Specificationspage 6.4.
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.

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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.

6
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)

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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
Specificationspage 6.4.
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.

TORQUE
Connecting Rod Fasteners:
a. Torque to 19 ft-lbs (26 N·m)
Left Right
b. Torque angle to 105 °

TORQUE
I-18-06 Connecting Rod Fasteners:
46 ft-lbs (62 N·m)

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7. Check that the connecting rods rotate smoothly

and freely on crankshaft journal.

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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 Specificationspage 6.4.

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 (20.0 Nm) 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.

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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 Crankcasepage 6.6. torque specification. See Crankcasepage 6.6.
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. 6
• 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 Systempage 3.33.
5. Install new oil passage o-ring w .

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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.

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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
Crankcasepage 6.6.
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
Installationpage 6.17.
10. Instal oil pump assembly. See Oil Pump 6
Installationpage 3.38.
4. Lubricate parts with engine oil. Apply assembly
lube to ends of transmission shafts. 11. Install crankshaft. See Crankshaft Installationpage
6.38.
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
both shafts are fully seated and rotate freely. Assemblypage 6.40.

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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.

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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
engine case prior to fastening on the plate
and install the case installation adapter onto the
transmission output shaft.
6
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 Patternpage 6.8.
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.
88.5 in-lbs (10.0 Nm) 16. Install the gear position switch. See Sensors —
Powertrain Managementpage 4.13.
17. Install the drive sprocket. See Drive Sprocket
Installationpage 8.61.
18. Install the balance shaft driven gear and drive
gear. See Balance Shaft Installationpage 6.17.
19. Install the starter drive. See Starter Drive
Installationpage 6.21.

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20. Install the inner cam chain cover. See Inner Cam
Chain Cover Installationpage 6.19.
21. Install the camshaft carrier assembly. See
Camshaft Carrier Installationpage 3.72.
22. Install the cam chain. See Cam Chain
Installationpage .
23. Install the stator. See Stator Installationpage 10.38.
24. Install the flywheel. See Flywheel Installationpage
5.25.
25. Install the clutch assembly. See Clutch
Installationpage 5.21.
26. Install the torque compensator. See Torque
Compensator Installationpage 5.23.
27. Install the primary cover. See Primary Cover
Installationpage 5.14.
28. Install lifters. See Lifter Installationpage 3.64.
29. Install cylinders. See Cylinder Installationpage
3.110.
30. Install cylinder heads. See Cylinder Head
Installationpage 3.90.
31. Install engine in frame. See Engine
Installationpage 3.19.

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S TA K E N U T I N S TA L L AT I O N 1. Clean threads on shaft so there is no oil or

contaminants.
• The Stake nut is located on the clutch side of the
transmission input shaft. 2. Thread NEW stake nut onto shaft finger tight.
• It is important that they are torqued and staked 3. Torque stake nut to specification.
correctly for proper function
4. Stake the stake nut as shown below using round
IMPORTANT side of punch. Do not crack or tear staking lip. Do
not use a sharp chisel to stake the nut.
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:

Be sure staking lip does not tear/crack in staking area.

Stake nut with round side of punch.
Properly Staked Nut
Do Not Stake Here

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TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR
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
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

PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR

RECOMMENDED
Transmission Hard to Shift Improper Clutch Clutch Refer to Clutch / Primary
Operation / Shift chapter

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PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR

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
Shifter Ratchet
Shift Drum or Shift
Linkage
Replace damaged shift
drum or shifter ratchet
6
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

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NOTES

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 FRAME / BODY

CHAPTER 7
FRAME / BODY
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
FENDERS / SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
FENDERS / SEAT (OPEN STYLE FENDER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
FLOORBOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
SIDE PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
SEAT - ALL (EXCEPT ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
SEAT - ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.10
SEAT, CHIEFTAIN (2019+). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.11
TRUNK, ROADMASTER (2017-19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.12
TRUNK, ROADMASTER (2020+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13
LOWER FAIRING, ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.15
FAIRING, CHIEFTAIN DARK HORSE (2017) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.16
FAIRING, CHIEFTAIN / ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.17
FAIRING, CHIEFTAIN (2019+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.18 7
SADDLEBAGS, CHIEFTAIN / ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19
SADDLEBAGS, CHIEFTAIN (2019+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.20
NACELLE, VINTAGE / SPRINGFIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.21
BODY / FRAME SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.22
SIDE COVER (UPPER), REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.22
SIDE COVER (LOWER), REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.22
PASSENGER FOOT PEG BLANKS (DARK HORSE), REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .7.23
FLOORBOARD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.23
FLOORBOARD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.24
FOOT PEGS (PASSENGER), REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.26
SEAT REMOVAL / INSTALLATION - ALL (EXCEPT ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.26
SEAT REMOVAL / INSTALLATION - (ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.27
SEAT REMOVAL / INSTALLATION - (DARK HORSE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.28
HIGHWAY BAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.29
HIGHWAY BAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.29
LOWER FAIRING REMOVAL - (ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.30
LOWER FAIRING INSTALLATION - (ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.31
FRONT FENDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.33
FRONT FENDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.34
FRONT FENDER REMOVAL (OPEN STYLE FENDER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.35
FRONT FENDER INSTALLATION (OPEN STYLE FENDER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.35
TRUNK REMOVAL, ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.36
TRUNK INSTALLATION, ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.37

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TRUNK LOCK REPLACEMENT - ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.38

REAR FENDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.40
REAR FENDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.41
FRONT CASTING (MAIN FRAME), REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.42
FRONT CASTING (MAIN FRAME), INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.44
CHIEF CLASSIC / CHIEF DARK HORSE / CHIEF VINTAGE / SPRINGFIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.47
INSTRUMENT PANEL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.47
NACELLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.48
NACELLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.50
CHIEFTAIN DARK HORSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.52
OUTER FAIRING REMOVAL - (CHIEFTAIN DARK HORSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.52
INNER FAIRING REMOVAL - (CHIEFTAIN DARK HORSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.54
INNER FAIRING INSTALLATION - (CHIEFTAIN DARK HORSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.55
OUTER FAIRING INSTALLATION - (CHIEFTAIN DARK HORSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.56
INSTRUMENT PANEL REMOVAL / INSTALLATION - (CHIEFTAIN DARK HORSE) . . . . . . . . . . . . . . . . . . . . . .7.57
CHIEFTAIN / ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.58
OUTER FAIRING REMOVAL - (CHIEFTAIN / ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.58
INNER FAIRING REMOVAL - (CHIEFTAIN / ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.60
INNER FAIRING INSTALLATION - (CHIEFTAIN / ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.61
OUTER FAIRING INSTALLATION - (CHIEFTAIN / ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.62
RIDE COMMAND SYSTEM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.64
RIDE COMMAND SYSTEM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.66

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G E N E R A L I N F O R M AT I O N
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
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

Bosch Automotive Service Solutions: 1-800-328-

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

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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 (24.4 Nm)

w Driver Seat Fastener 18 ft-lbs (24.4 Nm)

e Strut Cover Fastener 84 in-lbs (9.5 Nm)

r Rear Fender Upper Fastener 84 in-lbs (9.5 Nm)

t Rear Fender Lower Stud / Ball 84 in-lbs (9.5 Nm)

y Fender Fastener 84 in-lbs (9.5 Nm)

u Caliper Cover Acorn Nut 18 ft-lbs (24.4 Nm)

i Front Fender Fastener 18 ft-lbs (24.4 Nm)

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F E N D E R S / S E AT ( O P E N S T Y L E F E N D E R )

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

7
q Passenger Seat Fastener 18 ft-lbs (24.4 Nm)

w Driver Seat Fastener 18 ft-lbs (24.4 Nm)

e Strut Cover Fastener 84 in-lbs (9.5 Nm)

r Rear Fender Upper Fastener 84 in-lbs (9.5 Nm)

t Rear Fender Lower Stud / Ball 84 in-lbs (9.5 Nm)

y Fender Fastener 84 in-lbs (9.5 Nm)

u Front Fender Fastener 18 ft-lbs (24.4 Nm)

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FRAME

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Fastener, Down Tube (Lower)— M10 x 1.5 x 60 (QTY.4) 45 ft-lbs (61.0 Nm)

w Fastener, Down Tube (Lower LH) — M10 x 1.5 x 25 45 ft-lbs (61.0 Nm)
(QTY.1)

e Fastener, Down Tube (Upper) — M10 x 1.5 x 100 (QTY.2) 45 ft-lbs (61.0 Nm)

r Fastener — M12 x 1.75 x 120 (QTY.3) 75 ft-lbs (101.7 Nm)

t Fastener, Midcast — M12 x 1.75 x 50 (QTY.3) 75 ft-lbs (101.7 Nm)

y Fastener, Rear Subframe — M10 x 1.5 x 35 (QTY.6) 35 ft-lbs (47.5 Nm)

u Fastener, Rear Lower Subframe — M8 x 1.25 x 20 (QTY.4) 18 ft-lbs (24.4 Nm)

i Fastener, Engine Bracket — M8 x 1.25 x 20 (QTY.2) 18 ft-lbs (24.4 Nm)

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FLOORBOARDS

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

7
q Fastener, Floorboard Pivot — M8 x 1.25 x 120 (QTY.2) 18 ft-lbs (24.4 Nm)

w Fastener, Floorboard Support — M10 x 1.5 x 30 (QTY.4) 35 ft-lbs (47.5 Nm)

e Fastener, Brake Pedal Pad — M6 x 1.0 x 15 (QTY.2) 84 in-lbs (9.5 Nm)

r Shifter Toe Pedal 18 ft-lbs (24.4 Nm)

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 -

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S I D E PA N E L S

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Side Cover, Left Hand Upper —

w Rubber Grommet —

e Fastener, Left Hand Lower Side Cover — M6 x 1.0 x 15 84 in-lbs (9.5 Nm)
(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 84 in-lbs (9.5 Nm)

(QTY.2)

i Fastener, Right Hand Sprocket Cover — M6 x 1.0 x 40 84 in-lbs (9.5 Nm)

(QTY.2)

o Side Cover, Right Hand Upper —

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S E AT - A L L ( E X C E P T R O A D M A S T E R )

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

7
q Seat, Passenger (except Dark Horse) –

w Seat, Driver –

e Fastener, Seat - M8 x 1.25 x 20 (QTY.2) 18 ft-lbs (24.4 Nm)

Fastener, Seat - M8 x 1.25 x 16 (QTY.1) 84 in-lbs (9.5 Nm)
r (except Dark Horse)
Fastener, Passenger to Driver Seat - M x 84 in-lbs (9.5 Nm)
t 1.0 x 15 (QTY.4) (except Dark Horse)

y Washer (QTY.1) (except Dark Horse) –

u Washer (QTY.1) (except Dark Horse) –

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S E AT - R O A D M A S T E R

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

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) 84 in-lbs (9.5 Nm)

u Fastener, Seat - M8 x 1.25 x 20 (QTY.2) 18 ft-lbs (24.4 Nm)

i Fastener, Strap - M6 x 1.0 x 25 (QTY.2) 7.5 ft-lbs (10.2 Nm)

o Fastener (QTY.4) 14 in-lbs (1.6 Nm)

a Washer (QTY.1) –

s Washer (QTY.1) –

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S E AT , C H I E F TA I N ( 2 0 1 9 + )

TORQUE (IF APPLICABLE)

NUMBER PART DESCRIPTION
7
q Seat –

w Fastener, Seat - M8 x 1.25 x 20 (QTY.2) 18 ft-lbs (24.4 Nm)

e Fastener - M8 x 1.25x16 (QTY.1) 84 in-lbs (9.5 Nm)

r Washer –

t Bracket, Seat –

y Fastener, Bracket - M6 x 1.0x12 (QTY.2)

u Strap - Passenger Seat –

i Fastener, Strap - M6 x 1.0 x 25 (QTY.2) 7.5 ft-lbs (10.2 Nm)

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TRUNK, ROADMASTER (2017-19)

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

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)

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TRUNK, ROADMASTER (2020+)

TORQUE SEQUENCE

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Fastener, Trunk to Frame 12 in-lbs (1 N·m)
w Washer -
e Fasteners, Trunk Lock 12 in-lbs (1 N·m)
r Fastener, Trunk to Frame Arm 12 in-lbs (1 N·m)
t Washer -
y Washer -
u Luggage Rack -
i Grommet -
o Washer -
a Fastener, Luggage Rack 88 in-lbs (10 N·m)
s Plate -
d Latch, Hoop -
f Latch, Hoop 36 in-lbs (4 N·m)
g Fastener, Bezel 12 in-lbs (1 N·m)
h Fastener, Taillight 12 in-lbs (1 N·m)

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NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

j Bushing -
k Taillight asm. -
l Bezel, Taillight -
1( Fasteners, Speaker Cover / Backrest 36 in-lbs (4 N·m)
2) Seal -
2! Speaker Housing -
2@ Speaker Cover -
2# Clip -
2$ Backrest -

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L O W E R FA I R I N G , R O A D M A S T E R

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Fastener, Inner to Outer Fairing - (QTY.10) 36 in-lbs (4.1 Nm)

w Fastener, Clamp - M6 x 1.0 x 16 - (QTY 6) 36 in-lbs (4.1 Nm)

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FA I R I N G , C H I E F TA I N D A R K H O R S E ( 2 0 1 7 )

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Fastener, Bezel — M6 x 1.0 (QTY.2) 36 in-lbs (4.1 Nm)

w Headlight Bezel —

e Fastener, Headlight Bracket — M6 x 1.0 x 40 (QTY.3) NA

r Fastener, Fairing — NOTE: Fasteners differ in size See Fairing Installation (Frame / Body
chapter)

t Speaker Grill, RH —

y Speaker Grill, LH —

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FA I R I N G , C H I E F TA I N / R O A D M A S T E R

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

7
q Fastener, Bezel — M6 x 1.0 (QTY.2) 36 in-lbs (4.1 Nm)

w Headlight Bezel —

e Fastener, Headlight Bracket — M6 x 1.0 x 40 (QTY.3) NA

r Fastener, Fairing — NOTE: Fasteners differ in size See Fairing Installation (Frame / Body
chapter)

t Speaker Grill, RH —

y Speaker Grill, LH —

u Fastener, Speaker

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FA I R I N G , C H I E F TA I N ( 2 0 1 9 + )

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Headlight Bezel —

w Fastener, Headlight Bracket — M6 x 1.0 x 40 (QTY.4) NA

e Fairing, Front —
See Fairing Installation (Frame / Body
r Fastener, Fairing — NOTE: Fasteners differ in size
chapter)

t Speaker Grill, RH —

y Speaker Grill, LH —

u Fastener, Speaker

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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

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

Pad, Saddle Bag Mount (QTY.4) -
7
q
w Bracket, Saddle Bag Mount (QTY.4) -

e Fastener - M6 x 1.0 x 16 (QTY.16) 84 in-lbs (9.5 Nm)

r Fastener, Latch Striker - M4 x 0.7 x 16 (QTY.4) 36 in-lbs (4.1 Nm)

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 (33.9 Nm)

a Spool (QTY.4) -

s Hinge, Lid (QTY.4) -

d Fastener, Hinge - M5 x 0.8 x 12 (QTY.4) 45 in-lbs (5.1 Nm)

f Fastener, Latch Asm. - M6 x 1.0 x 20 (QTY.4) 65 in-lbs (7.3 Nm)

g Actuator, Lock (QTY.2) -

h Seal, Saddlebag Lock (QTY.2) -

j Lock Cylinder (QTY.2) -

k Handle, Latch (QTY.2) -

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S A D D L E B A G S , C H I E F TA I N ( 2 0 1 9 + )

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Pad, Saddle Bag Mount (QTY.4) -
w Bracket, Saddle Bag Mount (QTY.4) -
e Fastener - M6 x 1.0 x 16 (QTY.16) 84 in-lbs (9.5 Nm)
r Fastener, Latch Striker - M4 x 0.7 x 16 (QTY.4) 36 in-lbs (4.1 Nm)
t Fastener, Saddlebag Wire Guide M4x0.7x12
y Fastener, Saddlebag Mounting M8 1.25x33 (QTY.4)
u Bushing, Rubber (QTY.4) -
i Fastener, Saddlebag Mounting M8 1.25x38 (QTY.4)
o Spool (QTY.4) -
a Bushing, Spool (QTY.4) -
s Fastener, Saddlebag Limiter
d Bracket, Limiter -
f Receptacle, POD -
g Actuator, Lock (QTY.2) -
h Seal, Saddlebag Lock (QTY.2) -
j Lock Cylinder (QTY.2) -
k Handle, Latch (QTY.2) -
l Fastener, Latch Asm. - M6 x 1.0 x 20 (QTY.4) 65 in-lbs (7.3 Nm)
1( Fastener, Saddlebag Wire Cover
2) Fastener, Saddlebag Wire Guide M6 1.0x15 (QTY.2)
2! Grommet -
2@ Limiter -
2# Hinge, Lid (QTY.4) -

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N A C E L L E , V I N TA G E / S P R I N G F I E L D

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Cover, Front Headlight(QTY.1) - 7
w Fastener - #8-18 x .50” (QTY.4) 12 in-lbs (1.4 Nm)
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 (1.4 Nm)
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) 84 in-lbs (9.5 Nm)
k Fastener - M6 x 1.0 x 16 (QTY.2) 36 in-lbs (4.1 Nm)
l Clip, Speed Nut (QTY.2) -
1( Cover, Rear Nacelle (QTY.1) -
2) Spacer, Nacelle Bezel (QTY.1) -

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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 coverspage 7.22 from both
corners of the upper cover evenly straight outward
to disengage each tab from rubber grommet in sides of the motorcycle.
frame. 2. If applicable, remove the passenger foot pegspage
7.26 from both sides of the motorcycle.
3. Remove theCross Over Pipe Removalpage 3.116.
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.

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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
VIEWpage 7.7 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
84 in-lbs (9.5 Nm) 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 (47.5 Nm)

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.

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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 (47.5 Nm)

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:
84 in-lbs (9.5 Nm)

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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 (47.5 Nm)

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 (47.5 Nm)

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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 7.22
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 (47.5 Nm)

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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 7.22
2. Remove trunk assembly. See Trunk Removal,
Roadmasterpage 7.36.
3. Using a 6 mm hex wrench, remove the two
fasteners q securing the driver’s seat to the frame.

5. INSTALLATION is performed by reversing the

removal procedure.
6. Torque the seat fasteners to specification.
TORQUE
Seat Fasteners (All): NOTICE
96 in-lbs (10.8 Nm)
It may be necessary to lift the seat skirt to access the
side fasteners on some models.

4. Remove the passenger seat fastener w.

7

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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 7.22
2. Using a 6 mm hex wrench, remove the two
fasteners q securing the driver’s seat to the frame.

6. If applicable, disconnect the trunk harness q and

heated seat connector w.

NOTICE
It may be necessary to lift the seat skirt to access the
side fasteners on some models.

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.

8. INSTALLATION is performed by reversing the
removal procedure.
9. Torque the seat fasteners to specification.
TORQUE
Seat Fasteners (All):
96 in-lbs (10.8 Nm) 4. INSTALLATION is performed by reversing the
removal procedure.
TORQUE
Seat Fasteners (All):
96 in-lbs (10.8 Nm)

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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 7
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 (24.4 Nm)
Lower Highway Bar Fasteners: 35 ft-lbs (47.5 Nm)

3. Carefully maneuver the highway bar out from the

frame / fender area.

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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 )
CAUTION
Painted surfaces can be easily scratched or damaged
during removal and installation. Be sure you have a
safe location to store painted body components
before they are removed.

1. Remove fasteners q and carefully remove the

outer fairing assembly.

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.

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L O W E R FA I R I N G I N S TA L L AT I O N - 4. Position the center (outer) fairing clamp onto the

(ROADMASTER) highway bar and line up with the fastener hole in
the fairing.
1. Install the upper and lower fairing clamps onto the
highway bars as shown. 5. Starting with the upper clamp, followed by the
lower and center clamps, torque all clamp
NOTICE fasteners e to specification.

• The upper fairing clamp is positioned against the

locating dowel q.
• The lower fairing clamp is positioned to the outside
of the locating mark w.
• The center (outer) fairing clamp is attached last
and does not have a locating mark.

TORQUE
Lower Fairing Clamp Fasteners:
36 in-lbs (4.1 Nm)

7
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. 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.

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8. Alternately tighten outer fairing fasteners to

specified torque.
TORQUE
Inner to Outer Fairing Fasteners:
36 in-lbs (4.1 Nm)

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F R O N T F E N D E R R E M O VA L 5. Stand in front of the motorcycle facing the front

fender and squeeze the sides together while
NOTICE
“rolling” the fender out from the fork legs.
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.

1. Remove two acorn nuts q and fastener w from

each side of the motorcycle and remove the
caliper covers e.

7
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. IMPORTANT
4. Remove the three fasteners r from each side of Once fender has been removed from the
the fender. motorcycle, make sure the fender is stored safely
until it is reinstalled.

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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)
Use care not to scratch or damage painted surfaces
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.

2. Install the three fasteners q on each side of the

fender and torque to specification.

TORQUE
Front Fender Fasteners:
18 ft-lbs (24.4 Nm)

3. Route the fender light wire harness into the fairing

/ nacelle and reconnect.

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F R O N T F E N D E R R E M O VA L ( O P E N S T Y L E F R O N T F E N D E R I N S TA L L AT I O N ( O P E N
FENDER) STYLE FENDER)
NOTICE NOTICE
Motorcycle should be parked on a level surface Motorcycle should be parked on a level surface
resting on the side stand. resting on the side stand.

CAUTION CAUTION
Use care not to scratch or damage painted surfaces Use care not to scratch or damage painted surfaces
during fender removal and / or installation. during fender removal and / or installation.

1. Remove the two fasteners q from each side of the 1. Gently squeeze the sides of the front fender and
fender. “roll” the fender into position so the fastener holes
line up.

7
2. Stand in front of the motorcycle facing the front
fender and squeeze the sides together while 2. Install the two fasteners q on each side of the
“rolling” the fender out from the fork legs. fender and torque to specification.

IMPORTANT TORQUE
Once fender has been removed from the Front Fender Fasteners:
motorcycle, make sure the fender is stored safely 18 ft-lbs (24.4 Nm)
until it is reinstalled.

3. Turn the handlebar all the way to the left and right
to verify proper operation and freedom of
movement.

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T R U N K R E M O VA L , R O A D M A S T E R 4. Lift up on the rear of the trunk r and slide

rearward t to release the trunk from the
1. If applicable, remove the left and right saddlebags
motorcycle.
and remove the trunk lock fastener q from each
trunk latch.

2. Disconnect the trunk harness multi-plug w.

3. Lift the trunk latches e to unlock the trunk from the

mount.

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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 3. Push the trunk locking levers e down until fully

seated and the trunk is held securely in place.
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.

4. Reconnect the trunk harness connector r.

2. Slide the trunk forward q onto the mounting

bracket and lower w the rear of the trunk until fully
seated. 7

5. If applicable, install the mounting fasteners t into

left and right locking levers.

6. Install saddlebags, if equipped.

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TRUNK LOCK REPLACEMENT - 4. Insert body panel tool (PV-49955) or similar into
ROADMASTER the relief holes w cut into the bezel and gently pry
bezel off of the trunk base.
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.

NOTICE
Bezel is held in place with pressure sensitive
adhesive. It will be necessary to replace the adhesive
with a suitable alternative (e.g. double sided tape)
when the bezel is reinstalled.

5. Remove the two fasteners e from the lock actuator

bracket and disconnect electrical connector.

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6. Remove the four fasteners r securing the lock I N S TA L L AT I O N

assembly to the trunk.
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:
36 in-lbs (4.1 Nm)

7. Remove the latch and lock actuator together as an

assembly.
8. If replacing individual components, disconnect the
lock actuator cable from the latch assembly to
separate the components.

3. Torque lock actuator fasteners to specification. 7

TORQUE
Lock Actuator Fasteners:
13 ft-lbs (17.6 Nm)

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.

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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 7.26
3. Remove upper side panels. See Side Cover
(Upper), Removal / Installationpage 7.22.
4. Remove lower side panels. See Side Cover
(Lower), Removal / Installationpage 7.22.
5. Remove saddlebags, if equipped.
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.

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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
Use care not to scratch or damage painted surfaces
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.
7

6. Install forward fender fasteners t on both sides of

the fender and torque to specification.

TORQUE
Forward Fender Fasteners t:
84 in-lbs (9.5 Nm)

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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
84 in-lbs (9.5 Nm) 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.
1. Place the motorcycle in an upright position with the
TORQUE front wheel clamped in a wheel vise.
Inside Fender Fasteners e: 2. Remove the fuel tank. See Fuel Tank Removalpage
84 in-lbs (9.5 Nm) 4.17.
3. Disconnect the negative cable from the battery. See
9. Install strut covers i and strut cover fasteners u Battery Removalpage 2.46.
and torque to specification.
4. Remove the lower side covers. See Side Cover
TORQUE (Lower), Removal / Installationpage 7.22.
Strut Cover Fasteners: 5. Remove the front triple clamps. See Triple Clamp
84 in-lbs (9.5 Nm) Removalpage 8.38.
6. Remove the driver floorboard assemblies. See
10. Install saddlebag mounting cylinders and Floorboard Removalpage 7.23.
mounting cylinder fasteners y, if equipped, and
7. Remove the highway bar assembly. See Highway
torque to specification.
Bar Removalpage 7.29.
8. Remove the head pipes. See Head Pipe
Removalpage 3.118.
9. If applicable, disconnect the oil cooler from the
down tubes. See Oil Cooler Removalpage 3.41.
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 (33.9 Nm)

11. Install lower side panels. See Side Cover (Lower),

Removal / Installationpage 7.22.
12. Install upper side panels. See Side Cover (Upper),
Removal / Installationpage 7.22.
13. Install seat as outlined in this chapter.
14. Install saddlebags, if equipped.
15. Connect antenna cable to mast.

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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.

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16. Remove the front casting from the motorcycle. FRONT CASTING (MAIN FRAME),
I N S TA L L AT I O N
1. Lower the front casting into position over the
engine.

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.

IMPORTANT
The upper engine spacer will not be installed during
the initial torque and measurement stage of this
procedure.

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3. Loosely install the upper down tube fasteners e 5. Torque front casting fasteners u to specification.
through the front casting.

TORQUE
4. DO NOT install the upper engine spacer r at
this time; Starting with the lower engine mount y Front Cast to Mid-Cast Fasteners u:
torque mid-cast fasteners t and y to specification. 75 ft-lbs (101.7 Nm)

6. Torque left hand down tube fasteners i, o and a

to specification.

TORQUE
Upper Mid-Cast Fasteners t:
35 ft-lbs (47.5 Nm)
TORQUE
Upper, Left-Hand Down Tube Fasteners i:
TORQUE
45 ft-lbs (61.0 Nm)
Lower Mid-Cast Fastener y:
75 ft-lbs (101.7 Nm)
TORQUE
Lower, Left-Hand Down Tube Fasteners o & a:
45 ft-lbs (61.0 Nm)

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7. Torque lower right-hand down tube fasteners s to 10. If the gap is incorrect, repeat STEPS 4-8 until gap
specification. measurement is correct. Torque upper engine
mount fastener to specification.
11. Reverse STEPS 2 - 10 from the removal procedure
to complete installation.

TORQUE
Lower, Right-Hand Down Tube Fasteners s:
45 ft-lbs (61.0 Nm)

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

9. If the gap is correct, the upper spacer can be

installed and the upper fastener torqued to
specification.
TORQUE
Upper Engine Mount Fastener:
45 ft-lbs (61.0 Nm)

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CHIEF CLASSIC / CHIEF DARK HORSE / 5. Remove the rubber grommet e from the console
C H I E F V I N TA G E / S P R I N G F I E L D cover.

I N S T R U M E N T PA N E L R E M O VA L / I N S TA L L AT I O N
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 Removalpage 4.17.
3. Remove fasteners q securing bracket to
speedometer head and remove fasteners w
securing the speedometer bracket to the console
cover.

6. INSTALLATION is performed by reversing the

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:
15 in-lbs (1.7 Nm)
4. Remove the bezel from the speedometer and lift
the speedometer head out of the rubber grommet. TORQUE
7
Bracket to Console Cover Fasteners:
43 in-lbs (4.8 Nm)

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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.

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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

7
cube and chassis harness and route through the
front portion of the nacelle.
13. Remove nacelle.

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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

torque to specification.
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:
84 in-lbs (9.5 Nm)

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.

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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 (4.0 Nm)
18 ft-lbs (24.4 Nm) Tighten Front Bolts First,
then Rear 12. Torque the auxiliary light bar bracket fasteners r
to specification.
9. Push the front and rear portions of the nacelle
together into position around the triple clamp. TORQUE
10. Move the light bar / turn signal assembly into Auxiliary Light Bar Bracket Fasteners: 7
position and install the four fasteners r finger 18 ft-lbs (24.4 Nm)
tight.
13. Move the console cover into position and torque
fasteners to specification.
TORQUE
Console Cover Fasteners:
84 in-lbs (9.5 Nm)

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.

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C H I E F TA I N D A R K H O R S E 3. Remove the four LONG fasteners w from the top of

the fairing assembly.
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 D A R K
HORSE)
NOTE
Place the power windshield in the FULL UP position
prior to fairing removal.

CAUTION
Fasteners removed in STEPS 3 & 5 are different
lengths. It is imperative that the fasteners are
reinstalled in the same positions they are removed
from or damage to outer fairing may occur.

1. Place the motorcycle on a flat surface resting on it’s

side stand. 4. Using the Body Panel tool (PV-49955), gently pry
2. Remove the five fasteners q from the windshield the left-hand e and right-hand r speaker grill out
and remove windshield. of the inner fairing assembly.

NOTICE 5. Remove six fasteners t from the inner fairing

assembly.
When removing the five windshield fasteners be sure
to capture the T-nuts as they are not captive.

NOTICE
Some fasteners are longer than others, make sure to
note placement of fasteners when removing.

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6. Remove two fasteners y and head light bezel.

7. Remove three fasteners u and withdraw the head

light assembly far enough to disconnect electrical
connector.

8. Remove fairing assembly.

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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 D A R K 5. Using a side-cutter, carefully clip the outboard

HORSE) cable ties e.
NOTICE
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 Dark Horse)page 7.52.
2. Remove the instrument cluster. See Instrument
Panel Removal / Installation - (Chieftain Dark
Horse)page 7.57. IMPORTANT
Use a marker or tape to index each multi-plug before
3. Remove the four nuts and washers q as shown. 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.

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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 4. Verify that no wires or connectors have been

DARK HORSE) pinched between the inner fairing and the triple
clamp and torque mounting nuts to specifications.
CAUTION TORQUE
During installation of the inner fairing, pay close
Inner Fairing Mounting Nuts:
attention to harness routing and connector
orientation. Always route electrical wiring the same 12 ft-lbs (16.3 Nm)
way as it was removed to avoid damaging wires and
connectors. 5. Route the fog lamp button and 12V accessory
socket harnesses so they can be secured by their
1. Rest the inner fairing assembly on the lower respective cable ties e, and reconnect.
mounting studs q and tilt forward.

7
6. Paying attention to the natural form of the wiring
2. Carefully route all loose wires through the access harness, reconnect all of the multi-plugs between
hole in the inner fairing mount. the chassis and inner faring.

3. Install the inner fairing assembly on the four triple IMPORTANT

clamp studs w and install washers and nuts finger Pay attention to index marks placed on connectors
tight. during disassembly when reconnecting as some of
them are interchangeable.

7. Connect the radio antenna and radio multi-plugs.

8. Remove the cut cable ties from the four fir tree
clips and install new cable ties.
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 Dark Horse)page 7.56
12. Install the instrument cluster. See Instrument Panel
Removal / Installation - (Chieftain Dark Horse)page
7.57

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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 3. Install head light bezel and torque fasteners e to

DARK HORSE) specification.

CAUTION
Fasteners installed in STEPS 4 & 6 are different
lengths. It is imperative that the fasteners are
installed in the correct location or damage to outer
fairing may occur. Reference the drawing below for
proper fastener locations.

1. Install outer fairing assembly q onto fairing

subframe as shown.

TORQUE
Head Light Bezel:
36 in-lbs (4.1 Nm)

4. Install the six fasteners r into the inner fairing

assembly and torque to specification.

2. Install the head light assembly w and torque

fasteners to specification.

NOTICE
Refer to the notes made when removing the
fasteners. Some fasteners are longer than others,
make sure the correct placement of fasteners when
installing.
TORQUE
Head Light Bracket Fasteners: TORQUE
7 ft-lbs (9.5 Nm) Inner Fairing Fasteners:
36 in-lbs (4.1 Nm)

5. Install the LH and RH speaker grills.

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6. Install the four fasteners t into the top of the I N S T R U M E N T PA N E L R E M O VA L / I N S TA L L AT I O N

fairing assembly and torque to specification. - ( C H I E F TA I N D A R K H O R S E )
1. Position the motorcycle on it’s side stand on a flat
surface.
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.

TORQUE
Upper Fairing Fasteners:
36 in-lbs (4.1 Nm)

7. Install the windshield and torque fasteners y to

specification. 3. Lift instrument panel out of the fairing mount and
disconnect the single multi-plug.
4. INSTALLATION is performed by reversing the
removal procedure. Using a mild soapy water
solution on the rubber seal will make it easier
to press the instrument panel into position.
7
CAUTION
Do not use alcohol on seal for installation.

TORQUE
Windshield Fasteners:
36 in-lbs (4.1 Nm)

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C H I E F TA I N / R O A D M A S T E R
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 / R O A D M A S T E R )
NOTICE 3. Remove three fasteners w and withdraw the head
Place the power windshield in the FULL UP position light assembly far enough to disconnect electrical
prior to fairing removal. connector.

1. Place the motorcycle on a flat surface resting on it’s

side stand.
2. Remove the front bezel by either:
• Removing the two fasteners q and headlight
bezel.

4. Remove the five fasteners e from the windshield

and remove windshield.

OR
• Gently pull outward and remove Bezel.

NOTICE
When removing the five windshield fasteners be sure
to capture the T-nuts as they are not captive.

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5. Remove the four fasteners r from the top of the 7. Remove two short fasteners, four longer fasteners
fairing assembly. y and two washers u from the inner fairing
assembly.

6. Remove two fasteners from both the left and right

side speaker grills t. Pull speaker grills bottom NOTICE
out and then downward to remove.
Some fasteners are longer than others, make sure to
note placement of fasteners when removing.

8. Remove fairing assembly.

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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. Lift the inner fairing assembly off of the triple

ROADMASTER) clamp studs and route wire through the access
hole.
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 7.58
2. Remove the instrument cluster. See Ride Command
System Removalpage 7.64
3. Remove four nuts q and washers securing the
inner fairing support to the triple clamp assembly.
You may need to use an allen wrench to hold the
mounting studs.

4. Disconnect all multi plugs in harness holder

bracket.

IMPORTANT
Use a marker or tape to index each multi-plug before
disconnecting. Some of the connectors are unmarked
and interchangeable.

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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. Connect all multi plugs in harness holder bracket.

ROADMASTER)
CAUTION
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.

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.

7. Install the outer fairing assembly. See Outer Fairing

Installation - (Chieftain / Roadmaster)page 7.62
2. Carefully route all loose wires through the access 8. Install the instrument cluster. See Ride Command 7
hole in the inner fairing mount. System Installationpage 7.66
3. Install the inner fairing assembly on the four triple
clamp studs w and install washers and nuts finger
tight.

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)

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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 / 3. Install head light bezel and torque fasteners q to

ROADMASTER) specification.
1. Install outer fairing assembly onto fairing subframe
as shown.

TORQUE
Head Light Bezel:
2. Install the head light assembly w and torque 36 in-lbs (4.1 Nm)
fasteners to specification.
4. Install two short fasteners and four longer fasteners
y into the inner fairing assembly. Install one
washer u per side between the lower fasteners
and the fairing. Torque fasteners to specification.

TORQUE
Head Light Bracket Fasteners:
7 ft-lbs (9.5 Nm)

NOTICE
Some fasteners are longer than others, make sure to
note placement of fasteners when removing.

TORQUE
Inner Fairing Fasteners:
36 in-lbs (4.1 Nm)

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5. Install two fasteners into both the left and right side 7. Install the windshield and torque fasteners e to
speaker grills t. Torque to specification. specification.

TORQUE TORQUE
Speaker Fasteners: Windshield Fasteners:
25 in-lbs (3 N·m) 36 in-lbs (4.1 Nm)

6. Install the four fasteners r into the top of the

fairing assembly and torque to specification.

TORQUE
Upper Fairing Fasteners:
36 in-lbs (4.1 Nm)

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R I D E C O M M A N D S Y S T E M R E M O VA L 6. Remove Display hardware e.

1. Remove Outer Fairing, and Windshield. See Outer

Fairing Removal - (Chieftain / Roadmaster)page
7.58
2. Disconnect Windshield Linkage q.

CAUTION
Failure to separate display from bracket prior to
removal may cause damage during disassembly

3. Tie back Windshield Linkages to ease in display 7. Disengage Display bracket locking tabs
removal.
4. Disconnect Power Button, Speedometer, Tach and
Display harnesses.
5. Remove Display bracket hardware w from top and
bottom of display.

8. Pull up on dash tabs to disengage display bracket

pins

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9. Pivot display bracket back and out to remove

display.

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R I D E C O M M A N D S Y S T E M I N S TA L L AT I O N 6. Install display bracket fasteners w. Torque

fasteners to specification.
1. Place display into dash.
NOTICE
Temporarily secure display with a piece of tape to
aid in step 3

2. Ensure Tach and Speedo bezels are clipped into

dash.
3. Partially engage upper display bracket pins into
dash holes and pivot bracket into place.
4. Engage display bracket side locking tabs.
5. Install display fasteners e. Torque fasteners to
specification.

TORQUE
Display Bracket fasteners (top):
36 in-lbs (4 N·m)

TORQUE
Display Bracket fasteners (bottom):
36 in-lbs (4 N·m)

7. Connect Power Button, Speedometer, Tach and

Display harnesses
8. Route USB wire thru storage box grommet and
install storage box.
TORQUE
Ride Command Display fasteners:
36 in-lbs (4 N·m)

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9. Connect Windshield Lift Arm fasteners q. Torque

fasteners to specification.

TORQUE
Lift Arm Fasteners:
84 in-lbs (10 N·m)

NOTICE
Refer to image below to make sure the Lift Arm
hardware stack is in the correct order.

10. Install Outer Fairing and Windshield. See Outer

Fairing Installation - (Chieftain / Roadmaster)page
7.62.

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NOTES

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CHAPTER 8
STEERING / SUSPENSION
FRONT WHEEL / SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
SHOCK ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
HANDLEBAR CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
HANDLEBAR CONTROLS (2018+ MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
FRONT FORK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.10
TRIPLE CLAMP (16 INCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.11
TRIPLE CLAMP (19 INCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.12
FRONT WHEEL - CAST (16 & 17 INCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.13
FRONT WHEEL - CAST (19 INCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.14
FRONT WHEEL - SPOKED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.15
SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.16
HANDLEBAR, REMOVAL / INSTALLATION (ALL MODELS EXCEPT CHIEFTAIN /
ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.16
HANDLEBAR REMOVAL / INSTALLATION (CHIEFTAIN / ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . .8.18
CLUTCH CABLE, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.20
FRONT WHEEL, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.22 8
FRONT AXLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.23
FRONT WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.23
BRAKE DISC REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.24
FRONT WHEEL BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.24
FRONT WHEEL BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.25
FRONT FORK REMOVAL (ALL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.25
FRONT FORK DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.27
FRONT FORK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.30
FRONT FORK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.31
FRONT FORK INSTALLATION (ALL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.36
TRIPLE CLAMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.38
FRONT FORK LOCK REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.39
TRIPLE CLAMP INSTALLATION / STEERING HEAD BEARING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . .8.40
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.42
REAR WHEEL / SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.44
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.44
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.44
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.44
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.45

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© Copyright 8.1
STEERING / SUSPENSION

ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.47

REAR SUSPENSION (2017-19 MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.47
REAR SUSPENSION (2020+ MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.49
REAR SHOCK / PUSHROD (2017-19 MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.51
REAR SHOCK / PUSHROD (2020+ MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.52
REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.53
ROCKER ASSEMBLY (2017-19 MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.54
ROCKER ASSEMBLY (2020+ MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.55
SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.56
DRIVE BELT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.57
DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.57
DRIVE BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.57
DRIVE BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.57
DRIVE SPROCKET SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.58
DRIVE SPROCKET COVER, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.58
DRIVE SPROCKET REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.58
DRIVE SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.60
DRIVE SPROCKET INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.61
DRIVEN SPROCKET SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.62
DRIVEN SPROCKET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.62
DRIVEN SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.62
DRIVEN SPROCKET BEARING - REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.63
DRIVEN SPROCKET INSTALLATION (ALL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.65
REAR WHEEL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.66
REAR WHEEL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.66
REAR AXLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.68
REAR WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.68
REAR WHEEL BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.69
WHEEL BEARING REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.70
BRAKE DISC REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.70
SHOCK ABSORBER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.71
SHOCK ABSORBER INSPECTION (ALL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.71
SHOCK ABSORBER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.73
SWINGARM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.74
SWINGARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.74
SWINGARM BUSHING / BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.76
SWINGARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.78
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.81
TROUBLESHOOTING, REAR WHEEL / SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.81
TROUBLESHOOTING, FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.82
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.83
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.83
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.83
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.84
TIRE PRESSURE / SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.84
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.87
TIRE WEAR PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.87
OZONE CRACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.87

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 STEERING / SUSPENSION

FRONT TIRE CUPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.87

TIRE PRESSURE MONITORING SYSTEM (TPMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.88
TPMS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.88
TPMS SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.89
TPMS ACTIVATION (SPRINGFIELD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.90
TPMS ACTIVATION (CHIEFTAIN DARK HORSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.93
TPMS ACTIVATION (CHIEFTAIN / ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.96
TIRE CHANGING, GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.99
TIRE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.100
TIRE REMOVAL - (CHIEFTAIN / ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.100
TIRE REMOVAL - (CLASSIC / VINTAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.101
TIRE REMOVAL - (DARK HORSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.102
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.104
VISUAL INSPECTION & RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.104
TIRE REPAIR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.104
VALVE STEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.105
VALVE STEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.105
VALVE STEM INSTALLATION - RUBBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.105
VALVE STEM INSTALLATION - METAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.105
TIRE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.106
TIRE INSTALLATION - (CHIEFTAIN / ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.106
TIRE INSTALLATION - (CLASSIC / VINTAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.108
TIRE INSTALLATION - (DARK HORSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.110
TIRE BALANCING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.112
SPOKED WHEEL SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.113
WHEEL TRUING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.113
FINAL TIGHTENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.113
WHEEL LACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.114
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.115
8

9850035 R07 - 2017–21 Indian Motorcycle (Full-Size) Service Manual

© Copyright 8.3
STEERING / SUSPENSION

FRONT WHEEL / SUSPENSION

G E N E R A L I N F O R M AT I O N SPECIAL TOOLS
SERVICE NOTES TOOL DESCRIPTION PART NUMBER
Fork Spring Compressor PV-49463
WARNING
Fork Spring Compressor
Indian Motorcycles are produced using the Adapter PV-49464
designated tires listed as original equipment. This Cartridge Shaft Tool PV-49452
includes field testing to ensure stability and superior
handling. The use of tires other than original Damper Rod Holder PV-49453
equipment may cause instability which could lead to Fork Oil Level Tool PV-59000-A
a crash, resulting in serious injury or death. Use only
the recommended tires inflated to the recommended Fork Seal Driver PV-49494
tire pressures based on load conditions as listed on Wheel / Stem Bearing
PF-51324
the tire information label. Removal / Installation Kit
Tubeless tires are used on certain Indian Motorcycle Spanner Socket
models. Operating the motorcycle with damaged (Steering Stem) PV-43508
rims creates a safety hazard including air pressure
loss, steering imbalance and/or reduced steering
control. Do not attempt to repair or straighten
damaged rims.

CAUTION
Work performed to the front end of the motorcycle
usually involves supporting the machine with the
front end elevated. Take precautions so that the
motorcycle is securely supported when the front tire
is off the ground. This reduces the possibility of
personal injury or damage to the motorcycle.

Leaking front fork seals are a safety hazard and should

be replaced immediately if a leak is found. Fork oil
could contaminate front brake components which
could reduce stopping ability of the motorcycle.
Contaminated brake discs or pads greatly reduce
available stopping force & increase stopping distance.
Brake discs can be cleaned using commercially
available brake cleaner. NEVER attempt to clean
contaminated brake pads. Replace pads as a set.

• Refer to MAINTENANCE chapter for front end

components service.
• Refer to Steering / Suspension chapter for TIRE
REMOVAL, REPAIR, & BALANCING
• Refer to Brakes chapter for BRAKE SYSTEM
service and repairs.

9850035 R07 - 2017–21 Indian Motorcycle (Full-Size) Service Manual

8.4 © Copyright
 STEERING / SUSPENSION

S E R V I C E S P E C I F I C AT I O N S
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"
Cast 3.5” x 17” 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: 2208093)
Measured with spring Chief: 125 mm (4.92”)
Fork Oil Level (From Top of
removed, inner tube fully Chieftain: 132 mm +1 mm (.039”)
Tube)
compressed. (5.20")
Oil level must be measured Chief: 599 cc (599 ml)
Fork Oil Capacity (per leg,
and adjusted to Chieftain: 557 cc (557 Set Level
dry)
specification. ml)

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S H O C K A N A LY S I S
Shock “misting” q or “weepage” w is common and should be present during normal vehicle operation. All
Shock Absorber Seals are designed to allow a thin film of oil to pass into and out of the shock. This thin film of oil
lubricates the Seal to ensure low friction and reduces the corrosion rate of the Piston Rod.

Vehicle operating conditions have a high impact on how much shock oil might be present on the seal and shock
body (i.e. road conditions and operating temperature). It is important to properly identify the difference between
normal operation (weepage or misting) and a shock that has a leak. Below are some images to help determine
what is normal and what could be identified as a bad shock.

MISTING OR WEEPAGE LEAKAGE

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A S S E M B LY V I E W S
HANDLEBAR CONTROLS

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Bar End Trim Cap Push Evenly Until Fully Seated and Tabs Engage

w Clutch Lever Cap Fastener 70 in-lbs (7.9 Nm) Tighten Top Fastener First
8
IMPORTANT
Torque the Clutch Lever Cap upper fastener first
and the bottom fastener second.

e Brake Lever Cap Fastener 70 in-lbs (7.9 Nm) Tighten Top Fastener First

r Grip Retainer Fastener 14 in-lbs (1.6 Nm)

t Right-Hand Switch Cube 31 in-lbs (3.5 Nm) Tighten Top Two Fasteners First
Fastener
y Left-Hand Switch Cube 31 in-lbs (3.5 Nm) Tighten Top Two Screws First
Fastener

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HANDLEBAR CONTROLS (2018+ MODELS)

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Outer cube fasteners 12 in-lbs (1 N·m)

w Inner cube fasteners 12 in-lbs (1 N·m)

e Rear Switch Cover NA

r Front Switch Cover NA

t LH Handlegrip NA

y RH Throttle Handlegrip NA

u Throttle alignment slot NA

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HANDLEBAR

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Riser Fastener (QTY.2) 60 ft-lbs (81.3 Nm)

w Washer -
-
e Spacer 8
r Isolator -

t Washer -

y Riser Cap Fastener (QTY.4)

18 ft-lbs (24.4 Nm) Tighten Front Bolts
First, then Rear

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F R O N T F O R K A S S E M B LY

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

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 (97.6 Nm)

o Washer -

a Spring -

s Cylinder Assembly -

d Inner Fork Tube -

f Bushing -

g Oil Lock -

h Fork Cover -

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TRIPLE CLAMP (16 INCH)

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Lower Triple Clamp -
18 ft-lbs (24.4 Nm) See Tightening
Lower Fork Clamp Fastener (QTY.4)
Procedure Outlined in this Chapter
w Lower Fork Clamp Fastener (QTY.4) - 8
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 (24.4 Nm)
i Steering Lock -
See Tightening Procedure Outlined in this
o Steering Head Nut
Chapter
18 ft-lbs (24.4 Nm) See Tightening
a Upper Fork Clamp Fastener (QTY.2)
Procedure Outlined in this Chapter
s Upper Triple Clamp -
d Washer -
72 ft-lbs (97.6 Nm) See Tightening
f Top Triple Clamp Nut
Procedure Outlined in this Chapter

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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.

TRIPLE CLAMP (19 INCH)

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Lower Triple Clamp -
18 ft-lbs (24.4 Nm) See Tightening
Lower Fork Clamp Fastener (QTY.4)
Procedure Outlined in this Chapter
w Lower Fork Clamp Fastener (QTY.4) -
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 (24.4 Nm)
i Steering Lock -
See Tightening Procedure Outlined in this
o Steering Head Nut
Chapter
18 ft-lbs (24.4 Nm) See Tightening
a Upper Fork Clamp Fastener (QTY.2)
Procedure Outlined in this Chapter
s Upper Triple Clamp -

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NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

d Washer -
72 ft-lbs (97.6 Nm) See Tightening
f Top Triple Clamp Nut
Procedure Outlined in this Chapter

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.

FRONT WHEEL - CAST (16 & 17 INCH)

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

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 -

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FRONT WHEEL - CAST (19 INCH)

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Pulse Wheel / Brake Disc Fastener (QTY.6 per Disc) 22 ft-lbs (29.8 Nm)

w ABS Pulse Wheel -

e Brake Disc -

r Seal -

t Wheel Bearing -

y Inner Bearing Spacer -

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FRONT WHEEL - SPOKED

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Outer Bearing Spacer -

w Pulse Wheel / Brake Disc Fastener (QTY.6) 22 ft-lbs (29.8 Nm)

-
e ABS Pulse Wheel 8
r Brake Disc -

t Seal -

y Wheel Bearing -

u Inner Bearing Spacer -

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SERVICE PROCEDURES 6. Remove headlight nacelle and headlight bucket

assembly.
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
( A L L M O D E L S E X C E P T C H I E F TA I N / All Models (except Chieftain / Roadmaster):
ROADMASTER) 7. Remove front brake master cylinder assembly. See
Front Master Cylinder Servicepage 9.28.
WARNING
Clutch cable must be routed, installed, and CAUTION
adjusted correctly to function properly. Note how Keep brake reservoir in an upright position to
cable is routed and secured before removing the prevent air from entering the system. Bleeding is
cable. Permanent cable damage may result if the required if air enters the system.
inner cable is bent or twisted during installation.
If the cable is incorrectly routed, installed, or
adjusted, serious injury or death may occur. 8. Remove the clutch lever assembly. See Handlebar
Controlspage 8.7.
9. Place a soft piece of cloth or padded material on
CAUTION the top of the fuel tank if tank has not been
Cover painted or chrome parts to prevent damage. removed.
Use care to protect fuel tank and front fender. Tank 10.
removal is recommended. Secure, set aside, or
support parts as they are removed. NOTICE
Make an index mark on the handlebar along the
parting line of the riser cap to ensure proper
1. Place motorcycle in an upright position with the handlebar position upon reassembly.
front wheel clamped in a wheel vise.
Chieftain Dark Horse: If risers will be removed, remove handlebars /
2. Remove outer fairing. See Outer Fairing Removal - risers as an assembly. If risers will not be removed,
(Chieftain Dark Horse)page 7.52. hold the handlebars in place and loosen the rear
handlebar clamp fasteners w , and then the front w
3. Remove instrument cluster. See Instrument Panel .
Removal / Installation - (Chieftain Dark Horse)page
7.57. 11. Remove the riser cap e.

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).
5. Noting harness routing and connector locations, 13. Installation is performed by reversing the
disconnect all fairing electrical connectors and removal procedure.
remove inner fairing support.
Chief Classic / Chief Vintage / Chief Dark
Horse / Springfield:

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14. Line up the handlebar index mark made in STEP 10

and torque riser caps, starting with the front
fasteners, to specification.
TORQUE
Riser Cap Fasteners:
18 ft-lbs (24.4 Nm) Tighten Front Bolts First,
then Rear

15. If handlebar assembly was removed with risers

intact, torque riser fasteners to specification.
TORQUE
Riser Fasteners:
60 ft-lbs (81 N·m)

Chieftain Dark Horse:

16. Install the inner fairing support and torque nuts q
to specification.
TORQUE
Inner Fairing Support:
12 ft-lbs (16.3 Nm)

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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 6. Remove the clutch lever assembly. See Handlebar

( C H I E F TA I N / R O A D M A S T E R ) Controlspage 8.7.

WARNING CAUTION
Clutch cable must be routed, installed, and Always support the clutch when attempting to install
adjusted correctly to function properly. Note how mirrors. Excessive rotation to the clutch perch while
cable is routed and secured before removing the the clutch switch wires are in tension may result in
cable. Permanent cable damage may result if the damage to the clutch switch. Do not disconnect the
inner cable is bent or twisted during installation. clutch from the handlebar and let it hang freely,
If the cable is incorrectly routed, installed, or doing so may result in damage to the clutch switch
adjusted, serious injury or death may occur. wire q.

CAUTION
Cover painted or chrome parts to prevent damage.
Use care to protect fuel tank and front fender. Tank
removal is recommended. Secure, set aside, or
support parts as they are removed.

1. Place motorcycle in an upright position with the

front wheel clamped in a wheel vise.
2. Remove outer fairing. See Outer Fairing Removal -
(Chieftain / Roadmaster)page 7.58.
3. Remove four nuts q and washers securing the
inner fairing support to the triple clamp assembly.
7. Place a soft piece of cloth or padded material on
the top of the fuel tank if tank has not been
removed.
8.
NOTICE
Make an index mark on the handlebar along the
parting line of the riser cap to ensure proper
handlebar position upon reassembly.

If risers will be removed, remove handlebars /

risers as an assembly. If risers will not be removed,
hold the handlebars in place and loosen the rear
handlebar clamp fasteners w , and then the front w
.
4. Noting harness routing and connector locations, 9. Remove the riser cap e.
disconnect all fairing electrical connectors and
remove inner fairing support.
5. Remove front brake master cylinder assembly. See
Front Master Cylinder Servicepage 9.28.

CAUTION
Keep brake reservoir in an upright position to
prevent air from entering the system. Bleeding is
required if air enters the system.

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10. Lift handlebars out of riser clamps (or the risers off
of the upper triple clamp).
11. Installation is performed by reversing the
removal procedure.
12. Line up the handlebar index mark made in STEP 8
and torque riser caps, starting with the front
fasteners, to specification.
TORQUE
Riser Cap Fasteners:
18 ft-lbs (24.4 Nm) Tighten Front Bolts First,
then Rear

13. If handlebar assembly was removed with risers

intact, torque riser fasteners to specification.
TORQUE
Riser Fasteners:

14. Install the inner fairing support and torque nuts q

to specification.
TORQUE
Inner Fairing Support:
12 ft-lbs (16.3 Nm)

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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 8. Loosen the fasteners r securing the left-hand

frame downtube to the engine and steering head.
1. Place motorcycle in an upright position with the
front wheel clamped in a wheel vise.
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.

4. Withdraw the clutch cable from the mounting boss

located on the primary cover.
5. At the handlebar, pull the clutch cable casing
straight out until clear of lever perch and rotate
cable outward to align inner cable wire with slot in
lever.
6. Pull lever slightly until slotted opening in lever is
clear of perch and slide cable barrel end down and
out of lever.
7. Note routing of clutch cable through frame.

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Clutch Cable Installation

CAUTION
Do not kink, bend, or twist the inner cable or outer
cable casing during installation

1. Route clutch cable in the same manner as removed.

2. Torque the left-hand frame downtube fasteners to
specification. See Engine Brackets / Fastenerspage
3.11.
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.
8. Rotate the release arm inward until cable can be
installed in release arm.
9. Install the clutch cable E-clip at the mounting boss.
10. Install the side stand bumper and fastener. Torque
to specification.
TORQUE 8
Side Stand Bumper:
84 in-lbs (9.5 Nm)

11. Adjust clutch cable free play. See Clutch Lever Free
Playpage 2.30.

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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 3. Loosen axle pinch fasteners q on lower right fork

leg.
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.

CAUTION 4. Support wheel and remove axle w . Be prepared

to catch spacers on each side of the wheel and
CALIFORNIA MODELS: Remove the charcoal canister remove wheel.
prior to raising motorcycle wheels off the ground. As
the swingarm lowers it can contact the canister hose
fittings and damage them.

1. Secure the motorcycle in an upright position with

tie-down straps and a platform jack positioned
beneath the engine cases.

Installation
5. Install front wheel and spacers into fork.
6. Install the axle and torque to specification.
TORQUE
Front Axle:
NOTICE 52 ft-lbs (70.5 Nm)
Do not operate the front brake lever with the calipers
or wheel removed. 7. Tighten axle pinch fasteners to specification.
TORQUE
Removal
Axle Pinch Fasteners:
2. Remove the front fender. See Front Fender 18 ft-lbs (24.4 Nm)Tighten each screw once after
Removalpage 7.33. initial torque

8. Install front fender. See Front Fender

Installationpage 7.34.

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FRONT AXLE INSPECTION

1. Place axle in V-blocks and inspect runout.
Compare to specifications in this chapter.

2. Replace axle if it fails inspection. Do not attempt to

straighten a bent axle.

FRONT WHEEL INSPECTION

1. Install front wheel in truing stand.
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.

4. Visually inspect wheel for cracks.

5. Replace wheel if it fails visual or measured
inspection. Do not attempt to straighten cast or
wheels.

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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 FRONT WHEEL BEARING INSPECTION

1. Remove front wheel. See Front Wheel, Removal /
NOTICE
Installationpage 8.22.
Inspect bearings installed in the wheel. Do not
2. Position wheel with brake disc and ABS tone ring remove to inspect. Bearings cannot be repacked.
facing up (protect the other disc and wheel when Replace both wheel bearings if one or both fail
removing opposite disc). inspection, or if either bearing was removed.
3. Remove and discard brake disc / tone ring
fasteners q . 1. Visually inspect bearing seals q on each side for
wear or damage.
4. Remove tone ring w and brake disc e from
wheel.

2. Check bearings by turning inner race by hand.

5. Flip wheel over and repeat procedure to remove • Look for signs of discoloration, scoring, galling, or
opposite side brake disc (no tone ring on right- contamination from moisture or dirt. Replace
hand side). bearings if any of the above are present.
6. Installation is performed by reversing the • Turn the inner race of the bearings. The bearings
removal procedure. Use new brake disc should turn smoothly and quietly. The inner race
fasteners for installation should be firm with minimal side to side movement
7. Torque new brake disc fasteners to specification in and no detectable up and down movement.
a star pattern.
3. Discard bearings that fail any of the above
TORQUE inspections.
Brake Disc Fasteners:
CAUTION
22 ft-lbs (29.8 Nm)
Do not reuse bearings after removing them from the
wheel. Removal damages the bearings internally.

4. Inspect bearing fit into wheel hub. The outer race

of the bearing must fit tightly into the bore. You
should not be able to move it (or remove it) by
hand. Replace the wheel if outer race of a new
bearing does not fit tightly in the bore.

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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

Installationpage 8.22. 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
Installationpage 8.24. 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 CAUTION
the seal bore.
CALIFORNIA & INTERNATIONAL MODELS: Remove
the charcoal canister prior to raising motorcycle
wheels off the ground. As the swingarm lowers, it can
contact the canister hose fittings and damage them.

1. Remove front fender. See Front Fender

Removalpage 7.33.
2. Secure the motorcycle in an upright position with
tie-down straps and a platform jack positioned
beneath the engine cases.

8
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 NOTICE
followed by the inner bearing spacer.
Do not operate the front brake lever with the calipers
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
Installationpage 8.24. Servicepage 9.30.

13. Install the front wheel. See Front Wheel, Removal / 4. Remove front wheel. See Front Wheel, Removal /
Installationpage 8.22. Installationpage 8.22.

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Chieftain Dark Horse: 11. Loosen lower triple clamp pinch fasteners e for
each fork tube.
5. Remove fairing assembly. See Outer Fairing
Removal - (Chieftain Dark Horse)page 7.52.
Chieftain / Roadmaster:
6. Remove fairing assembly. See Outer Fairing
Removal - (Chieftain / Roadmaster)page 7.58
Chief Classic / Chief Vintage / Chief Dark
Horse / Springfield:
7. Remove nacelle and headlight bucket.
ALL Models
8. If triple clamp will be removed, remove front brake
line guides from the upper and lower triple clamps.
9. Loosen upper triple clamp pinch fastener q for
each fork tube.
12. Slide fork legs down and remove.

10. If disassembling the fork tube(s), loosen the fork

cap(s) w prior to loosening the lower triple clamp
fasteners.

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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.

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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.

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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.

8
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
remove the inner tube.
21. Separate the tubes.

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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.

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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
so will weaken the tube and make the motorcycle
unsafe to operate.

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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.

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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.

8
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 (23.0 Nm) is smooth and consistent.

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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.

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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.

8
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 (14.9 Nm)
TORQUE
35. Slowly release spring pressure and remove fork Fork Cap to Outer Tube:
leg from spring compressor. 16 ft-lbs (21.6 Nm)
36. Install special socket in compressor as outlined for
disassembly.

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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 ) 3. Torque the bottom fastener on the lower triple

clamp q .
NOTICE
Clean the fork tubes and the clamping surfaces of the
triple clamps to remove any oil or grease prior to
installation.

1. Install one fork tube assembly into lower triple

clamp.

TORQUE
Lower Triple Clamp Pinch Fasteners (All except
Springfield):
18 ft-lbs (24.4 Nm)

TORQUE
2. Continue to slide tube through lower triple clamp Lower Triple Clamp Pinch Fasteners (Springfield):
and into upper triple clamp. Stop when the top of 23 ft-lbs (31 N·m)
the fork cap is flush with the top of the upper triple
clamp.
4. Torque the top fastener on the lower triple clamp
w.

5. REPEAT torque process in steps 3 & 4.

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6. Torque the upper triple clamp fastener e .

TORQUE
Upper Triple Clamp Fastener (All Models):
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 /
Installationpage 8.22.
10. Install brake calipers. See Front Caliper
Servicepage 9.30.
11. Install front fender. See Front Fender
Installationpage 7.34.
12. Install fairing.
• Chieftain Dark Horse: See Outer Fairing
8
Installation - (Chieftain Dark Horse)page 7.56
• Chieftain / Roadmaster: See Outer Fairing
Installation - (Chieftain / Roadmaster)page 7.62

13. Chief Classic / Chief Vintage / Chief Dark

Horse / Springfield:
Install headlight bucket and nacelle.
14. Inspect all fasteners for proper torque. Inspect
hoses and wiring for proper routing.
15. Lower front end of motorcycle to the ground and
test front suspension / fork operation.

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T R I P L E C L A M P R E M O VA L 5. Remove fairing assembly. See Outer Fairing

Removal - (Chieftain / Roadmaster)page 7.58
WARNING
Chief Classic / Chief Vintage / Chief Dark
This procedure requires raising and supporting Horse / Springfield:
the motorcycle so that the front wheel is off the
ground. Precautions should be taken to ensure 6. Remove nacelle and headlight bucket.
the motorcycle is properly stabilized at all times. ALL Models
Failure to properly support motorcycle may result
in personal injury or damage to the motorcycle. 7. Remove the handlebar / riser assembly. See
Handlebar, Removal / Installation (All Models
except Chieftain / Roadmaster)page 8.16 or
CAUTION Handlebar Removal / Installation (Chieftain /
Roadmaster)page 8.18.
Do not twist the brake hose or brake line. Do not
allow calipers to hang from the brake hose. Secure 8. Remove fork tubes. See Front Fork Removal (All
calipers in such a way to avoid hose damage. Models)page 8.25.
9. Remove brake line guides from upper and lower
triple clamp.
CAUTION
10. Remove center nut q and washer on upper triple
CALIFORNIA & INTERNATIONAL MODELS: Remove clamp.
the charcoal canister prior to raising motorcycle
wheels off the ground. As the swingarm lowers it can
contact the canister hose fittings and damage them.

1. Secure the motorcycle in an upright position with

tie-down straps and a platform jack positioned
beneath the engine cases.

11. Slide upper triple clamp off steering stem.

NOTICE
Do not operate the front brake lever with the calipers
or wheel removed.

2. Remove the front fender. See Front Fender

Removalpage 7.33.
3. Remove front wheel. See Front Wheel, Removal /
Installationpage 8.22.
Chieftain Dark Horse:
4. Remove fairing assembly. See Outer Fairing
Removal - (Chieftain Dark Horse)page 7.52.
Chieftain / Roadmaster:

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12. Remove stem adjuster nut w with a suitable F R O N T F O R K L O C K R E M O VA L / I N S TA L L AT I O N

spanner socket.
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.

13. Remove lower triple clamp, with steering stem, and

lower bearing (outer race will remain in head
tube).
14. Inspect bearings and bearing races.

3. Install NEW fork lock w and Install two NEW

fasteners q. Torque fasteners to specification.
TORQUE
Fork Lock Fasteners:
18 ft-lbs (24 Nm)

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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.

NOTICE
Nut will be torqued after fork tubes are installed.

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11. Slide fork tubes through lower triple clamp and 20. Install front wheel. See Front Wheel, Removal /
into upper triple clamp. Align top edge of fork cap Installationpage 8.22
with top edge of upper triple clamp and hold in
21. Verify all fasteners are installed and properly
position.
torqued.
12. Tighten top triple clamp pinch fastener enough to
hold tubes in place. Leave lower triple clamp pinch
fasteners loose.
13. Torque the top steering stem nut to specification.
TORQUE
Top Steering Stem Nut:
72 ft-lbs (97.6 Nm)

NOTICE
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 fasteners
(both sides) to specification.
TORQUE
Upper Triple Clamp Pinch Fasteners:
18 ft-lbs (24.4 Nm) 8
16. Torque bottom fasteners on lower triple clamp to
specification.
17. Torque top fasteners on lower triple clamp to
specification.
TORQUE
Lower Triple Clamp Pinch Fasteners (All except
Springfield):
18 ft-lbs (24.4 Nm)

TORQUE
Lower Triple Clamp Pinch Fasteners (Springfield):
23 ft-lbs (31 N·m)

18. Repeat STEPS 15–17.

19. Install handlebar assembly. See Handlebar,
Removal / Installation (All Models except Chieftain
/ Roadmaster)page 8.16 or Handlebar Removal /
Installation (Chieftain / Roadmaster)page 8.18

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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
Low Tire Pressure Inflate to specification
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

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PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED

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
Low Tire Pressure Inflate to specification
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 8
Brake Dragging Repair as Necessary
(Hydraulic or Mechanical Problem)
Brake Dragging (Bent Disc) Replace
Improper Assembly After Repairs Correct as Necessary

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REAR WHEEL / SUSPENSION

G E N E R A L I N F O R M AT I O N • The rear shock absorber is serviceable.
SERVICE NOTES • Refer to Maintenance chapter for maintenance of
rear wheel & suspension components, and
WARNING suspension ride height adjustment.
This motorcycle was produced with the designated
tires as original equipment. The testing to ensure
stability and superior handling was done using the SPECIAL TOOLS
OEM tires. Using non-OEM tires could result in poor
motorcycle stability and handling, which can lead to SPECIAL TOOL PART NUMBER
a crash resulting in serious injury or death. Use only
the recommended tires inflated to the recommended Swing-arm Bushing Tool PF-51237
tire pressures. Shock Spanner Wrench PV-46993
Bearing Removal / PF-51324
IMPORTANT Installation Kit
Visual inspection of the cushion drive damper q for Platform Jack Commercially Available
cracks or deformation is required whenever the rear
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.

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S E R V I C E S P E C I F I C AT I O N S
MODEL YEARS 2017-2019
ITEM STANDARD SERVICE LIMIT
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 / 8.0” (203.2 cm) –
Dark Horse
Shock Spring Free
Length Chieftain /
Roadmaster / 7.0” (177.8 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")
Left-Hand Ball Bearing Journal: 8
Swing Arm Pivot Shaft O.D. 19.965–19.99 mm / –
Right-Hand Needle Bearing Journal:
24.95–25.00 mm
Swing Arm Needle Bearing Bore O.D.
31.946–31.972 mm –
(Right-Hand)
Swing Arm Ball Bearing Bore O.D. (Left-
41.967–41.992 mm –
Hand)
Wheel bearing O.D. (approx) 51.987–52.00 mm –
Wheel bearing I.D. (approx) 19.998–20.00 mm –

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MODEL YEAR 2020+

ITEM STANDARD SERVICE LIMIT
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
Standard Shock
(Vintage / Chief 8.0” (203.2 cm) –
Dark Horse)
Shock Spring Free
Length Low Shock
(Chieftain /
7.0” (177.8 cm) –
Roadmaster /
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
Standard Shock
(Vintage / Chief 425 lbs / in –
Dark Horse)
Spring Rate Low Shock
(Chieftain /
600 lbs / in –
Roadmaster /
Springfield)
Swing Arm Pivot Shaft Runout Not Applicable .20 mm (.008")
Left-Hand Ball Bearing Journal:
Swing Arm Pivot Shaft O.D. 19.965–19.99 mm / –
Right-Hand Needle Bearing Journal:
24.95–25.00 mm
Swing Arm Needle Bearing Bore O.D.
31.946–31.972 mm –
(Right-Hand)
Swing Arm Ball Bearing Bore O.D. (Left-
41.967–41.992 mm –
Hand)
Wheel bearing O.D. (approx) 51.987–52.00 mm –
Wheel bearing I.D. (approx) 19.998–20.00 mm –

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A S S E M B LY V I E W S
REAR SUSPENSION (2017-19 MODELS)

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NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

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 (2017-19) -
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 -

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REAR SUSPENSION (2020+ MODELS)

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NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

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
y Shock Absorber Fastener 96 ft-lbs (130 N·m)
u Rocker Arm Assembly -
i Shock (2020+) -
o Jam Nut, Shock Air Line 20 ft-lbs (27 N·m)
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 (Right-Hand) -
2* Nut — M8 x 1.25 (QTY.2) -
2( Axle Adjuster (QTY.2) -
3) Wheel Spacer (Right-Hand) -
3! Axle, Rear -

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REAR SHOCK / PUSHROD (2017-19 MODELS)

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Retaining Ring -

w Pivot Shaft, Rocker -

e Shock Absorber Fastener (2017-19) 55 ft-lbs (75Nm)

Rocker Arm -
8
r
Upper Pushrod fastener, Rear Suspension 55 ft-lbs (74.5 Nm)
t (2017-19)

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)

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REAR SHOCK / PUSHROD (2020+ MODELS)

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Retaining Ring -
w Pivot Shaft, Rocker -
e Shock Absorber Fastener 96 ft-lbs (130 N·m)
r Rocker Arm -
t Jam Nut, Shock Air Line 20 ft-lbs (27 N·m)

y Nut – (QTY.6) -
u Gusset Plate, Swingarm -
i Gusset Plate, Fasteners – (QTY.4) 96 ft-lbs (130 N·m)

o Pushrod -
a Gusset Plate, Swingarm -
s Shock Assembly -

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REAR WHEEL

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Belt, Drive — 152T / 24 mm -

w Bearing, Cushion Drive -

e Spacer, Inner -

r Sprocket — 66T - 8
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 -

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R O C K E R A S S E M B LY ( 2 0 1 7 - 1 9 M O D E L S )

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Bearing, Needle -
w Bearing, Thrust -
e Spherical Bearing -
r Seal -
t Rocker -

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R O C K E R A S S E M B LY ( 2 0 2 0 + M O D E L S )

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Bearing, Needle -

w Seal -

e Bearing, Thrust -
Rocker -
8
r

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SWINGARM

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Nut, Swingarm — M18 x 1.5 (QTY.1) 65 ft-lbs (88 Nm)
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 Nm)

s Fastener, Belt Guard — M6 x 1.0 x 20 (QTY.2) 96 in-lbs (10.8 Nm)
d Sleeve -

f Guard, Lower Belt -

g Axle, Rear -

h Nut, Axle Adjuster -

j Axle Adjuster -

k Spacer, RH -

l Adjuster Plate, LH -

1( Nut, Axle — M18 x 1.5 (QTY.1)

65 ft-lbs (88 Nm)

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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 TA L L AT I O N
1. Inspect sprockets and verify sprocket fasteners
D R I V E B E LT I N S P E C T I O N are tight.
1. Inspect belt tension and adjust if necessary. See
Drive Belt Inspectionpage 2.48. 2. Install drive belt with the Indian Motorcycle script
situated so that it reads correctly when viewed
2. If one or more component is damaged, replace from the RH side of the motorcycle.
belt and both sprockets as a set if the drive system
has been in service for 5000 miles or more (8000 3. Install the drive sprocket cover. See Drive
Km). Sprocket Cover, Removal / Installationpage 8.58.
4. Install the exhaust system. See Head Pipe
Installationpage 3.119.
D R I V E B E LT R E M O VA L
5. Install the swingarm assembly. See Swingarm
NOTICE Installationpage 8.78.
If belt is to be reinstalled, mark direction of rotation 6. Install the rear wheel. See Rear Wheel Removal /
on the outer surface of belt. Reinstall belt in same Installationpage 8.66.
direction as it was removed.
7. Set drive belt alignment and tension. See Drive
Belt Adjustmentpage 2.52.
WARNING
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 /

Installationpage 8.66.
2. Remove swingarm
Removalpage 8.74.
assembly. See Swingarm 8
3. Remove exhaust assembly. See Muffler
Removalpage 3.115.
4. Remove drive sprocket cover. See Drive Sprocket
Cover, Removal / Installationpage 8.58.
5. Remove belt from drive sprocket.

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DRIVE SPROCKET SERVICE D R I V E S P R O C K E T R E M O VA L

This procedure requires use of the Clutch Shaft
D R I V E S P R O C K E T C O V E R , R E M O VA L / Holding Tool (PF-51232).
I N S TA L L AT I O N
1. Remove the rear muffler and head pipe assembly. 1. Place motorcycle in an upright position with the
See Head Pipe Removalpage 3.118. front wheel clamped in a wheel vise.

2. Using a 5mm hex wrench, remove the two short 2. Remove exhaust system. See Muffler Removalpage
3.115
fasteners q and two long fasteners w securing the
cover to the engine and remove cover. 3. Remove the drive sprocket cover. See Drive
Sprocket Cover, Removal / Installationpage 8.58.
4. Drain the engine oil. See Engine Oil & Filter
Change in the Maintenance Chapter.
5. Remove primary cover. See Primary Cover
Removalpage 5.9.
6. Remove clutch assembly. See Clutch Removalpage
5.16.
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):
84 in-lbs (9.5 Nm) 9. Loosen both axle adjuster nuts evenly to move
wheel forward until belt is loose.
10. Pull belt off drive sprocket.
11. Remove two locking plate fasteners w and locking
plate e .

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12. Remove drive sprocket retaining nut r and drive

sprocket t .

13. Remove spacer y , and O-ring u from output

shaft.

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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.

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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. 88.5 in-lbs (10.0 Nm)
5. Apply a light film of anti-seize compound to
splines of shaft. Place belt onto front sprocket,
11. Remove the clutch shaft holding tool and install the
clutch assembly. See Clutch Installationpage 5.21.
8
place sprocket over splines of output shaft.
12. Install the primary cover. See Primary Cover
6. Apply Loctite™ 262 to threads of shaft and nut.
Installationpage 5.14.
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 / Installationpage 8.58.
shaft prior to tightening sprocket nut. 15. Install the exhaust system. See Head Pipe
Installationpage 3.119.
TORQUE 16. Adjust belt tension and wheel alignment. See
Drive Sprocket Nut: Drive Belt Adjustmentpage 2.52.
180 ft-lbs (244.0 Nm)

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DRIVEN SPROCKET SERVICE DRIVEN SPROCKET INSPECTION

1. Visually inspect sprocket teeth q for excessive
D R I V E N S P R O C K E T R E M O VA L wear and damage from foreign material or road
debris.
CAUTION
Protect brake disc surface while working on wheel.

1. Remove rear wheel. See Rear Wheel Removal /

Installationpage 8.66.
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 .

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3. Visually inspect the cushion drive damper e for DRIVEN SPROCKET BEARING - REPLACEMENT
cracks or deformation. Replace damper if damage BEARING REMOVAL
is found.
1. Remove the driven sprocket. See Driven Sprocket
Removalpage 8.62.
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. 8
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.

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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 8.65.
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.

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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.

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REAR WHEEL SERVICE 6. Remove two caliper mounting fasteners q and

remove caliper.
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
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.

CAUTION
WARNING Do not hang rear brake caliper brake line or twist the
If working on a motorcycle equipped with a charcoal brake line or damage may result.
canister (EVAP), remove the canister prior to
elevating the rear of the motorcycle to prevent
damage to the canister hose fittings. NOTICE
Do not apply rear brake pedal after the brake caliper
1. Place the motorcycle in an upright position on a lift has been removed.
table with the front wheel clamped in a wheel vise.
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 2.38.
3. Remove saddlebags, if equipped.
4. Remove upper left side panel. See Side Cover
(Upper), Removal / Installationpage 7.22. NOTICE
5. Position a platform jack beneath the engine cases Move sensor aside so that it is not damaged.
and raise until the rear tire is barely in contact with
the ground.

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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.

8
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.

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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.

16. Installation is performed by reversing the

removal procedure.
17. Torque fasteners to specification.
TORQUE
Axle Nut:
65 ft-lbs (88.0 Nm)
Wheel Speed Sensor Fastener: 96 in-lbs (10.8 Nm)
Rear Caliper Mounting Fasteners: 31 ft-lbs (42.0 Nm)

Set drive belt tension and alignment. See Drive

Belt Tensionpage 2.50 and Drive Belt Adjustment- NOTICE
page 2.52. Wheel bearings must be in good condition.

1. Set up a dial indicator to measure axial and radial

REAR AXLE INSPECTION runout of the wheel and compare to service limit.
1. Install rear axle in V-blocks and measure runout See Visual Inspection & Runoutpage 8.104.
and compare to service limit. See Service
Specificationspage . 2. Visually inspect wheel for cracks or other damage.
2. Axle diameter should be measured on bearing 3. Replace wheel if it fails visual or measured
surfaces. inspection.

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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.
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.

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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 Installationpage 8.66.
Do not reuse bearings that have been removed. 2. Remove the driven sprocket and cushion damper.
See Driven Sprocket Removalpage 8.62.
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 .
1. Remove rear wheel. See Rear Wheel Removal /
Installationpage 8.66.
2. Remove driven sprocket. See Driven Sprocket
Removalpage 8.62.
3. Remove brake disc. See Brake Disc Removal /
Installationpage 8.70.
4. Carefully pry seal q out of LH side of hub.

6. Installation is performed by reversing the

removal procedure.
7. Torque brake disc fasteners to specification in a
star pattern.
TORQUE
Brake Disc Fasteners:
22 ft-lbs (29.8 Nm)
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 /
Installationpage 8.70.
12. Install driven sprocket. See Driven Sprocket
Installationpage 8.65.
13. Install the rear wheel. See Rear Wheel Removal /
Installationpage 8.66.

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S H O C K A B S O R B E R R E M O VA L SHOCK ABSORBER INSPECTION (ALL MODELS)

2017–19 Chief Classic / Chief Vintage / Chief Dark
WARNING 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 Removalpage 8.74.
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.

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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 Specificationspage .
released.
9. Inspect shock spring for cracks or distortion.
Measure free length and compare to specification.
See Service Specificationspage .
2017–19 Chieftain / Chieftain Dark Horse /
Roadmaster / Springfield, All 2020+ models
10. Install the shock / spring assembly in a suitable
spring compressor.

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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 Installationpage 8.78.
6. Set suspension ride height / preload to
accommodate rider /cargo weight. See “REAR
SHOCK PRELOAD INSPECTION”.

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SWINGARM SERVICE 7. Remove rear wheel assembly. See Rear Wheel

Removal / Installationpage 8.66.
S W I N G A R M R E M O VA L
8. Remove the rear brake hose rear p-clamp q and
WARNING front p-clamp w fasteners located on the left inner
surface of the swingarm.
Swingarm removal involves supporting the machine
with the rear end elevated. Take precautions so that 9. Remove the rear ABS wheel speed sensor harness
the motorcycle is securely supported when the rear p-clamp fastener e from the front left side of the
tire is off the ground. Severe personal injury or death swingarm.
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
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.
10. Disconnect the rear ABS wheel speed sensor
1. Place the motorcycle in an upright position on a lift connector located at the front of swingarm.
table with the front wheel clamped in a wheel vise. 11. Remove the plastic darts r securing the rear wheel
2. Position a platform jack beneath the engine cases debris flap t to the forward upper edge of the rear
and raise until it contacts the engine. 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 2.38.
4. Remove saddlebags, if equipped. Refer to Owner’s
Manual.
5. Remove upper and lower side panels. See Side
Cover (Upper), Removal / Installationpage 7.22
and Side Cover (Lower), Removal /
Installationpage 7.22.
6. Remove the seat. See Seat, Removal / Installation -
Classic / Vintage / Chieftainpage 7.26.

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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.

8
15. Use an 8 mm hex wrench to thread the swingarm
shaft a out of the right side of the frame.

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SWINGARM BUSHING / BEARING REPLACEMENT 5. Working from the RH side of the swingarm, gently
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 Removalpage 8.74.
2. Remove shock absorber assembly from swingarm.
See Shock Absorber Removalpage 8.71.
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 .

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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.

8
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.

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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
Installationpage 8.73.
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 Installationpage 8.73.
Install the shock absorber air line into the LH frame
22. Install swingarm assembly. See Swingarm section and torque nut to specification.
Installationpage 8.78.
TORQUE
Air Line Jam Nut:
20 ft-lbs (27.0 Nm)

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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 (11.0 Nm) 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 (88.0 Nm)

10. Install the debris flap y and three plastic dart clips
u and reconnect the tip over sensor i .
8

TORQUE
Swingarm Shaft Jam Nut:
75 ft-lbs (102.0 Nm)

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.

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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”.
fasteners to specification.

TORQUE
P-Clamp Fasteners:
84 in-lbs (9.5 Nm)

14. Install the rear wheel. See Rear Wheel Removal /

Installationpage 8.66.
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 / Installationpage 7.22.
18. Install saddlebags, if equipped. Refer to Owner’s
Manual.
19. If equipped, install the charcoal canister. See
Evaporative Emission Control System (CA Models)
page 2.38.
20. Test ride motorcycle to be sure rear suspension
operates smoothly without binding or abnormal
noises.

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TROUBLESHOOTING
TROUBLESHOOTING, REAR WHEEL / SUSPENSION
PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED
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 8
Excessive load placed on motorcycle Reduce load weight
Low tire pressure Inflate to specification
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

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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.

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TIRES
G E N E R A L I N F O R M AT I O N WARNING
SERVICE NOTES Do not attempt to repair tires that have:
WARNING • Punctures with a diameter of greater than 6mm
If a consumer wishes to replace the Original (0.240").
Equipment Manufacturer (OEM) tires with another • Cuts with a length of greater than 6mm (0.240").
brand of tire, Indian Motorcycle recommends
contacting the tech-line department of the tire • Any punctures or cuts on the sidewall of the tire.
manufacturer being considered to ensure
• Tread depth of less than 1.6mm (.063") for the front
compatibility. Indian Motorcycle makes no other
tire.
recommendation other than the OEM tires. Tires
other than OEM may or may not adversely affect the • Tread depth of less than 1.6mm (.063") for the rear
handling characteristics of the motorcycle or may not tire.
have adequate clearance between tire and various
parts of the motorcycle. • Ply separation.
• Tread separation.
• Severe tread cupping.
WARNING
Indian Motorcycles are produced using the • Cuts, gouges or scratches on the sealing surface of
designated tires listed as original equipment. This the bead.
includes field testing to ensure stability and superior • Flat spots on the tread.
handling. The use of tires other than original
equipment may cause instability which can lead to a • Bubbles, separation or any unusual damage to the
crash resulting in serious injury or death. Use only inner liner of the tire.
the recommended tires inflated to the recommended • Chemical sealants or balance additives added to
tire pressures. Operating the motorcycle with the tire.
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 rims. WARNING
All repairs must be made from inside the tire.
8
WARNING
No form of temporary repair should ever be
attempted. Secondary damage caused by a
penetrating object may not be detected and tire or
tube deflation may occur at a later date.

WARNING
It is dangerous to ride with a worn tire. When a
tire reaches the minimum tread depth listed
below, replace the tire immediately.

CAUTION
Two of the biggest factors contributing to premature
tire wear are overloading and under-inflation. Do not
deviate from the specifications for loading or
inflation.

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SPECIAL TOOLS 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
TOOL DESCRIPTION PART NUMBER
WARNING
TPMS Activation Tool PF-51288 Indian motorcycles are produced using the
Tire Changing Machine Commercially Available designated tires listed below as original equipment.
This includes field testing to ensure stability and
superior handling. The use of tires other than original
equipment may cause instability. See Steering /
Suspension chapter for a review of all tire related
Warnings.

1. Inspect tires for weather checking, cuts, imbedded

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)

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TIRE PRESSURE TABLE (COLD) NOTICE

Also refer to Manufacturing Information label.

2017–18 CHIEF CLASSIC

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

2017–19 CHIEF DARK HORSE

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

2020 CHIEF DARK HORSE

FRONT: Dunlop American Elite (130/80 B17) 36 PSI(248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

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

CHIEF VINTAGE DARK HORSE

FRONT: Metzeler Cruisetec (130/80-B17) 36 PSI (248 kPa)
REAR: Metzeler Cruisetec (180/60-R16) 40 PSI (276 kPa)

2017–19 SPRINGFIELD
FRONT: Dunlop Elite 3 (130/90 B16) 46 PSI (317 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2020 SPRINGFIELD 8
FRONT: Dunlop American Elite (130/80 B17) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2021 SPRINGFIELD
FRONT: Metzeler Cruisetec (130/80-B17) 36 PSI (248 kPa)
REAR: Metzeler Cruisetec (180/60-R16) 41 PSI (283 kPa)

2018–19 SPRINGFIELD DARK HORSE

FRONT: Dunlop Elite 3 (130/60 B19) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2020 SPRINGFIELD DARK HORSE

FRONT: Dunlop American Elite (130/60 B19) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2021 SPRINGFIELD DARK HORSE

FRONT: Metzeler Cruisetec (130/60-B19) 36 PSI (248 kPa)
REAR: Metzeler Cruisetec (180/60-R16) 41 PSI (283 kPa)

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2015–17 CHIEFTAIN
FRONT: Dunlop Elite 3 (130/60 B19) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2018–20 CHIEFTAIN CLASSIC

FRONT: Dunlop Elite 3 (130/90 B16) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2018–20 CHIEFTAIN
FRONT: Dunlop American Elite (130/60 B19) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2021 CHIEFTAIN MODELS

FRONT: Metzeler Cruisetec (130/60-B19) 36 PSI (248 kPa)
REAR: Metzeler Cruisetec (180/60-R16) 41 PSI (283 kPa)

2017–19 CHIEFTAIN DARK HORSE

FRONT: Dunlop Elite 3 (130/90 B16) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2020 CHIEFTAIN DARK HORSE

FRONT: Dunlop American Elite (130/60 B19) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

CHIEFTAIN LIMITED / ELITE

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

ROADMASTER
FRONT: Dunlop Elite 3 (130/90 B16) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2021 ROADMASTER
FRONT: Metzeler Cruisetec (130/80-B17) 36 PSI (248 kPa)
REAR: Metzeler Cruisetec (180/60-R16) 41 PSI (283 kPa)

ROADMASTER CLASSIC
FRONT: Dunlop Elite 3 (130/90 B16) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2020 ROADMASTER DARK HORSE

FRONT: Dunlop American Elite (130/60 B19) 36 PSI (248 kPa)
REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa)

2021 ROADMASTER DARK HORSE / LIMITED

FRONT: Metzeler Cruisetec (130/60-B19) 36 PSI (248 kPa)
REAR: Metzeler Cruisetec (180/60-R16) 41 PSI (283 kPa)

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TIRE INSPECTION
T I R E W E A R PAT T E R N S

TIRE WEAR PATTERNS

SYMPTOM CAUSE
Wear on Left Side Riding on Crowned Roads

Edges Worn Underinflation or Excessive Loads

Excess Wear in the Middle of Tire Over-inflation or Tire Abuse
Underinflation, Excessive Loads, Suspension
Cracks in Tread Grooves Bottoming

Tread Block Cupping (Usually Front Tire -See Below) Normal Braking Wear

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 8
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.

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TIRE PRESSURE MONITORING SYSTEM (TPMS)

TPMS OVERVIEW
The Chieftain and Roadmaster models are equipped with an electronic tire pressure monitoring system (TPMS).
The TPMS provides real-time tire pressure 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.

With TPMS, the pressure of each tire can be viewed in 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.

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TPMS SENSOR REPLACEMENT

1. Remove tire from rim. See Tire Removal, Chieftain / Roadmasterpage 8.100.
2. Remove fastener q and sensor w.

3. Reverse the removal procedure for installation. Torque fastener to specification.

TORQUE
TPMS Sensor Fastener:
6 ft-lbs (8.1 Nm)

4. Install tire. See Tire Installation - (Chieftain / Roadmaster)page 8.106.

5. Perform the TPMS sensor activation procedure.

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T P M S A C T I VAT I O N ( S P R I N G F I E L D )
TPMS sensor activation is required any time the following occur:

• TPMS sensor has been replaced.

• Vehicle Control Module (VCM) has been reflashed.
• Vehicle Control Module (VCM) has been replaced.

TPMS activation or “Wake Up” requires the use of the TPMS Activation tool (PF-51288).

NOTICE
The TPMS sensor is located 180° from the valve stem q. 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.

NOTICE
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.

1. Press the power button to power up the motorcycle electrical system.

2. Press and hold RH and LH mode buttons simultaneously until the TMPS LEARN screens toggle on the screen.

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3. Press the LH mode button to begin the activation process. The following screens should toggle.

NOTICE
Once TPMS setup has been initiated on the motorcycle, there is approximately 30 seconds to complete
the activation procedure before the system times out and must be restarted. Make sure the TPMS
Activation tool is close at hand and powered up before initiating setup.

4. With the Activation tool powered up and “Searching” for the TPMS sensor, hold the device no more than 3 in
(7.6 cm) from the sidewall where the tape was placed on the front tire. You should hear a short audible “beep”
acknowledging sensor activation. A value will appear on the screen indicating the successful reading of the
front wheel. The display will switch to the rear wheel.

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5. 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. A value
will appear on the screen indicating the successful reading of the rear wheel. The following screens will
toggle indicating successful activation of both TPMS sensors.

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T P M S A C T I VAT I O N ( C H I E F TA I N D A R K H O R S E )
TPMS sensor activation is required any time the following occur:

• TPMS sensor has been replaced.

• Vehicle Control Module (VCM) has been reflashed.
• Vehicle Control Module (VCM) has been replaced.

TPMS activation or “Wake Up” requires the use of the TPMS Activation tool (PF-51288).

NOTICE
The TPMS sensor is located 180° from the valve stem q. 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.

NOTICE
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. 8
1. Press the power button to power up the motorcycle electrical system.
2. Press and hold RH and LH mode buttons simultaneously until the SETUP screen is displayed on the MFD.

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3. Press the RH mode button until TPMS is highlighted.

4. Press the LH mode button to begin the activation process. The following screen should appear.

NOTICE
Once TPMS setup has been initiated on the motorcycle, there is approximately 30 seconds to complete
the activation procedure before the system times out and must be restarted. Make sure the TPMS
Activation tool is close at hand and powered up before initiating setup.

5. After a few seconds the following screen will appear, indicating that the TPMS sensors are ready to be
activated with the Activation tool.

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6. With the Activation tool powered up and “Searching” for the TPMS sensor, hold the device no more than 3 in
(7.6 cm) from the sidewall where the tape was placed on the front tire. You should hear a short audible “beep”
acknowledging sensor activation. The MFD will switch to the rear wheel.

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 both TPMS sensors.

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T P M S A C T I VAT I O N ( C H I E F TA I N / R O A D M A S T E R )
TPMS sensor activation is required any time the following occur:

• TPMS sensor has been replaced.

• Vehicle Control Module (VCM) has been reflashed.
• Vehicle Control Module (VCM) has been replaced.

TPMS activation or “Wake Up” requires the use of the TPMS Activation tool (PF-51288).

NOTICE
The TPMS sensor is located 180° from the valve stem q. 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.

NOTICE
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.

1. Press the power button to power up the motorcycle electrical system.

2. Press the middle dropdown button on top of screen to open the settings menu.

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3. Press the “SETTINGS” icon in the upper right hand corner.

4. Press the “TPMS Learn” arrow button.

NOTICE
Once TPMS setup has been initiated on the motorcycle, there is approximately 30 seconds to complete 8
the activation procedure before the system times out and must be restarted. Make sure the TPMS
Activation tool is close at hand and powered up before initiating setup.

5. Press the “Vehicle” icon on the left hand side of screen. This screen indicates that the TPMS sensors are ready
to be activated with the Activation tool. Press the green check to start the TPMS learn procedure.

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6. With the Activation tool powered up and “Searching” for the TPMS sensor, hold the device no more than 3 in
(7.6 cm) from the sidewall where the tape was placed on the front tire. You should hear a short audible “beep”
acknowledging sensor activation. The display will switch to the rear wheel.

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
screen will display a screen indicating successful activation of both TPMS sensors.

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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.
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 8
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 Overviewpage 8.88.

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T I R E R E M O VA L 4. Flip the wheel assembly over and repeat STEP 3 on

the other side.
T I R E R E M O VA L - ( C H I E F TA I N / R O A D M A S T E R )
IMPORTANT
NOTICE
Take great care not to bend or otherwise damage the
This procedure is written assuming that a brake disc and/or belt driven sprocket. If the bead
pneumatic, electric, or manually operated rim- breaker being used interferes with either the brake
clamp type tire machine is being used. disk and/or belt driven sprocket, remove the disc or
sprocket as required.
1. Remove wheel / tire assembly from motorcycle.
See Steering / Suspension chapter for front and 5. Push tire down and lubricate tire bead with tire
rear wheel removal procedures. lubricant on both sides of the tire.
2. Remove valve core q from valve stem and let all 6.
air escape.
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.
7. Carefully work around the circumference of the
upper bead w with the tire lever until it is
completely off of the rim.

3.

CAUTION
The TPMS sensor is located 180° from the valve stem.
If the bead is broken 180° from the valve stem the
TPMS sensor may be damaged and require
replacement.

Mount the wheel assembly onto a tire bead

breaker and break the bead starting at the valve 8. Paying attention to the location of the TPMS sensor
stem, then again at 90° and again at 270° from the
valve stem as necessary.
e, lift the lower tire bead up until the tire lever can
be positioned and the tire completely removed.

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9. Work around the circumference of the rim until the T I R E R E M O VA L - ( C L A S S I C / V I N TA G E )

tire can be lifted free of the rim.
NOTICE
This procedure is written assuming that a
pneumatic, electric, or manually operated rim-
clamp type tire machine is being used.

1. Remove wheel / tire assembly from motorcycle.

See Steering / Suspension chapter for front and
rear wheel removal procedures.
2. Remove valve core q from valve stem and let all
air escape.

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. 8
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.
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.

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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 )

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.

1. Remove wheel / tire assembly from motorcycle.

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
disk and/or belt driven sprocket, remove the disc or
sprocket as required.

5.
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.

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6. Carefully work around the circumference of the

upper bead w with the tire lever until it is
completely off of the rim.

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.

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WHEEL INSPECTION T I R E R E PA I R P R E C A U T I O N S
VISUAL INSPECTION & RUNOUT WARNING
1. Clean the rim of all rubber particles and
corrosion. Only permanent plug-patch repairs of small tread
area punctures from inside the dismounted tire are
2. Inspect wheel for cracks and/or distortion. recommended. Never perform an exterior repair and
never use an inner tube as a substitute for a proper
3. Inspect bead seating area for scratches, distortion,
repair. Speed should not exceed 50 MPH for the first
or damage that could prevent proper sealing.
24 hours after repair and the repaired tire should
4. Measure wheel for radial runout (1). never be used over 80 MPH. Inspect inflation
pressure after tire cools for at least three hours
5. Measure wheel for axial runout (2). 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 Specificationspage
. 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.

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VA LV E S T E M 2. Remove valve stem nut q , valve stem w and o-

ring e .
VA LV E S T E M I N S P E C T I O N
1. Remove the valve stem cap and spray the valve
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
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.
4. Place new valve stem (with seal washer or O-ring
VA LV E S T E M I N S TA L L AT I O N - R U B B E R installed) through hole in rim and position it so the
1. Remove tire from wheel and cut valve stem with a stem is perpendicular from wheel center and,
diagonal cutter to remove. valve opening facing away from surface containing
direction indicator.
2. Clean tire valve hole and sealing area thoroughly.
3. Lubricate tire valve and hole with P-80 rubber
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) 8
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 5. Hold stem and tighten nut to specification.
to markings to ensure proper tire and valve stem
orientation. TORQUE
Valve Stem Nut:
1. Remove tire from wheel as outlined in this chapter. 44 in-lbs (5.0 Nm)

6. Install tire as outlined in this chapter.

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T I R E I N S TA L L AT I O N 2.
T I R E I N S TA L L AT I O N - ( C H I E F TA I N / NOTICE
ROADMASTER) Refer to manufacturer’s instructions for proper
tire changer operation.
NOTICE
This procedure is written assuming that a
pneumatic, electric, or manually operated rim- Mount the tire and wheel assembly on the tire
clamp type tire machine is being used. machine per the manufacturers instructions.
3. Orient tire correctly as to the balance dot and
NOTICE directional arrows.
Balance Dots 4.
Dunlop tires have a yellow dot on the sidewall which
corresponds to the lightest part of the tire. This dot is CAUTION
meant to line-up with the tire valve which often is the Use care not to damage the TPMS sensor while
heaviest part of the rim (although this is not always installing the tire bead over the edge of the rim.
the case).
Indian Motorcycle does not recommend the use of
liquid balancer/sealers. These are a form of Push tire on to rim until one bead is installed. It
temporary repair which may adversely affect ply shouldn’t be necessary to use tire irons to put one
material and mask secondary damage caused by the side of the tire onto the rim. Remember to keep
penetrating object. Reliance upon sealants can result bead(s) in the drop center of the wheel whenever
in sudden tire failure and accident. possible.
Directional Arrows
Tires q and rims w have directional arrows that must
be observed when installing tires to rims.

NOTICE
Confirm tire is positioned correctly by observing
The wheel assemblies must be free of foreign debris directional arrows.
that would affect balancing.
Carefully inspect the wheel bearings, seals and axle 5. Lubricate the tire bead.
for damage or corrosion. 6. With your hands, push as much of the remaining
tire bead as possible into the rim, pinching both
1. Lubricate both tire beads with rubber lubricant. upper and lower beads into the drop center.

CAUTION 7. When no more of tire can be installed by hand,

press down on portion of tire in front of you with
Never apply grease, oil, gasoline, spray type your knee to keep the top bead in the drop center.
lubricants or anything other than rubber lubricant or
a neutral soap and water solution to the tire bead.
Doing so can damage the tire.

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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
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
8
• 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.

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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.
clamp type tire machine is being used.
Mount the tire and wheel assembly on the tire
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
meant to line-up with the tire valve which often is the 5. Push tire on to rim until one bead is installed. It
heaviest part of the rim (although this is not always shouldn’t be necessary to use tire irons to put one
the case). side of the tire onto the rim. Remember to keep
bead(s) in the drop center of the wheel whenever
Indian Motorcycle does not recommend the use of
possible.
liquid balancer/sealers. These are a form of
temporary repair which may adversely affect ply
material and mask secondary damage caused by the
penetrating object. Reliance upon sealants can result
in sudden tire failure and accident.
Directional Arrows
Tires and rims have directional indicators that must
be observed when installing tires to rims.
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.

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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.
• 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
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
must be the same distance from the rim all the way
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
spin. Observe the wheel assembly while it is
11. For tube type tires, also observe the following: spinning to make sure the tire is seated properly.
19. Adjust tire pressures to specifications.
CAUTION
20. Balance tire / wheel assembly. 8
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
not immediately produce improved reactions the
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
cools down for at least three hours following “run-
in”.

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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.
clamp type tire machine is being used.
Mount the tire and wheel assembly on the tire
machine per the manufacturers instructions.
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.
liquid balancer/sealers. These are a form of
temporary repair which may adversely affect ply
material and mask secondary damage caused by the
penetrating object. Reliance upon sealants can result
in sudden tire failure and accident.
Directional Arrows
Tires q and rims w have directional arrows that must
be observed when installing tires to rims.

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.

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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
IMPORTANT three hours following run-in.
FOR NEW TIRES: Replacement of OEM tires or
Tire Inflation & Precautions replacement with differently constructed tires will
not immediately produce improved reactions the
• 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
cools down for at least three hours following “run-
• Stand back with no part of your body within the in”.
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. 8
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.

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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.

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SPOKED WHEEL SERVICE 3. Adjust axial runout.

WHEEL TRUING NOTICE
1. Measure axial and radial runout. It’s important to work slowly and make adjustments in
small increments. Alternate between radial and axial
adjustments until runout is within specification.

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.

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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.

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TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE REPAIR RECOMMENDED
Rear Wheel (Wobbles) Bent rim Replace
Worn or damaged wheel bearings Replace as a set
Worn or damaged swing arm Replace as a set
bushings.
Damaged or incorrect tire Replace rear tire
Wheel assembly out-of-balance Balance wheel
Low tire pressure Inflate to specification
Loose swing arm, axle or Torque to specification
suspension fasteners.
Handlebars Oscillate (Wobble) Bent front axle Replace
Worn or damaged wheel bearings Replace as a set
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
Worn or damaged wheel bearings Replace as a set
Damaged or incorrect tire Replace
Loose axle or axle pinch fasteners Torque to specification 8
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

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NOTES

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 BRAKES

CHAPTER 9
BRAKES
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
FRONT BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
REAR BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
BRAKE LINE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
FRONT MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
REAR MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
FRONT BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10
REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.11
ABS MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.12
WHEEL SPEED SENSOR, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.13
WHEEL SPEED SENSOR, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.14
ANTI-LOCK BRAKES SYSTEM (ABS) SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15
ABS SYSTEM SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15
ABS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15
ABS SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.16
ABS OVERVIEW OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.16
ABS TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.17
ABS AND LOW BATTERY VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.17
WHEEL SPEED SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.18
WHEEL SPEED SENSOR AIR GAP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19
ABS MODULE REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.20
ABS BRAKE SYSTEM BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21
9
BRAKE FLUID REPLACEMENT & BLEEDING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21
ABS BRAKE VACUUM BLEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21
ABS FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.22
ABS REAR BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.22
ABS FRONT BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.23
BRAKE LEVER RESERVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.24
BRAKE SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.25
FRONT BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.25
REAR BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.26
BRAKE DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.27
FRONT MASTER CYLINDER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.28
FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.30
FRONT CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.32
REAR MASTER CYLINDER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.33
REAR CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.34

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REAR CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.36

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.37

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 BRAKES

G E N E R A L I N F O R M AT I O N
SERVICE NOTES NOTICE
Use only genuine Indian Motorcycle replacement Brake fluid and some types of brake cleaners will
parts when servicing the brake system. Clean all damage paint, plastics and some rubber compounds.
system components prior to disassembly, including Cover or remove plastic and painted parts before
the fluid reservoir cover(s) to reduce the chance of working on the brake system. If brake fluid is spilled
debris entering the system during repair or on cosmetic surfaces, immediately rinse the area
maintenance work. Start with a clean work area away with a mild solution of soap and water until all traces
from dust, water or other contamination. Cleanliness is of brake fluid are removed. Make sure the master
very important for proper brake system maintenance cylinder reservoir being worked on is level and
and repair. Follow procedure outlined in this manual clean before removing the cap.
carefully, including fastener torques and the
application of special lubricant in required areas.
Special lubricants are included with service kits.

WARNING
Contaminated brake discs or pads greatly reduce the
amount of stopping force available & increase
stopping distance. Brake discs can be cleaned using
a commercially available brake disc cleaner. Follow
the manufacturer instructions printed on the
container. NEVER attempt to clean contaminated
brake pads. Always replace pads as a set.

WARNING
The brake system uses ethylene-glycol based fluid
(DOT 4). Do not use or mix with different types of
fluid such as silicone-based (DOT 5) or any
petroleum-based fluid.
Do not let water or moisture enter the master
cylinder when refilling. Water significantly lowers the
boiling point of the fluid and can result in poor
braking.
Do not use brake fluid taken from old, used or
unsealed containers. Never reuse brake fluid.
Keep brake fluid containers completely sealed and
out of reach of children. 9
Brake hoses should be replaced whenever the
exterior shows signs of deterioration or damage.
Brake hoses should be replaced every four (4) years
regardless of their exterior condition.
Bleed the brake system any time it is disassembled
or when the brake action is spongy.
Always inspect the operation of the brakes before
riding the motorcycle.
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.

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BRAKES

SPECIAL TOOLS
TOOL DESCRIPTION PART NUMBER
ABS Tool (Lever Reserve) PV-50104
Vacuum Brake Bleeder Commercially Available

S E R V I C E S P E C I F I C AT I O N S
ITEM STANDARD SERVICE LIMIT
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 -

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A S S E M B LY V I E W S
FRONT BRAKE SYSTEM

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Fastener, Front Disc — M8 x 25 (QTY.12) 22 ft-lbs (29.8 Nm)

w Stud, Front Caliper 35 ft-lbs (47.5 Nm)

e Washer, Copper Sealing -

r Fastener, Banjo — 10 x 1.25 18 ft-lbs (24.4 Nm)

t Fastener, Banjo — 10 x 1.25 18 ft-lbs (24.4 Nm) 9

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 13 in-lbs (1.5 Nm)

d Fastener, Brake Lever Clamp 70 in-lbs (7.9 Nm)

IMPORTANT
Torque the Brake Lever Clamp
upper fastener first and the
bottom fastener second.

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BRAKES

REAR BRAKE SYSTEM

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Valve, Bleeder 48 in-lbs (5.4 Nm)

w Fastener, Caliper — 10 x 1.25 x 25 31 ft-lbs (42.0 Nm)

(QTY.2)

e Fastener, Banjo — 10 x 1.25 18 ft-lbs (24.4 Nm)

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 (24.4 Nm)

a Rubber Diaphragm -

s Cover, Rear Master Cylinder -

d Fastener, Rear Master Cylinder 13 in-lbs (1.5 Nm)

Cover

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 BRAKES

BRAKE LINE ROUTING

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Brake Line, Rear (Rear Caliper to ABS Module) -

w Fastener, P-Clamp — (QTY.3) 84 in-lbs (9.5 Nm)

e Fastener, Bracket — (QTY.6) 84 in-lbs (9.5 Nm)

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 (24.4 Nm) 9

u Retaining Strap -

i Routing Clip -

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BRAKES

FRONT MASTER CYLINDER

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Lever, Brake -

w Adjuster, Brake Lever -

e Pivot Pin, Brake Lever -

r Fastener, Front Master Cylinder Cover 13 in-lbs (1.5 Nm)

t Cover, Front Master Cylinder -

y Rubber Diaphragm -

u Fastener, Brake Lever Clamp 70 in-lbs (7.9 Nm)

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 -

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 BRAKES

REAR MASTER CYLINDER

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Fastener, Rear Master Cylinder Cover 13 in-lbs (1.5 Nm)

w Cover, Rear Master Cylinder -

e Rubber Diaphragm -

r Reservoir, Rear Master Cylinder -

t Cartridge, Rear Master Cylinder -

y Push Cap - 9
u Pushrod -

i Dust Boot -

o Washer -

a Snap Ring, External -

s Sight Glass -

d O-Ring, Sight Glass -

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BRAKES

FRONT BRAKE CALIPER

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Fastener, Caliper Body 20 ft-lbs (27.0 Nm)

w Pad Retaining Pin 120 in-lbs (13.5 Nm)

e Screw, Bleeder 48 in-lbs (5.4 Nm)

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 -

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 BRAKES

REAR BRAKE CALIPER

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Fastener, Caliper Retainer 20 ft-lbs (27.0 Nm)

w Pad Retaining Pin 120 in-lbs (13.5 Nm)

e Caliper Body -

r Guide Pin -

t Piston Seal -

y Dust Seal - 9
u Piston -

i Brake Pad, Outboard -

o Pad Spring -

a Brake Pad, Inboard -

s Carrier, Caliper -

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ABS MODULE

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WHEEL SPEED SENSOR, FRONT

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WHEEL SPEED SENSOR, REAR

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 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
• Surface transitions (from asphalt to oily asphalt or
Proper brake system bleeding is extremely 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 • When the ABS lamp is illuminated, the anti-lock
recommended. Change every 10,000 miles (16,000 brakes will not activate, but the conventional brake
km) or 2 years, 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 9
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.

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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.

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 BRAKES

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
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
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.
9
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.

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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 Adjustmentpage
9.19.
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 Removalpage 10.14.
Installation - Rear
12. Reverse procedure to install.
13. Verify speed sensor air gap is within specification.
Perform adjustment procedure if necessary. See
Wheel Speed Sensor Air Gap Adjustmentpage
9.19.

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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:
8 ft-lbs (10.8 Nm)
NOTICE
Wheel Speed Sensor air gap is adjusted by adding
and removing shims. Shims are added to increase
gap and removed to decrease gap. No more than 3
shims (per Wheel Speed Sensor) should be used at
one time.

1. Using a suitable feeler gauge, measure the air gap

between the ABS Pulse Ring and the Wheel Speed
Sensor.

2. If the Wheel Speed Sensor air gap is out of

specification, proceed to step 3.
3. Remove Wheel Speed Sensor from bracket.
4. Withdraw the speed sensor and remove any
existing shims.
5. Based on air gap measurement, add or remove 9
shims to achieve the specified air gap.

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ABS MODULE REPLACEMENT 7. Disconnect three multi plugs from the ABS Module.
NOTICE 8. Disconnect hydraulic lines e r from ABS module
Do not disassemble the ABS module. The ABS and cap off lines to prevent contamination.
module is serviceable only as a sealed (pre-bled)
assembly. If ABS module has failed internally, replace
complete assembly.

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.

REMOVAL
1. Disconnect the negative battery cable.
2. Position motorcycle in an upright position with the 9. Remove fastener t securing ABS module to
front wheel clamped in a wheel vise. bracket.
3. California Models ONLY: Remove the
evaporative emissions charcoal canister, if
equipped. See Evaporative Emission Control
(California Models)page 1.46
4. Remove the swingarm assembly. See Swingarm
Removalpage 8.74
5. Remove nut q securing P-clamp to bottom of ABS
Module bracket.

10. Remove ABS module.

INSTALLATION
1. Reverse procedure to install.
2. Bleed brake system as outlined in this chapter.
3. Attach Digital Wrench and check for ABS trouble
codes.
IMPORTANT
6. Remove two starter solenoid fasteners w .
2017 Models:Special Tests>Auxiliary Controller
Reprogramming>Indian ABS
2018+ Models:On Digital Wrench - Special Tests >
Vehicle Controller Update

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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
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 9
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:

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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 (5.4 Nm)
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.

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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.

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. 9
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.

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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:
13 in-lbs (1.5 Nm) 2. Set front brake lever reach adjustment q so it is
closest to handlebar.
16. Perform Brake Lever Reserve Inspection. See
Brake Lever Reserve Inspectionpage 9.24.

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.

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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.

1. Remove two acorn nuts q and fastener w from

each side of the motorcycle and remove the
caliper covers e.

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
9
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 (13.5 Nm)

12. Inspect brake fluid in reservoir and set to proper

level.

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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:
13 in-lbs (1.5 Nm) 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.

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 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 Specificationspage 9.4.
engaged with caliper as it is for the inner pad.
5. Apply silicone grease to O-ring on pad retaining
pin.
TORQUE
Brake Pad Retaining Pin:
120 in-lbs (13.5 Nm)

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 Specificationspage 9.4.
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. 9

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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.

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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).

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.
9
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 (7.9
Nm)

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FRONT CALIPER SERVICE 3. Remove front caliper mounting studs w and

remove the caliper.
CAUTION
Brake fluid and 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 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.
1. Remove two acorn nuts q and fastener w from
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.

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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)
Standard = 33.96 mm | Limit = 34.04 mm (1.3401
in)

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)
Standard = 33.91 mm | Limit = 33.85 mm (1.3327
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
different diameters.
21. Clean threads of each caliper body fastener. Be
sure threads are free from any oil, grease, or brake
9
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 (27.0 Nm)
residue that could cause the pistons to stick,
resulting in brake drag.

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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 (13.5 Nm)
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 (47.5 Nm)

5. Connect brake hose to caliper with banjo fastener

and new sealing washers. Torque to specification.
TORQUE
Banjo Fastener (Brake Line): 18 ft-lbs (24.4 Nm)

6. Fill and bleed the front brake hydraulic system.

See ABS Front Brake Bleedingpage 9.23.

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.

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 BRAKES

REAR MASTER CYLINDER SERVICE 3. Remove jamb nut e .

CAUTION
Brake fluid and 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 before removing
the cap. Replace all rubber parts upon assembly.

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 9
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
Specificationspage 9.4.
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.

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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 (24.4 Nm)
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.

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 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 (24.4 Nm)
7. Clean caliper thoroughly with isopropyl alcohol.
Dry with compressed air. Clean seal grooves 22. Bleed brake system. See ABS Rear Brake
thoroughly. Any residue left behind in the grooves Bleedingpage 9.22.
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
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 9
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 (13.5 Nm)

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
fasteners to specification.
TORQUE
Caliper Fasteners: 31 ft-lbs (42.0 Nm)

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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 (42.0 Nm)

2. Install brake hose, and banjo fastener with new

sealing washers.
TORQUE
Banjo Fastener (Rear Caliper): 18 ft-lbs (24.4 Nm)

3. Fill and bleed the rear hydraulic brake system.

See ABS Rear Brake Bleedingpage 9.22.

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.

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 BRAKES

TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE POSSIBLE REPAIR NEEDED
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.
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 9
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)

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BRAKES

PROBLEM POSSIBLE CAUSE POSSIBLE REPAIR NEEDED

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

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 ELECTRICAL

CHAPTER 10
ELECTRICAL
STARTING / CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.5
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.5
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.5
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.6
SERVICE SPECIFICATIONS - STARTING / CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.7
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.8
STARTER MOTOR / SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.8
STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.9
REGULATOR / RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
BATTERY BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
BATTERY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
BATTERY BOX REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
BATTERY BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
BATTERY CHARGING AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
STARTER MOTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
STARTING SYSTEM DIAGNOSTIC TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
STARTER CIRCUIT DIAGRAM (2017) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
STARTER CIRCUIT DIAGRAM (2018+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
TROUBLESHOOTING FLOW CHART 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
TROUBLESHOOTING FLOW CHART 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
TROUBLESHOOTING FLOW CHART 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
STARTING SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
STARTER SOLENOID GROUND CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
GEAR POSITION SWITCH NEUTRAL INDICATOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
CLUTCH SWITCH CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
10
CLUTCH SWITCH REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
STARTER SOLENOID POSITIVE CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
STARTER CURRENT DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
STARTER CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
STARTER MOTOR, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
CHARGING SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
TROUBLESHOOTING, CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
CURRENT DRAIN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
REGULATED VOLTAGE / AMPERAGE OUTPUT INSPECTION (ALL MODELS) . . . . . . . . . . . . . . . . . . 10.33
STATOR AC VOLTAGE OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
STATOR RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36

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ELECTRICAL

STATOR WINDINGS TO GROUND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36

STATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
STATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
RECTIFIER / REGULATOR CONNECTOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
DIODE LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
REGULATOR / RECTIFIER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
KEY FOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41
KEY FOB OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41
KEY FOB OPERATION AND PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.42
KEY FOB AUTHENTICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44
KEY FOB TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44
ALARM SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.46
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.47
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.47
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.47
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.47
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.47
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.48
BASICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.48
TEST LEAD ADAPTER KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.48
ECM CONNECTOR MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.48
IGNITION SYSTEM TEST FLOWCHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.49
BATTERY VOLTAGE INSPECTION: TEST 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50
SPARK INSPECTION: TEST 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50
IGNITION CABLE RESISTANCE: TEST 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50
IGNITION COIL POWER & GROUND SIGNAL TEST 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.51
IGNITION COIL RESISTANCE: TEST 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.52
CRANKSHAFT POSITION SENSOR (CPS) RESISTANCE INSPECTION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.52
IGNITION COIL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.53
CHASSIS ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54
ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.55
HEAD LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.55
TAIL LIGHT / LICENSE PLATE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.56
FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.57
FUSE BOX LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.57
FUSE APPLICATION CHART (2017) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.58
FUSE APPLICATION CHART (2018+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.60
VEHICLE CONTROL MODULE (VCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.62
VEHICLE CONTROL MODULE (VCM) SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.62
VEHICLE CONTROL MODULE (VCM), REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.62
VCM CONNECTOR MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.63
HEADLIGHT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.66
HEADLIGHT BULB REPLACEMENT - ALL MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.66
HALOGEN HEADLIGHT LENS COMPLIANCE MARKINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.67

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HEADLIGHT LENS REPLACEMENT (FAIRING MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.68

HEADLIGHT LENS REPLACEMENT (NON-FAIRING MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.69
HEADLIGHT WARNING INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.72
HORN SERVICE (2017) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.73
GENERAL OVERIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.73
LOAD SIDE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.73
SWITCH SIDE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.73
HORN BREAKOUT DIAGRAM (2017) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.74
HORN REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.75
HORN SERVICE (2018+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.75
GENERAL OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.75
LOAD SIDE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.75
SWITCH SIDE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.75
HORN BREAKOUT DIAGRAM (2018+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.76
HORN REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.77
TAIL LIGHT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.78
LED TAIL / BRAKE LIGHT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.78
TAIL / BRAKE / LICENSE PLATE LIGHT, REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.78
TRUNK LED REPLACEMENT - BRAKE / INTERIOR (ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.80
TURN SIGNAL / HAZARD SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.81
TURN SIGNAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.81
FRONT TURN SIGNAL REMOVAL / INSTALLATION (CHIEFTAIN / ROADMASTER) . . . . . . . . . . . . . . . . . . 10.81
FRONT TURN SIGNAL, REMOVAL / INSTALLATION (CLASSIC / VINTAGE / DARK HORSE /
SPRINGFIELD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.81
REAR TURN SIGNAL,REMOVAL / INSTALLATION (ALL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.82
SWITCH CUBE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.83
INSTRUMENTATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.85
INSTRUMENT CLUSTER (CHIEF CLASSIC / CHIEF VINTAGE /CHIEF DARK HORSE /
SPRINGFIELD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.85
INSTRUMENT CLUSTER (2017 CHIEFTAIN DARK HORSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.90
INSTRUMENT CLUSTER (CHIEFTAIN / ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.92
SPEEDOMETER DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.92
TACHOMETER DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.94
RIDE COMMAND DIAGNOSTICS / TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.96
CRUISE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.101
CRUISE CONTROL OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.101
CRUISE CONTROL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.102
10
SECURITY ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.103
POWER WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.105
POWER WINDSHIELD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.105
POWER WINDSHIELD MOTOR, REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.108
POWER WINDSHIELD MOTOR, INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.110
CELL MODEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.111
CELL MODEM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.111
CELL MODEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.112
GEAR POSITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.113
GEAR POSITION SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.113
GEAR POSITION SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.119

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GEAR POSITION SWITCH TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.120

SHIFT DRUM SPRING / PIN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.124
SWITCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.125
BRAKE LIGHT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.125
CLUTCH SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.125
TIPOVER SENSOR (ANGLE SENSOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.125
SIDE STAND SWITCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.126
BREAKOUT WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.127
ANTI-LOCK BRAKE SYSTEM, WIRING DIAGRAM (2017) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.127
ANTI-LOCK BRAKE SYSTEM, WIRING DIAGRAM (2018+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.128
CENTRAL LOCKING SYSTEM, WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.129
STARTING SYSTEM, WIRING DIAGRAM (2017) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.130
STARTING SYSTEM, WIRING DIAGRAM (2018+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.131
KEYLESS IGNITION SYSTEM, WIRING DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.132
POWER WINDSHIELD, WIRING DIAGRAM (2017) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.133
POWER WINDSHIELD, WIRING DIAGRAM (2018+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.134
ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.135
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.135
DIGITAL MULTI-METER (DMM) NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.135
STATIC AND DYNAMIC TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.135
CONNECTOR PROBING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.136
TESTING CONTINUITY / RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.137
TESTING FOR A SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.138
TESTING FOR A SHORT TO VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.139
TESTING FOR INTERMITTENT CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.139
TESTING CURRENT FLOW (AMPERAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.140
TESTING PARASITIC DRAW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.140
TESTING VOLTAGE DROP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.141

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S TA R T I N G / C H A R G I N G
G E N E R A L I N F O R M AT I O N WARNING
SERVICE NOTES Battery electrolyte is poisonous. It contains sulfuric
All electrical system and component service can be acid. Serious burns can result from contact with skin,
performed with the engine in the frame. eyes or clothing. Antidote:
• External: Flush with water.
IMPORTANT
• Internal: Drink large quantities of water or milk.
CAUTIONS TO OBSERVE DURING ELECTRICAL Follow with milk of magnesia, beaten egg, or
SYSTEM SERVICE vegetable oil. Call physician immediately.
• Always turn off ignition switch before • Eyes: Flush with water for 15 minutes. Call
disconnecting any electrical component. physician immediately.
• Always verify that bullet-type connectors are free Batteries produce explosive gases. Keep sparks,
of corrosion, contamination or breaks when flame, cigarettes, etc. away. Ventilate when
troubleshooting electrical problems. charging or using in an enclosed space. Always
• Verify that bullet-type connectors are firmly shield eyes when working near batteries.
seated. Listen and/or feel for a click when KEEP BATTERIES AND BATTERY ACID OUT OF
connecting them. REACH OF CHILDREN
• Ensure to release the lock on lock-type couplers
The charging system used on the motorcycle is
before disconnecting them to avoid damaging the
calibrated for the maintenance free battery that is
connector.
installed as original equipment. Do not replace with a
• Pulling on the wires when disconnecting couplers conventional lead-acid battery. Before
can introduce problems. Hold the connectors troubleshooting the charging system, inspect the
themselves when disconnecting them, not their battery thoroughly. A discharged, poorly charged or
associated wires. faulty battery will make the readings obtained
during charging system troubleshooting erroneous
• Inspect each male and female terminal of multi-pin or difficult to interpret.
connectors for corrosion, contamination, loose or
A battery will self-discharge when the motorcycle is
bent pins.
not in use. Make sure to properly store the battery as
outlined later in this section.
Battery Label 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.
10
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.

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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.
Do not use wire, tin foil or other substitutes for fuses.

CAUTION
ELECTRONIC COMPONENTS
Semiconductor parts used in electronic components
will not withstand careless handling.
Do not drop or strike parts that contain
semiconductors such as the ECM or rectifier/
regulator. Dropping electronic components can
cause damage to the component.
Follow instructions supplied in this chapter, including
Fuel Delivery / EFI chapter and Electrical chapter,
very carefully when working on electronic
components. Failure to follow instructions may cause
irreparable damage to the part being inspected.

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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 CHARGING SPECIFICATIONS

(2017 CHIEF DARK HORSE)
ITEM SPECIFICATIONS
Electrical Ignition System Distributor-less ITEM SPECIFICATIONS
(General) Transistorized Dual Coil
Alternator No Load AC Output @ 800–
Type Ignition 25 VAC ± 25%
1000 RPM (Engine cool)
Starting System Electric
Alternator No Load AC Output @
2000 RPM (Engine cool) 40 VAC ± 25%
Charging System Permanent Magnet / 3 Phase
/ Full Wave Rectification
Stator Coil Resistance (@ 21oC / 70oF)
Regulator/Rectifier Solid State Three Phase (Black to each other black) 90.7 mΩ ± 20%
Voltage Regulator/Rectifier (Disconnect regulator - see test.)
Lighting System 12 V DC Stator Coil Resistance To Ground
Infinity (no continuity)
(Each black wire)
Regulator/Rectifier Regulated Voltage 14.3 - 14.7 V DC
CHARGING SPECIFICATIONS Alternator Output (Amps / Watts) 48 A / 610 W @ 3500 RPM
(ALL MODELS EXCEPT 2017 CHIEF DARK HORSE)
Type Yuasa: YTX20HL
ITEM SPECIFICATIONS Voltage 12 Volts DC
Alternator No Load AC Output @ 800– Nominal Capacity @ 10
17-26.5 VAC @ Idle 18 AH
1000 RPM (Engine cool) Battery Hr Rate
Alternator No Load AC Output @ Recommended Battery
40-45 VAC at 2000 RPM Charging Current STD: 1.85 A for 5 to 10 hrs
2000 RPM (Engine cool)
Stator Coil Resistance (@ 21oC / 70oF) CCA Rating 310
(Black to each other black) 90.7 mΩ ± 20%
(Disconnect regulator - see test.)
Stator Coil Resistance To Ground
(Each black wire)
Infinity (no continuity) STARTING SYSTEM SPECIFICATIONS
Regulated Voltage 14.3 - 14.7 V DC ITEM SPECIFICATION

Alternator Output (Amps / Watts) 56 A / 710 W @ 2000 RPM Battery Voltage, No Load Above 12.5 V DC

Type Yuasa: YTX20HL Resistance: Between Any Two Continuity (0 Ohms)

Commutator Bars
Voltage 12 Volts DC Resistance: Commutator to Armature Infinity (OL on Fluke™
Nominal Capacity @ 10 Shaft 73)
Battery 18 AH
Hr Rate Resistance: Battery Input Terminal to Continuity (0 Ohms)
Recommended Battery Insulated Brush
Charging Current STD: 1.85 A for 5 to 10 hrs Resistance: Bat. Input Terminal to Starter Infinity (OL on Fluke™
Motor Case 73)
CCA Rating 310
Starter Motor Operating Amp Draw 140–160 Amps
Starter Motor No Load Amp Draw (Bench 30-37 Amps after
Test) initial surge
Starter Torque Limit Clutch Break-Away
Torque
50 – 60 ft-lbs (70 - 80
Nm) when new
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A S S E M B LY V I E W S
S TA R T E R M O T O R / S O L E N O I D

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Terminal Cover -

w Nut, Starter Terminal (B+) — M6 (QTY.1) 60 in-lbs (6.8 Nm)

e Starter Motor -

r Fastener, Starter Motor — M6 x 1.0 x 25 (QTY.2) 88.5 in-lbs (10.0 Nm)

t Cable, Solenoid to Starter Motor (B+) -

y Starter Solenoid -

u Nut, Solenoid Terminal (B+) — M6 (QTY.2) 60 in-lbs (6.8 Nm)

i Fastener, Starter Solenoid — M6 x 1.0 x 12 (QTY.2) 84 in-lbs (9.5 Nm)

o Cable, Battery to Solenoid (B+) -

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S TAT O R

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Stator -

w Fastener, Stator — M6 x 1.0 x 35 (QTY.3) 88.5 in-lbs (10.0 Nm)

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R E G U L AT O R / R E C T I F I E R

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Bracket, Regulator / Rectifier -

w Fastener, Regulator Bracket — M6 x 1.0 x 12 (QTY.3) 88.5 in-lbs (10.0 Nm)

e Regulator / Rectifier -

r Fastener, Regulator — M6 x 1.0 x 15 (QTY.2) 84 in-lbs (9.5 Nm)

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B AT T E R Y B O X

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Fastener, ECM — M4 x 0.7 x 8 (QTY.4) 36 in-lbs (4.1 Nm)

w Fuse Box, J-Case -

e Fastener, Fuse Box — M6 x 1.0 x 22 (QTY.1) 63 in-lbs (7.1 Nm)

r Fastener, Battery Box — M6 x 1.0 x 12 (QTY.2) 84 in-lbs (9.5 Nm)

t Fastener, VCM Mounting Plate — M6 x 1.0 x 25 84 in-lbs (9.5 Nm)

(QTY.1)

y Battery -

u Fastener, Battery Box — M6 x 1.0 x 25 (QTY.2) 84 in-lbs (9.5 Nm)

i Battery Box - 10
o ECM -

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B AT T E R Y S E R V I C E 6. Lift battery straight up and out of the battery box.

B AT T E R Y R E M O VA L
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 7.26.
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 /
Installationpage 10.62.
4. Remove negative (-) battery terminal fastener and
cable first q .
5. Remove positive (+) battery terminal fastener and
cable last w .

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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
torque to specification.

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 /
Installationpage 10.62. 10
7. Install seat.
See Seat Removal / Installation - All (except
Roadmaster)page 7.26.

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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.
front wheel clamped in a wheel vise.
2. Remove the rear fender. See Rear Fender
Removalpage 7.40
3. Remove battery. See Battery Removalpage 10.12.
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.

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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.

TORQUE
2. Move the J-Case fuse box into position and torque Battery Box Fasteners, Front: 84 in-lbs (9.5 Nm)
fastener w to specification.
5. Install rear battery box fasteners t and torque to
specification.

TORQUE
J-Case Fuse Box Fastener: 63 in-lbs (7.1 Nm)
TORQUE
3. Connect the ECM multi-plugs e . Battery Box Fasteners, Rear: 84 in-lbs (9.5 Nm)

6. Install battery. See Battery Installationpage 10.13.

10
7. Install rear fender. See Rear Fender
Installationpage 7.41.

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B AT T E R Y C H A R G I N G A N D M A I N T E N A N C E AGM BATTERY CHARGING RECOMMENDATIONS – LOW

CHARGE
AGM BATTERY CHARGER RECOMMENDATIONS
The nominal voltage for an Indian Motorcycle battery
Indian Motorcycle recommends using the is 12.8 Volts when fully charged. The battery will self-
BatteryMINDer® 2012 AGM - 2 AMP battery charger
discharge when disconnected from a vehicle, and will
(PN 2830438) to charge and maintain AGM batteries.
discharge at a faster rate when connected. If the
The charger can be found on the Polaris PG&A website
battery voltage falls below 12.5V, it should be charged
and ordered in DEX – Item Availability.
immediately using the recommended battery charger.
Batteries that fall below 12.5V run the risk of sulfation, Listed below are the recommended battery inspection
a condition whereby sulfate crystals form inside the schedules.
battery and significantly reduce performance. AGM
chargers are designed specifically for charging AGM • Batteries which are not connected to a vehicle
type batteries and use high frequency pulses to should be inspected every 60 days. The battery
partially reverse sulfation. must be charged if found to be below 12.5 volts.
• Batteries which are connected to motorcycles
IMPORTANT should be inspected when they arrive at your
The use of non-AGM battery chargers or non-AGM dealership and at least once every month thereafter.
battery tenders may result in a misleading “battery The battery must be charged if found to be below
not found” or “open cell” fault message. Please 12.5 volts.
ensure you are using the recommended AGM
• Showroom bikes used to demonstrate radio, display
charger when charging AGM type batteries.
and infotainment features should be charged daily.
If possible, these bikes should be connected to the
INDIAN MOTORCYCLE RECOMMENDED AGM BATTERY recommended battery charger continuously.
TESTING PROCEDURE:
Always use the recommended automatic battery
1. Test battery using the battery tester PU-50296. charger, and wait for the charger to complete the
2. If the tester indicates a test result other than “Good charge cycle before disconnecting it.
Battery,” follow the steps below before replacing
the battery:
a. Connect battery to the recommended battery
charger. If charging sequence begins as
normal, fully charge battery and proceed to
step 3.
The time listed on the PU-50296 battery tester
printout is an estimate. The recommended
automatic charger will indicate when the
battery is fully charged on its display.
b. If charging sequence does not initialize, refer to
AGM Battery Charging Recommendations –
Deeply Discharged (below 3 volts) to attempt
to restore the deeply discharged battery. If
charging sequence will not finish as intended,
the battery needs to be replaced.
3. Re-test battery. If the test results show that battery
failed, proceed with battery replacement.

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AGM BATTERY CHARGING RECOMMENDATIONS –

DEEPLY DISCHARGED (BELOW 3 VOLTS)
AGM batteries discharged to a voltage of 3 volts or
less may not be recognized by the recommended
automatic battery charger. (The minimum voltage
threshold recognized by other battery chargers may
be as high as 10.5 volts). Often times deeply
discharged batteries can be restored by attaching
another, fully-charged, battery to “jump start” the low
battery. Follow the steps below to restore a deeply
discharged battery.
1. Carefully connect the two batteries’ positive
terminals, then the negative terminals using
jumper cables.
2. Connect the recommended battery charger to the
low battery and initiate the charging sequence.

WARNING
Always check to ensure the positive cables are
connected to the positive terminals before powering
the charger on. Reversing polarity when charging
can damage electrical components and risk personal
injury. Be careful not to let battery cable clamps
touch each other.

3. After the charging sequence has initiated,

disconnect the fully-charged battery. Always
disconnect the fully-charged battery positive first,
followed by low battery positive, low battery
negative, and finally fully-charged battery negative
4. Proceed with charging both batteries to full
capacity. Listed in the table below are the
approximate charging times for deeply discharged
batteries. Always use the recommended automatic
battery charger, and wait for the charger to
complete the charge cycle before disconnecting it.
The recommended automatic charger will indicate
when the battery is fully charged on its display.
BATTERY CHARGING BATTERY CHARGING
PN TIME CAPACITY RATE

4011496 11 hours 18 AH 2 amps

10
4014770 8 hours 12 AH 2 amps

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AGM BATTERY MAINTENANCE TIPS 4. Battery connections should be tightened to the

correct torque during installation. This will reduce
1. If the motorcycle will not be driven for more than 2 voltage drop and ensure a reliable connection
weeks, maintaining the battery with the between the regulator/rectifier and battery.
BatteryMINDer® 2012 AGM - 2 AMP charger (PN
2830438) is recommended. 5. The recommended BatteryMINDer® 2012 charger
comes with the mating connector for easy plug and
2. To help prolong battery life, it is recommended to play maintenance.
remove the battery from vehicles stored ONE
month or longer. To maximize the life of stored • Model year 2017–2020 Indian Motorcycles with
batteries, they should be kept in a cool / dry 111 c.i. engines are conveniently equipped with
location. Batteries will self discharge more rapidly a SAE bullet style connector for quick access to
when stored in extreme temperatures. Batteries charging the battery.
should be maintained using the recommended • Model Year 2021 (except Vintage and
battery charger while in storage. Springfield Dark Horse) Indian Motorcycle 111 ci
3. Batteries will self-discharge more quickly when / 116 ci models come with the connector built
dirty. Periodic cleaning of the battery terminals into the console.
using a terminal brush will help maximize battery
life. Wash terminals with a solution of one
tablespoon baking soda and one cup water. Rinse
well with tap water and dry off with clean shop
towels. Coat the terminals with dielectric grease or
petroleum jelly.

2017–2020 2021+
The connector is located behind the left hand side The connector is located on the dash of the
cover and taped back to the chassis harness. Carefully motorcycle, just to the right of the ride command
remove the tape to expose the connector and length of display screen. Flip the cap up to expose the
wire. Be sure to properly secure the wire and connector. Be sure to close the cap when finished
connector before operating the vehicle. charging.

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B AT T E R Y I N S P E C T I O N
1. Remove battery. See Battery Removalpage 10.12.
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
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 Installationpage 10.13.
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 /
Installationpage 10.62.
8. Install seat. See Seat Removal / Installation - All
(except Roadmaster)page 7.26.
9. Install upper side covers. See Side Cover (Upper),
Removal / Installationpage 7.22.

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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

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S TA R T E R C I R C U I T D I A G R A M ( 2 0 1 7 )

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S TA R T E R C I R C U I T D I A G R A M ( 2 0 1 8 + )

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TROUBLESHOOTING FLOW CHART 1

NOTICE
Make sure the Key Fob authorization has occurred before performing troubleshooting.

10

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TROUBLESHOOTING FLOW CHART 2

NOTICE
These procedures require a Digital Multi Meter (DMM) and high a high current shunt, or an inductive ammeter
clamp and a DMM.

TROUBLESHOOTING FLOW CHART 3

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.

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S TA R T I N G S Y S T E M T E S T S 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
B AT T E R Y L O A D T E S T WARNING
1. Load test battery using a commercially available
battery load tester. Follow the battery load tester Ensure that the motorcycle is secure and that the
manufacturer instructions. transmission is in neutral for the following test.

NOTICE 1. Shift transmission to Neutral.

Although not as conclusive, the following test can be 2. Disconnect the start solenoid connector q .
used to direct troubleshooting efforts if a battery load
tester is not readily available.

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.

10

Resistance should be ≤ 0.5 Ω

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G E A R P O S I T I O N S W I T C H N E U T R A L I N D I C AT O R T E S T
NOTICE
The gear position switch is different based off of engine build date. These switches are not interchangeable.

2017–19 (MULTIPLE RESISTANCE SWITCH) 2020+ (ROTARY SWITCH)

Symptoms of a faulty Gear Position Switch may

include:
• Starter motor does not operate when transmission is
in neutral,
but...
• Starter motor does operate when clutch is pulled in.

2017–19 MODELS • Disconnect the gear position switch at connector

1. Press the POWER button to power up the electrical q located beneath the engine at the rear of the
system. cases.

2. Place engine stop switch in the RUN position.

3. Shift transmission into Neutral.
4. Observe neutral indicator light.
5. If indicator is not lit with transmission in neutral:
• Place the RUN/STOP switch in the STOP position
and turn motorcycle power off.
• Roll the motorcycle forward and back enough to
verify that it is in neutral.

• Set the multi meter to test resistance and insert

meter leads into the appropriate jacks.

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• 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, perform the gear position switch
cleaning procedure (Gear Position Switch
Replacementpage 10.113) and retest. If resistance
value is still out of specification, repair wiring or
replace switch. .
7. If the gear position 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.

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2020+ MODELS • Locate the gear position sensor and trace the
wires to the connector located near the rear of
1. Press the POWER button to power up the electrical the engine.
system.
2. Place engine stop switch in the RUN position. Letter Wire Color Function
3. Shift transmission into Neutral. A Red VCC
4. Observe neutral indicator light. B Black Ground
5. If indicator is not lit with transmission in neutral: C Blue Gear
• Place the RUN/STOP switch in the STOP position
and turn motorcycle power off. • Backprobe the connector and compare the value
with the table below.
• Roll the motorcycle forward and back enough to
verify that it is in neutral.

VOLTAGE
GEAR NOMINAL MIN MAX
1st 0.63 0.59 0.67
N 1 0.96 1.04
2nd 1.38 1.34 1.42
3rd 2.13 2.09 2.17
4th 2.88 2.84 2.92
5th 3.63 3.59 3.67
6th 4.38 4.34 4.42

IMPORTANT
Voltage can also be viewed by using digital wrench.

6. If the reading is not within specified parameters,

replace switch or repair wiring as necessary.

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CLUTCH SWITCH CIRCUIT TEST 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

NOTICE 1. Remove clutch switch cover fasteners q and clutch
2018+ motorcycles communicate using a CAN switch cover w .
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
Removalpage 4.41.
3. Set multi meter to measure resistance and insert
meter leads into appropriate jacks. 2. Remove clutch switch retaining fastenere and
4. Connect red (+) lead of multi meter to PIN 19 in toothed washer.
ECM connector 1 (harness side). See ECM
Connector Mappage 4.30.
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 3. Gently pull the clutch switch out of the lever perch
operates but does not open and close electrically, until the locating pins are free and the switch can
replace switch. be disconnected.

CAUTION
The clutch switch has two locating pins on the top 10
side which slide into the clutch lever perch. Use
caution when removing the clutch switch so the
locating pins do not break off.

4. Installation is performed by reversing the

removal procedure.

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5. Torque clutch switch and cover fasteners to S TA R T E R C U R R E N T D R AW T E S T

specification.
NOTICE
TORQUE This procedure requires the use of an inductive
Clutch Switch Fastener: 6 in-lbs (0.7 Nm) ammeter to read current draw and a volt meter to
Clutch Switch Cover Fasteners: 6 in-lbs (0.7 Nm) monitor battery voltage during the test.

WARNING
Do not allow any part of the jumper cable clamp
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 T E S T to touch the chassis or any other ground.
WARNING
Secure motorcycle on the side stand and place CAUTION
transmission in neutral for the following test.
Disable the ignition system so that the engine will not
1. Place the transmission in neutral. start during this test.
2. Remove the positive cable q from starter motor. • Remove spark plug caps.
• Install test spark plugs into plug caps.
• Ground spark plugs against engine.

1. Remove seat. See Seat Removal / Installation - All

(except Roadmaster)page 7.26.
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.
3. Set multi meter to DC Volts and insert meter leads 6. Connect black lead of meter to negative post of
in the appropriate jacks. battery.
4. Connect the red meter lead (+) to the positive
starter cable eyelet and the black (-) meter lead to
chassis ground.
5. Press the power button to power up the electrical
system and place the STOP/RUN switch in the RUN
position.
6. Press starter button. The meter should display
battery voltage. If voltage is more than .2 volts
below battery voltage, inspect the power supply
circuit.

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.

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8. Place the engine STOP/RUN switch is in the RUN S TA R T E R M O T O R , R E M O VA L / I N S TA L L AT I O N

position, transmission is in neutral, clutch lever
pulled in and that the ignition system is disabled. WARNING
9. Press starter switch and crank starter for about 5 Ensure that the ignition switch is turned off.
seconds and observe both meters and the Remove the negative cable at the battery before
tachometer. removing the starter motor.
10. The battery voltage should remain above 9.6 volts.
1. Disconnect the negative battery cable. See Battery
11. The amperage draw of the starter should not Removalpage 10.12.
exceed 160 amps.
2. Disconnect the positive terminal q from the
Starter current draw @ 77°F (25°C): ≤160 Amps 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.
S TA R T E R C L U T C H R E M O VA L
1. See Starter Drive Removalpage 6.20.

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:
88.5 in-lbs (10.0 Nm)

7. 10
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:
35 in-lbs (4.0 Nm)

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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.

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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 I N -

IMPORTANT SPECTION (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 7.26.
1. Remove seat. See Seat Removal / Installation - All 2. Place the inductive ammeter over the positive (+)
(except Roadmaster)page 7.26. 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 (+)
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.
10
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.

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8. Use results obtained from preceding tests and the

following descriptions to determine if charging
system is functioning properly.
CHARGING SYSTEM OPERATING
CORRECTLY: Ammeter goes up a small amount,
then stabilizes slightly above +0 amps. Volt meter
rises toward 14.8 ± V DC, drops off a little and
starts to stabilize.
LOW BATTERY: Amperage continues to rise,
voltage levels off as battery is absorbing voltage.
Charging system may be okay. Need to charge
battery fully or use a good battery and repeat test.
Meters will indicate similar reading to the
overcharging chart.
CHARGING SYSTEM UNDERCHARGING: Ammeter
drops to 0 or remains below 0 (negative reading) at
all rpm, volt meter remains the same or goes down.
Go to voltage drop inspection.
CHARGING SYSTEM OVERCHARGING: Ammeter
rises well above 0 and remains there or continues
to rise. Volt meter goes well above 14.8 V DC and
may continue to rise.
EXCESSIVE LOAD: Current levels off or starts to
drop, voltage continues to rise. Load may be
excessive (accessories or shorted components).
Determine if excessive loads are present.
Disconnect accessories and re-test.
9. Turn ignition key off.
10. Remove inductive ammeter clamp.
11. Install seat. See Seat Removal / Installation - All
(except Roadmaster)page 7.26.

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S TAT O R A C V O LTA G E O U T P U T T E S T 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.
NOTICE
Set multi meter to VAC (alternating current). Engine
cold. Regulator / Rectifier disconnected (2-pin and 3-
pin connector). Engine must be running. Be sure to
heed the following Warnings and Cautions.

WARNING
HOT COMPONENTS:
The engine and exhaust system become very hot
during operation and remain hot for a period of time
after the engine is shut off. Wear insulated protection
for hands and arms or wait until the engine and
exhaust system have cooled sufficiently before
working on the machine.

CAUTION
WARNING
VOLTAGE / ARCING
CARBON MONOXIDE: Use caution not to touch any of the connections or
Never run an engine in an enclosed area. Exhaust allow the exposed terminals to come close to any
contains poisonous carbon monoxide gas that can other part of the vehicle or other objects, as an arc
cause loss of consciousness and may lead to death. If may occur.
you must run the engine to do some repairs, do so in
an open area or with an exhaust evacuation system
operating. 4. Start the engine and let it run at idle. Observe the
multi meter reading.
5. The meter should indicate the following readings:
CAUTION
VOLTAGE / ARCING: No load AC Volts @ 800 RPM:
Use caution not to touch any of the connections or All Models: 22 VAC ±25%
allow the exposed terminals to come close to any
other part of the vehicle or other objects, as an arc 6. Repeat test for pins A e & C t.
may occur.
7. Repeat test for pins B r & C t.

1. Disconnect the 3-pin stator connector. NOTICE

2. Set multi meter to measure AC Volts. 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.
10
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.

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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.

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S TAT O R R E M O VA L 8. Remove the three fasteners q from stator.

1. Remove primary cover. See Primary Cover
Removalpage 5.9.
2. Remove the clutch assembly. See Clutch
Removalpage 5.16
3. Remove the torque compensator assembly. See
Torque Compensator Removalpage 5.22.
4. Remove the flywheel. See Flywheel
Removalpage
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.

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.

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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
stator assembly before it can be installed in the motor- WARNING
cycle. See Stator Removalpage 10.37 for information The flywheel contains powerful magnets. Use caution
on connector removal. when lifting flywheel off of stator to avoid personal
1. Feed the stator wires through the hole in the LH injury.
engine case and push the rubber harness seal q
through until fully seated.
1. Remove primary cover. See Primary Cover
2. Place stator in position over the crankshaft and Removalpage 5.9.
install fasteners w . Torque to specification.
2. Remove clutch assembly. See Clutch Removalpage
5.16.
3. Remove torque compensator assembly (2017
models). See Torque Compensator Removalpage
5.22.
Remove Primary Drive Gear (2018+ models). See
Primary Drive Gear Removalpage 5.24
4. Remove thrust washer q and compensator sleeve
w (2017 models).

TORQUE
Stator Fasteners: 88.5 in-lbs (10.0 Nm)

3. Press the three wire terminals into the connector

housing until there is an audible “click” and the
wires cannot be backed out.
NOTICE
Wires can be installed into any position on the
electrical connector. Charging performance will not
be affected. 5. Thread two primary cover fasteners e into
threaded holes on flywheel r.
4. Install the silicone plugs into each of the connector
cavities and snap the terminal retaining clip into
place.
5. Plug the stator connector into the regulator /
rectifier connector.
6. Install the flywheel. See Flywheel Installationpage
5.25.
7. Install the torque compensator. See Torque
Compensator Installationpage 5.23.
8. Install the clutch assembly and clutch rack. See
Clutch Installationpage 5.21.
9. Install the primary cover. See Primary Cover
Installationpage 5.14.
6. Grasp the two fasteners and lift the flywheel off of
the stator.

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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 DIODE LEAKAGE TEST

INSPECTION IMPORTANT
1. Remove the regulator / rectifier assembly. See
Rectifier / Regulator Replacementpage 10.40. Engine must be OFF. Perform this test at the regulator
/ rectifier 2-Pin connector. Testing at any other point
2. Disconnect both 2-pin q and 3-pin connector w . (between battery and battery cable for example)
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 /
rectifier side.

3. Inspect male and female pins in the 3-pin

connector and the 2-pin connector carefully.
Check for corrosion, loose pins, poor connections,
or evidence of overheating or other damage.
4.
IMPORTANT
If damage is found to either connector, there may be
auxiliary damage to the ground wire of the gear
position switch. See Gear Position Switch
Troubleshootingpage 10.120
4. Compare leakage to specification below.
5. If the wiring and connectors are undamaged and
appear to be clean and tight, inspect the battery, Specification:
stator, and related wiring. Test the regulator / Leakage: Less than 1.0 mA
rectifier for diode leakage.

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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 7. INSTALLATION is performed by reversing the

removal procedure.
1. Disconnect the stator q from the regulator /
rectifier. 8. Torque the bracket and regulator / rectifier
fasteners to specification.
2. Remove the two fasteners w securing the regulator
/ rectifier to the bracket. TORQUE
Bracket Fasteners: 88.5 in-lbs (10.0 Nm)
Regulator / Rectifier Fasteners: 84 in-lbs (9.5 Nm)

3. Remove the three fastenerse securing the

regulator / rectifier bracket to the engine.

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.

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KEY FOB
KEY FOB OVERVIEW
Indian Chief, Chieftain and Roadmaster motorcycles utilize a keyless ignition system (Key Fob) for vehicle startup
and operation. The Key Fob acts as a two-way transmitter which provides an authentication signal to the Vehicle
Control Module (VCM) located on the motorcycle. When the Key Fob is detected, the ignition system is enabled
and the motorcycle becomes operational.
Two different Key Fobs are used on Indian Motorcycles:

Chief, Vintage and Springfield models Chieftain and Roadmaster models

use a button-less Key Fob which equipped with electronically lockable
authenticates the motorcycle for start-up storage utilize a multi-function Key Fob
and operation. which, in addition to authentication, allows
MODEL the user to remotely lock and unlock the
saddlebags and/or trunk.
2016+ models have an integrated Alarm /
Immobilizer feature which is armed and
disarmed using the Multi-Function Key Fob.

Basic (No Button) Multi-Function (Two Button)

BUTTON TYPE

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K E Y F O B O P E R AT I O N A N D P R O G R A M M I N G 3. Enter either the master or current customer 4-digit

Key Fob Operation: security PIN within 20 seconds. If the PIN is
successfully entered, the security light and/or
• When the electrical system is activated using the power switch will remain on and the horn will
power or starter switch, the key fob must be within sound briefly.
range.
NOTICE
• If the key fob is not detected: If the PIN is not entered within 20 seconds, the
– The security light and/or power switch will flash. security light and/or power switch will flash for 10
– The electrical system will automatically shut seconds, and then the system will shut down. Return
down. The starter motor will not engage during to step 1 to try again.
this time.
• If the key fob is not available, the personal 4. Enter new customer 4-digit security PIN. If the PIN
identification number (PIN) can be entered using is successfully entered, the security light and/or
the turn signal switches to unlock the security power switch will remain on and the horn will
system. sound briefly.
• Use the following guide to enter a valid pin. 5. Re-enter the new 4-digit security PIN. If this entry
matches the first entry, the security light and/or
TURN SIGNAL power switch will turn off and the horn will sound
DIGIT TO briefly. The new customer PIN has been saved.
FEATURE PROCEDURE
ENTER
USED 6. When the security light and/or power switch turns
The number CANCEL switch Press and off, press and hold the turn signal CANCEL switch
“0” release for 10 seconds. The security light and/or power
switch will turn on to confirm access to the security
First digit (1-9) LEFT turn Move and system.
switch release once
per digit value. Driving Key Fob Operation:
Second digit (1- RIGHT turn See example
9) switch • After starting the engine, the Vehicle Control
below.
Module (VCM) will verify that the key fob is within
Third digit (1-9) LEFT turn range again when shifting from neutral into gear.
switch The security light will flash once during this check.
Fourth digit (1- RIGHT turn • The VCM will not search for the key fob again as
9) switch long as the engine continues running. If the key fob
Example for entering the number 1024: is lost during riding, the operator will need to enter
LEFT - CANCEL - LEFT - LEFT - RIGHT - RIGHT - their PIN to restart the vehicle.
RIGHT - RIGHT • If the key fob is not detected when shifting into gear:
– The engine will turn off. The security light and/or
Entering a Security System PIN power switch will flash.
The master security system PIN must be available – The electrical system will then automatically shut
prior to entering the customer security PIN for the first down.
time. The master PIN can be located on the Key Fob
Maintenance Screen in Digital Wrench®. The Saddlebag Key Fob Operation:
customer PIN should be set before delivering the
vehicle to the customer. The customer can then set • If equipped with electric saddlebag locks, the locks
their own security PIN: can be controlled by either the key fob or the lock
switch on the console.
1. Turn the power switch on. Do NOT start the engine.
The security light and/or power switch will turn on • When using the console lock switch, the key fob
briefly until the key fob is detected or the valid, must be within range.
current PIN is entered.
• If the key fob is not detected:
2. Push and hold the turn signal CANCEL switch for – The power switch will flash.
10 seconds until the security light and/or power – The system will not perform the lock or unlock
switch turn on. procedure.

Programming the Key Fob:

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Programming the key fob can only be done by the 5. To change or add a new key fob number, type in
dealer and must be done using Digital Wrench®. A the 4 digit number under "New Value" and then
single key fob can be programmed to multiple select "Write New”.
motorcycles. One motorcycle can have up to 4 key
NOTICE
fobs programmed to the VCM.
When adding additional key fobs, all current and
Programming Procedure: additional key fobs must be present.
1. Connect Digital Wrench® and turn power switch to
"ON" position. Do NOT start the engine. 6. If a key fob number is to be cleared out, type "0"
2. In Digital Wrench®, select "Special Tests" (Red into "New Value" cell of desired key fob and select
Toolbox) , next select "#4: Key fob Maintenance”. "Write New".
NOTICE
At least one key fob must be programmed to the
motorcycle at all times

3. Select "Continue." Digital Wrench® will then read

the VCM information for key fob.

4. The Key fob Settings menu will then display the

original and current key fob(s) programmed to the 10
VCM.

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K E Y F O B A U T H E N T I C AT I O N KEY FOB TROUBLESHOOTING

Four things must occur for the VCM to authenticate the 1. Test Key Fob Battery (preliminary test).
Key Fob and enable the motorcycle for operation:
a. Two-Button Fob – Press LOCK / UNLOCK
1. Motorcycle battery is sufficiently charged for button and verify that red LED illuminates.
normal vehicle operation.
b. No-Button Fob – Remove screw and carefully
2. Key Fob must be within range of VCM receiver pry fob apart to access button. Press button and
(within 3 feet of motorcycle) verify that LED illuminates.
3. Key Fob battery must have sufficient voltage (LOW c. Measure fob battery voltage with DVOM. If
Key Fob battery will illuminate the Security Light voltage measures less than 3.0VDC, replace
and the Battery Indicator on the instrument cluster) battery. Does LED illuminate?
4. Key Fob PIN is properly paired with motorcycle YES — Proceed to STEP 2
VCM (Digital Wrench)
NO — Replace Key Fob
2. Test Key Fob Range (indicates Key Fob battery
Authentication Tell Tales condition).
SUCCESSFUL: a. Hold the Key Fob 8-12 inches from the
motorcycle seat; press the POWER button to
• Security Light turns OFF energize the electrical system.
• Neutral Indicator illuminates (verify motorcycle is in b. Verify that Key Fob LED flashes within 1 second.
Neutral by rolling back and forth) Does it flash?
• Motorcycle Starts / Runs YES — Proceed to STEP 2c
NO — Replace Key Fob battery and retest. If
UNSUCCESSFUL:
LED still does not flash, proceed to STEP 3
• Electrical system shuts down after 20 seconds c. Move the Key Fob away from the seat in 1 foot
• Security Light / Power Button flashes 2x’s per second increments and verify that the LED flashes when
for 10 seconds the motorcycle is energized up to 2-3 feet. Does
the range test pass?
• Horn honks every 5 seconds after startup
YES — Perform STEPS 3a-3b. No further action
• Motorcycle DOES NOT Start / Run required.
NO — Verify motorcycle battery voltage is at
Reference Key Fob Troubleshootingpage 10.44
least 11.5VDC. If voltage is LOW, charge the
battery. If voltage is acceptable, proceed to
STEP 4.
NOTICE
If key fob is suspect for decreased range, learn in
new key fob and repeat STEP 2.

Normal Range: Up to 2-3 feet.

Cannot be closer than 8 inches

3. Verify Key Fob and VCM are paired.

a. Connect motorcycle to Digital Wrench.
b. Verify VCM software is up-to-date.
c. Select the ‘Special Tests’ menu.
d. Select ‘Key Fob Maintenance’.
e. Verify correct Key Fob ID is present.
f. Click ‘Write’.

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g. Repeat STEPS 2a-2b. Does Key Fob b. Check 433 MHz antenna (located at Signal
authenticate? Connector 2 – PIN 5). Verify that connector is
properly seated in multiplug and connection to
YES — No further action required. VCM is secure.
NO — Verify motorcycle battery voltage is at c. Does antenna test within specification?
least 11.5VDC. If voltage is LOW, charge the
battery. If voltage is acceptable, learn in a YES — Replace VCM
second known good key fob and repeat STEPS
2a-2b. NO — Contact Indian Motorcycle Technical
Service.
4. Test VCM Receiver Antenna.
a. Inspect the 125 kHz 2-wire antenna (on top of
VCM) using a DVOM. Pin 7 is Antenna OUT B;
Pin 18 is Antenna OUT A.
SPECIFICATION
Capacitance: 3.4 nF (± 2 %)

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ALARM SYSTEM OVERVIEW

2016+ Indian Motorcycles (all Full Size models) have
incorporated an Alarm / Immobilizer feature which
can be activated using the multi-function (two button)
key fob. This feature can be used on Dark Horse, Chief
and Vintage models if the multi-function key fob
(PN:4014121) is purchased and paired with the VCM.
Alarm System Operation
To Activate the Alarm:

• Press the LOCK button on the Key Fob 2 times.

• The horn will sound briefly to confirm that the alarm
is activated.

To Deactivate the Alarm (Key Fob must be within

range):

• Press the UNLOCK button on the Key Fob. OR

• Press the power button on the console panel. OR
• Press the starter button. OR
• Press the LOCK / UNLOCK switch on the center
console. OR
• Move the motorcycle to the fully upright position
from leaning on the sidestand. (The horn will sound
repeatedly if the Key Fob is not detected within 5
seconds.)

Alarm Compatibility with other model years:

model years (2014-2015) that do not have the
incorporated Alarm System can be reflashed to
include this feature. Verify that Digital Wrench
Version 3.7 – Update 10/07/15 or newer has been
installed on your PC or laptop and perform the
Vehicle Controllers Update reflash, located under
Special Tests.

IMPORTANT
Motorcycles that use a Basic (No Button) Key Fob
must purchase the Multi-Function (Two Button) Key
Fob in order to use the Alarm System.

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IGNITION SYSTEM
G E N E R A L I N F O R M AT I O N GENERAL PRECAUTIONS
SERVICE NOTES • This ignition system is controlled electronically and
There are many hazards present when working on or no provisions are available to inspect or change
around the ignition system. Read and pay close ignition timing. A timing light is still valuable as a
attention to the following warnings and cautions when diagnostic tool.
working on any component in this section. • Poor connections are the most common cause of
ignition problems. Inspect all connections and
WARNING replace the spark plugs before doing extensive
Never run an engine in an enclosed area. Exhaust ignition system troubleshooting.
contains poisonous carbon monoxide gas that can • Make sure the battery is fully charged and that the
cause loss of consciousness and may lead to death. If charging system is operating correctly.
you must run the engine to do some repairs, do so in
an open area or with an exhaust evacuation system • A signal from the Crankshaft Position Sensor must
operating. be present at the ECM for spark to occur.

WARNING
SPECIAL TOOLS
The engine and exhaust system become very hot
during operation and remain hot for a period of time SPECIAL TOOL PART NUMBER
after the engine is shut off. Wear insulated protection Electrical Tester Kit PV-43526
for hands and arms or wait until the engine and
exhaust system have cooled before working on the Digital Multimeter Commercially Available
machine.
Inductive Timing Light Commercially Available

CAUTION
Some procedures call for the engine to be run in S E R V I C E S P E C I F I C AT I O N S
order to warm the engine to operating temperature.
If this is done the exhaust pipes can “blue” if a ITEM SPECIFICATIONS
cooling air stream is not provided by means of a shop
Spark Plug NGK DCPR8E
fan directed the exhaust system.
Spark Plug Gap .034 in (.9 mm)

CAUTION Primary 0.3 - 0.6 Ohms ± 20%

Parts containing semi-conductors can be easily Ignition Coil / Secon-
damaged if handled carelessly. Do not drop or dary See coil test
Cables
subject the electronic components to shock loads. Resistance
Values Plug Wire
(with 1860 Ohms ± 20%
CAUTION cap*) 10
Follow the instructions closely when troubleshooting Crank Position Sensor 1050 Ohms ± 10% @
items in this section. Some electrical components can Resistance 68°F (20°C)
be damaged if they are connected or disconnected
while the ignition is powered ON and current is * Spark plug end caps are not removable
present.

CAUTION
Using incorrect heat range spark plugs can damage
the engine. Always follow the manufacturer’s
recommendations for spark plug heat range.

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TROUBLESHOOTING TEST LEAD ADAPTER KIT

1. Tests in this section may include the testing of
BASICS voltage and / or resistance at the connectors for
Before troubleshooting the ignition system, ensure that various sensor and system components. Use the
the engine STOP/RUN switch is in the RUN position, appropriate test adapter lead when performing
the battery is fully charged, and system related fuses these tests at connector pin(s).
are not open (blown). Check visually for corroded,
2. Forcing an incorrect or oversized probe into a
loose, or broken connections in critical areas (e.g.
connector may cause inaccurate test results (due
sensor connector). Check for loose wire pins in the
to lack of a solid mechanical connection to the
individual sensor connectors and at the ECM (beneath
terminal). It can also damage the connector being
the battery box).
probed or the connector housing, creating another
Don’t forget the spark plugs! problem which greatly complicates the diagnostic
process. Extreme care must be taken not to
The Ignition System Troubleshooting flow chart (and introduce problems while probing a connector.
the accompanying text) is designed to help you
troubleshoot ignition system problems. It will not lead Electrical Tester Kit: PV-43526
you to faulty or fouled spark plugs. Always inspect
spark plug condition first (and replace if necessary) CAUTION
when troubleshooting ignition system problems. Once the ECM connector has been disconnected, do
Be sure that the spark plugs are the correct heat range not touch the pins on the ECM. Static electricity from
and are the correct size specification. your body can damage the ECM. Do not attempt to
perform tests on the ECM.
WARNING
Extremely high voltage is present in the ignition
system. Do not touch the ignition coil, wires or spark ECM CONNECTOR MAP
plugs during test procedures.
See ECM Connector Map in the Fuel Delivery / EFI
Chapter.

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IGNITION SYSTEM TEST FLOWCHART

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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 7. Replace spark plugs, connect plug wires and re-

1. Remove the seat. See Seat Removal / Installation - test.
All (except Roadmaster)page 7.26.
8. If timing light does not flash consistently for one or
2. Set multi meter to measure DC Volts. both cylinders, test high tension leads (Test 3).
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
4. If the battery voltage is below 12.5 V DC charge or ends.
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.
3. Shift transmission into neutral and pull in clutch
lever. High Tension Lead Resistance: 1860Ω ± 20%
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.

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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,
Installationpage 10.53. 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.
5. Press the power button to power up the
motorcycle electrical system and place the STOP/
RUN switch in the RUN position.
6. Battery voltage should appear on the center
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. 10
12. Press the power button to power up the
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.

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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 /
Installationpage 10.53.
CRANKSHAFT POSITION SENSOR (CPS) RE-
6. Select DIODE CHECK function on the multi meter. 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 / Replacepage
primary and black lead on secondary terminal 4.57.
and record.
8. Move black DMM lead to the other secondary
terminal and record. (Reading should be the same
for both secondary windings).

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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 /
Installationpage 10.75.
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.

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.

10
7. INSTALLATION of the ignition coil is
performed by reversing the removal
procedure. Torque fasteners to specification.
TORQUE
Coil Ground to Bracket: 84 in-lbs (9.5 Nm)
Ignition Coil to Bracket: 84 in-lbs (9.5 Nm)

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CHASSIS ELECTRICAL
G E N E R A L I N F O R M AT I O N
SERVICE NOTES
Keep the following notes in mind when diagnosing an
electrical problem:

• Refer to wiring diagram for stator and electrical

component resistance specifications.
• When measuring resistance of a component that has
a resistance value under 10 Ohms, remember to
subtract meter lead resistance from the reading.
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.

SPECIAL TOOLS
TOOL DESCRIPTION PART NUMBER
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

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A S S E M B LY V I E W S

HEAD LIGHT

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Fastener, Retaining Ring (QTY.4) 12 in-lbs (1.4 Nm)

w Retaining Ring -

e Head Light Housing -

r Fastener, Head Light Mount NA

t Fastener, Adjuster NA

y Spring, Adjuster -

u Head Light Carrier - 10

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TA I L L I G H T / L I C E N S E P L AT E L I G H T

NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Fastener, Turn Signal — M8 x 1.25 x 12 (QTY.2) 18 ft-lbs (24.4 Nm)

w Fastener, Tail Light Asm — M6 x 1.0 x 10 84 in-lbs (9.5 Nm)

(QTY.3)

e Pad, Tail Light Bezel -

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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.

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F U S E A P P L I C AT I O N C H A R T ( 2 0 1 7 )

PIN CIRCUIT DESCRIPTION FROM TO

1 Engine Breaker Output Fuse Box Splice (ENGBRK)
2 Engine Relay Power Output Fuse Box Splice (ENGPWR)
3 Engine Relay Power Output Fuse Box Splice (ENGPWR)
4 Fuel Pump Power Fuse Box Fuel Pump
5 Engine Breaker Output Fuse Box Splice (ENGBRK)
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
9 Engine Relay Power Output Fuse Box Splice (ENGPWR)
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)

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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)
34 Main Fuse Output Fuse Box Splice (MPWR)
35 Main Fuse Output Fuse Box Splice (MPWR)
36 Main Fuse Output Fuse Box Splice (MPWR)
37 Engine Breaker Output Fuse Box Splice (ENGBRK)
38 Chassis Fuse Output Power Fuse Box Splice (CHPWR)
39 Switched Power Fuse Box Fuse Box
40 Radio Fuse Output Power Fuse Box Fairing
41 Main Fuse Output Splice (MPWR) Fuse Box
42 Main Fuse Output Splice (MPWR) Fuse Box
43 Main Fuse Output Fuse Box Splice (MPWR)
10
44 Main Fuse Output Fuse Box Splice (MPWR)
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

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F U S E A P P L I C AT I O N C H A R T ( 2 0 1 8 + )

PIN CIRCUIT DESCRIPTION FROM TO

1 Trunk Amp Power Fuse Box Chassis_Trunk
2 Switched Power Fuse Box Fuse Box
3 Ground Splice_0044 Splice (ENGPWR)
4 VCM Accessory Power Out Fuse Box SPL_0071
5 Main Fuse Output Fuse Box Splice_MNPWR_1
6 Main Fuse Output Fuse Box Splice_MNPWR_2
7 Switched Power Fuse Box Fuse Box
8 Switched Power Control Fuse Box Splice_11
9 Radio Fuse output Power Fuse Box Chassis Fairing
10 Chassis Fuse Power Output Fuse Box Splice_0191
11 Main Engine Relay Control Fuse Box Splice_0115
12 Chassis Fuse Power Output Fuse Box Splice_0191
13 Main Fuse Output Fuse Box Splice_MNPWR_1
14 Main Fuse Output ECM 1 Splice_MNPWR_2
15 Aux Engine Relay Power Output Fuse Box Splice_0194

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PIN CIRCUIT DESCRIPTION FROM TO

16 Chassis Fuse Power Output Fuse Box Splice_0191
17 Instrumentation Fuse Output Fuse Box Chassis Speedo
18 Empty — —

19 Fuel Pump Relay Control ECM 1 Fuse Box

20 Run/Stop Switch Power Fuse Box Splice_0127
21 Main Fuse Output Fuse Box Fuse Box
22 Empty — —

23 Fuel Pump Power Fuse Box Fuel Pump

24 Engine Relay Power Output Splice (GND2) Fuse Box
25 Accessory Constant Fuse Output Fuse Box Splice_0153
26 Aux Switched Fuse Output Fuse Box Fuse Box
27 Auxiliary Switched Relay Control ECM 1 Fuse Box
28 Aux Switched Fuse Output Fuse Box Fuse Box
29 Main Fuse Output Splice_MNPWR_1 Fuse Box
30 Main Fuse Output Splice_MNPWR_1 Fuse Box
31 Accessory Switched Output Fuse Box Splice_0043
32 Aux Engine Relay Power Output Fuse Box Splice_0194
33 VCM Control Power Fuse Box Splice_0083
34 Empty — —

35 Starter Relay Control ECM 1 Fuse Box

36 Engine Relay Power Output Splice_0085 Fuse Box
37 Main Fuse Output Splice_MNPWR_2 Fuse Box
38 Empty — —

39 Starter Solenoid Control Fuse Box Starter Solenoid

40 Engine Relay Power Output Fuse Box Splice_0085
41 Ignition Coil Feed Fuse Box Coil
10
42 Engine Breaker Output Fuse Box Splice_0127
43 Main Engine Relay Control Fuse Box Splice_0115
44 Engine Breaker Output Fuse Box Splice_0127
45 Engine Relay Power Output Fuse Box Splice (ACCCONST1)
46 Main Fuse Output Fuse Box Splice_MNPWR_2
47 Engine Relay Power Output Fuse Box Splice_0085
48 Engine Breaker Output Fuse Box Splice_0127

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VEHICLE CONTROL MODULE (VCM) 6. Disconnect the negative battery cable.

VEHICLE CONTROL MODULE (VCM) SERVICE 7. Disconnect the three multi-plugs q from the VCM.
NOTES 8. Lift the VCM / mounting plate assembly from the
Replacement of the Vehicle Control Module (VCM) rear and disengage hinge pins from the battery
should only be performed by a qualified dealer. box to remove.
Vehicle Control Module (VCM) setup and
initialization requires the use of Digital Wrench.

VEHICLE CONTROL MODULE (VCM),

R E M O VA L / I N S TA L L AT I O N
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. 9. INSTALLATION is performed by reversing the

2. Using Digital Wrench, access and record the Key removal procedure.
Fob number. 10. Torque the VCM mounting fastener to
3. Record the 4 digit consumer PIN (as provided by specification.
the consumer).
TORQUE
4. Remove seat. See Seat Removal / Installation - All
Vehicle Control Module Mounting Plate Fastener:
(except Roadmaster)page 7.26.
84 in-lbs (9.5 Nm)
5. Using a 5mm hex wrench, remove the bolt w
securing the VCM mounting plate to the battery
box. 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.
16. Test ride the vehicle to verify all systems are
operating correctly.

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VCM CONNECTOR MAP

CONNECTOR: VCM A
PIN NUMBER WIRE COLOR FUNCTION
1 YE/WH START SWITCH OUTPUT (2017 ONLY)
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
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 - -
15 - -
16 - -
17 YE/BK TRANS GEAR POSITION SENSOR OUTPUT
18 BK NOT USED

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CONNECTOR: VCM 1
PIN NUMBER WIRE COLOR FUNCTION
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

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CONNECTOR: VCM B
PIN NUMBER WIRE COLOR FUNCTION
1 RD/YE VCM CONTOL POWER
2 WH/BK MODE SWITCH 1 (2017 ONLY)
3 GN MODE SWITCH 2 (2017 ONLY)
4 GY HORN SWITCH OUTPUT (2017 ONLY)
5 DG/YE HEADLIGHT CONTROL (2017 ONLY)
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 (2017 ONLY)
11 WH CRUISE CONTROL SET/ACCEL SWITCH (2017 ONLY)
12 WH/DG CRUISE CONTROL RESUME / DECEL SWITCH (2017 ONLY)
13 BU/YE HEATED GRIP SWITCH INCREASE
14 BU/BK HEATED GRIP SWITCH DECREASE
15 YE/DG LEFT TURN SIGNAL CONTROL (2017 ONLY)
16 BN RIGHT TURN SIGNAL CONTROL (2017 ONLY)
17 BN/DB WINDSHIELD SWITCH UP
18 DG/DB WINDSHIELD SWITCH DOWN

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HEADLIGHT SERVICE 4. Perform headlight adjustment. See “HEADLIGHT

AIM INSPECTION”.
HEADLIGHT BULB REPLACEMENT - ALL
MODELS Chieftain Dark Horse / Chieftain / Roadmaster

IMPORTANT 1. Remove two fasteners q and head light bezel w.

Avoid touching a halogen bulb with bare fingers. Oil
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.

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4. Remove the headlight bulb from the reflector and HALOGEN HEADLIGHT LENS COMPLIANCE
unplug. MARKINGS
5. Using a clean, oil-free cloth, install the new There are two different halogen bulbs, one for the
headlight bulb. North America and one for Europe. Make sure the
Halogen Headlight Lens you are replacing is marked
6. Install headlight retaining ring r and fasteners e with the appropriate agency markings.
to the headlight bracket. Torque fasteners to
specification. • In the 4 o’clock position, the SAE marking indicates
North America headlight lens.
TORQUE
Headlight Retaining Ring Fasteners:
12 in-lbs (1.4 Nm)

7. Perform headlight adjustment. See “HEADLIGHT

AIM INSPECTION”.
8. Install headlight bezel w and retain with two
fasteners q. Torque to specification.
TORQUE
Bezel Fasteners:
36 in-lbs (4.1 Nm)

• In the 9 o’clock position, the E4 markings indicates

Europe headlight lens.

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H E A D L I G H T L E N S R E P L A C E M E N T ( FA I R I N G 3. Remove fasteners e and headlight retaining ring

MODELS) r.
NOTICE
If you are replacing a halogen headlight lens, make
sure it has the correct agency markings before
installation. See Halogen Headlight Lens Compliance
Markingspage 10.67

1. Remove two fasteners q from headlight bezel w

4. Unplug the headlight electrical connection and

remove the headlight from the headlight bracket.
5. Install NEW headlight lens.
6. Install headlight retaining ring r and fasteners e
to the headlight bracket. Torque fasteners to
specification.
TORQUE
2. Gently pull out on the top of the bezel to release it Headlight Retaining Ring Fasteners:
from the body. Tilt the bezel out and remove.
12 in-lbs (1.4 Nm)

7. Perform headlight adjustment. See “HEADLIGHT

AIM INSPECTION”.
8. Install headlight bezel w and retain with two
fasteners q. Torque to specification.
TORQUE
Bezel Fasteners:
36 in-lbs (4.1 Nm)

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H E A D L I G H T L E N S R E P L A C E M E N T ( N O N - FA I R - 3. Remove two fasteners w securing the console

ING MODELS) cover to the fuel tank and lift console back and set
on protected fuel tank.
NOTICE
If you are replacing a halogen headlight lens, make
sure it has the correct agency markings before
installation. See Halogen Headlight Lens Compliance
Markingspage 10.67

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 4. Remove two fasteners per side e securing the
routing and connector orientation. Always route windshield mounting bracket assembly.
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 front portion of the nacelle out far enough
to access the four fasteners r securing the
headlight bucket to the front nacelle cover. Remove
four fasteners and washers.
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7. Pull the headlamp bucket out far enough to 10. Install NEW headlight. Install headlight retaining
disconnect the headlamp connector and remove ring i and fasteners u to the headlight bracket.
the bucket assembly t. Torque fasteners to specification.
TORQUE
Headlight Retaining Ring Fasteners:
12 in-lbs (1.4 Nm)

11. Install three fasteners y and washers securing the

headlight to the bucket assembly. Torque fasteners
to specification.

8. Remove three fasteners y and washers securing

the headlight to the bucket assembly.

TORQUE
Headlamp Assembly Fasteners:

12. Install the four headlamp bucket fasteners r and

washers. Torque to specification.

9. Remove fasteners u and headlight retaining ring

i.

TORQUE
Headlamp Bucket Fasteners:
84 in-lbs (9.5 Nm)

13. Connect the headlamp connector t.

14. Push the front and rear portions of the nacelle
together into position around the triple clamp.

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15. Install the two fasteners q located at the top of the 18. Move the console cover in place and torque
nacelle finger tight. fasteners w to specification.

16. Move the light bar / turn signal assembly into TORQUE
position and install four fasteners e. Torque to Console Cover Fasteners:
specification.
84 in-lbs (9.5 Nm)

19. Perform headlight adjustment. See “HEADLIGHT

AIM INSPECTION”.
20. Install windshield assembly, if equipped.

TORQUE
Auxiliary Light Bar Bracket Fasteners:
18 ft-lbs (24.4 Nm)

NOTICE
Verify the rubber grommets securing the auxiliary
10
light / turn signal harness have been slid into place.

17. Torque the upper nacelle fasteners q to

specification.
TORQUE
Upper Nacelle Fasteners:
36 in-lbs (4.0 Nm)

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H E A D L I G H T WA R N I N G I N D I C AT O R S
IMPORTANT
For all models: If bulbs have been replaced or
verified operational and OEM, The blinking high
beam indicator is a sign that too much current is
being drawn at the VCM. This can be a result of
damage to the VCM. Inspect VCM pin 11 on
connector one. Inspect both VCM and harness
connection for signs of corrosion, loose pins, poor
connections, or evidence of overheating or other
damage. Reference VCM Connector Mappage
10.63.

Indian motorcycles are equipped with “tell tales”

indicating when a fault occurs with the low or high
beam headlight.

2014 models: If a fault occurs with the headlight bulb

(low or high beam) the ‘Check Engine’ light will
illuminate and fault codes will be stored. Once the
bulb has been replaced and the issue corrected, the
‘Check Engine’ light will turn off however stored fault
codes will need to be erased.

2015 and later models: If a fault occurs with the

headlight bulb (low or high beam) the high beam
indicator light will flash on the instrument cluster.
Once the bulb has been replaced and the issue
corrected, the high beam indicator will return to
normal operation.

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HORN SERVICE (2017) LOAD SIDE TESTING

12 VDC is supplied to the WH wire.
GENERAL OVERIEW
The horn uses a load-sensing circuit for diagnostic • Engage the horn connector to the horn, and back
purposes. The VCM sends a 12V pull-up voltage to the probe the WH wire at the hornconnector with one
horn through the WH wire. DVOM probe. Connect the other probe to chassis
ground. Key on, voltage reading should be nearly
• With the horn disconnected, you should see 12V at battery voltage when the horn button is depressed.
the horn connector when checked with a DVOM.
• With the horn connected, back probe the BK and
• When the horn is connected, the 12V pull-up goes WH wires at the horn. key on, Depress the horn
away. button. Voltage reading should be near battery
• The horn circuit is a Normally Open circuit, so voltage.
depressing the horn provides the VCM a path to • With the horn connected, back probe the BK wire at
ground. The VCM responds by sending 12V to the the horn, and place the other probe at battery
horn making it sound. negative. Your reading should be close to 0 volts.

SWITCH SIDE TESTING

8 VDC is supplied on the Gray wire to the horn button.

• Voltage should read 0.005 when the button is

depressed.
• Digital Wrench can see button switch open and
close.
• With the VCM connected, bypass the switch by
providing the the GY wire a direct path to ground.
The horn should sound until the ground path is
removed.

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HORN BREAKOUT DIAGRAM (2017)

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H O R N R E M O VA L / I N S TA L L AT I O N HORN SERVICE (2018+)

1. Remove the three fasteners q securing the horn
cover to the bracket and remove cover. GENERAL OVERVIEW
The horn uses a load-sensing circuit for diagnostic
purposes. The VCM sends a 12V pull-up voltage to the
horn through the WH wire.
• With the horn disconnected, you should see 12V at
the horn connector when checked with a DVOM.
• When the horn is connected, the 12V pull-up goes
away.
• The horn button circuit is a node on the CAN bus.
depressing it sends a signal to the VCM. The VCM
responds by sending 12V to the horn, making it
sound.

2. Disconnect the horn electrical connector w . LOAD SIDE TESTING

3. Using a 10mm wrench, remove the fastener e 12 VDC is supplied to the WH wire.
securing the horn to the ignition coil bracket.
Remove the horn. • Engage the horn connector to the horn, and back
probe the WH wire at the hornconnector with one
DVOM probe. Connect the other probe to chassis
ground. Key on, voltage reading should be nearly
battery voltage when the horn button is depressed.
• With the horn connected, back probe the BK and
WH wires at the horn. key on, Depress the horn
button. Voltage reading should be near battery
voltage.
• With the horn connected, back probe the BK wire at
the horn, and place the other probe at battery
negative. Your reading should be close to 0 volts.

SWITCH SIDE TESTING

4. Installation is performed by reversing the
removal procedure. • The horn button/switch is on the CAN bus.
Disconnect the switch/button, and turn the ignition
5. Torque fasteners to specification. off.
TORQUE • Ensure all modules have gone to sleep. The time will
vary from model to model, but this may take a few
10
Horn to Bracket: 84 in-lbs (9.5 Nm)
minutes.
• Set your DVOM to ohms, and place one probe on the
TORQUE DARK GREEN, and one on the YELLOW wire. You
Ignition Coil Cover: 84 in-lbs (9.5 Nm) should read near 60 ohms.
• For more information regarding the CAN Network,
refer to: CAN (Controller Area Network) Diagnostic
Overviewpage 4.62

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HORN BREAKOUT DIAGRAM (2018+)

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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.

4. Installation is performed by reversing the

removal procedure.
5. Torque fasteners to specification.
TORQUE 10
Horn to Bracket: 84 in-lbs (9.5 Nm)

TORQUE
Ignition Coil Cover: 84 in-lbs (9.5 Nm)

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TA I L L I G H T S E R V I C E TA I L / B R A K E / L I C E N S E P L AT E L I G H T , R 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 M O VA L / I N S TA L L AT I O N
The multiple LED tail / brake lamp functions much like NOTICE
a conventional incandescent tail / brake lamp. LED The tail and brake lights are LEDs and cannot be
lights require a regulated current supply to prevent replaced individually. If the lights fail to function
damage, so a current regulation circuit is incorporated when activated, and all circuit tests indicate correct
inside the tail lamp unit. Direct 12 volt battery power power and ground distribution, the tail /brake light
can be applied directly to the brake or tail lamp wire must be replaced as an assembly. The license plate
for testing purposes, but polarity MUST be observed light can be replaced individually.
or the LEDs will be permanently damaged.
Tail / Brake Light Power Supply: 1. Place the motorcycle in an upright position with
the front wheel clamped in a wheel vise.
When the motorcycle is powered ON, battery voltage
is delivered to the TAIL / BRAKE LEDs on the DARK 2. Working from beneath the rear fender, access the
BLUE / PINK wire from the Secondary Engine Relay. three tail light fasteners q and remove.
Current through each TAIL LED (WHITE wire) is
limited (inside tail lamp unit) to approximately 250
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
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

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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:
84 in-lbs (9.5 Nm)

TORQUE
License Plate Light to Mount:
15 in-lbs (1.7 Nm)

TORQUE
License Plate Bracket to Tail Light:
7. Remove the license plate light t from the license 84 in-lbs (9.5 Nm)
plate bracket.
TORQUE
Tail Light Asm to Fender:
84 in-lbs (9.5 Nm)

10

Tail / Brake Light Removal

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TRUNK LED REPLACEMENT - BRAKE / INTERI-

OR (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.

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.
6. Installation is performed by reversing the
removal procedure. Torque all fasteners to
specification.
TORQUE
LED Trunk Light Fasteners: 36 in-lbs (4.1 Nm)

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TURN SIGNAL / HAZARD SYSTEM SERVICE 4. Installation is performed by reversing the

removal procedure. Torque all fasteners to
T U R N S I G N A L O P E R AT I O N specification.
The turn signal / hazard light system does not utilize a
conventional “flasher module”, but instead receives a TORQUE
grounding signal from the ECM. Power to the LED turn Turn Signal Fasteners: 36 in-lbs (4.1 Nm)
signals is provided via the SEC ENGINE RELAY
located in the main fuse box. Turn Signal INPUTS &
OUTPUTS can be located in the ECM Connector Map
and Fuse Application Chart.
F R O N T T U R N S I G N A L , R E M O VA L / I N S TA L L A -
See ECM Connector Mappage 4.30.
T I O N ( C L A S S I C / V I N TA G E / D A R K H O R S E /
Depending on the model year of the motorcycle, See SPRINGFIELD)
Fuse Application Chart (2017)page 10.58 or Fuse
Application Chart (2018+)page 10.60. NOTICE
NOTICE Turn signals are LEDs and must be replaced as an
assembly. Turn signal bulbs cannot be replaced
The turn signals use LED lights and must be replaced independently.
as an assembly. Bulbs cannot be replaced
individually.
1. Locate turn signal connectors inside the nacelle
and disconnect.
2. Remove fastener q and remove turn signal from
F R O N T T U R N S I G N A L R E M O VA L / I N S TA L L A - bracket.
T I O N ( C H I E F TA I N / R O A D M A S T E R )
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

Outer Fairing Removal - (Chieftain Dark Horse)
page 7.52 or Outer Fairing Removal - (Chieftain /
Roadmaster)page 7.58.
2. Remove two fasteners q securing the turn signal
light to the fairing.

3. Installation is performed by reversing the

removal procedure. Torque all fasteners to
specification.
10
TORQUE
Turn Signal Fastener: 18 ft-lbs (24.4 Nm)

3. Remove turn signal.

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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
(ALL MODELS)
1. Remove the tail light assembly. See Tail Light /
License Plate Lightpage 10.56.
2. Remove fastener q and withdraw the turn signal
from the tail light assembly.

3. Installation is performed by reversing the

removal procedure. Torque all fasteners to
specification.
TORQUE
Turn Signal Fastener: 18 ft-lbs (24.4 Nm)

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SWITCH CUBE REPLACEMENT 3. Loosen and remove inner Switch Cube fasteners
and separate inner switch cube.
CAUTION
Always support the clutch when attempting to
replace switch cubes. Excessive rotation to the clutch
perch while the clutch switch wires are in tension
may result in damage to the clutch switch. Do not
disconnect the clutch from the handlebar and let it
hang freely, doing so may result in damage to the
clutch switch wire q.

REMOVAL
1. Disconnect Switch Cube electrical connection.
2. Loosen and remove outer rear w and front e
switch cube fasteners q and separate front and
rear switch cube covers.

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INSTALLATION 3. Install inner switch cube to handlebar. Torque

inner cube fasteners to specification.
NOTICE
Before assembling cube halves, ensure the wire TORQUE
harness is completely pulled through and no wires Cube Fasteners:
are pinched. Confirm there is no wire slack in 12 in-lbs (1 N·m)
handlebars.

4. Install both front and rear halves of outer switch

1. Pull harness through egress opening in handlebars cube covers. Torque fasteners to specification.
q. Connect cube electrical connection.
TORQUE
Cube Cover Fasteners:
12 in-lbs (1 N·m)

2. Align inner switch cube control half with locating

hole in handlebar.

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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 / S P R I N G F I E L D )

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 Cruise control is enabled, but not set. Arrow appears in
Status the upper left hand corner when cruise control is set to 10
q the desired speed.

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.
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
e warning is activated. All segments including the fuel icon
will flash. Refuel promptly.

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NUMBER LIGHT INDICATES CONDITION

Vehicle speed When standard mode is selected, speed displays in miles
r per hour.
High Beam The headlight switch is set to high beam. This indicator
t will flash if there is a problem with the low or high beam
light.

Chassis Fault The alert symbol illuminates if a chassis fault occurs.

y

u — Vehicle Speed Analog display of vehicle road speed in MPH or km/h.

Left Turn Signal The turn signal indicator flashes when the left turn signal
(hazard) is active. If there is a problem in the signal system,
i 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.
Neutral The transmission is in neutral.
a

Tire Pressure (If equipped) The TPMS indicator illuminates if low tire
Monitoring System pressure is detected. It will also illuminate along with the
s (TPMS) Low Battery Voltage indicator when TPMS battery power
is low, requiring service.
Right Turn Signal The turn signal indicator flashes when the right turn
signal (hazard) is active. If there is a problem in the signal
d system, the lamps will flash at twice the normal rate.

Check Engine 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 engine. If abnormal sensor or engine
f operation is detected the light will remain on as long as
the fault condition exists. Retrieve the error codes for
diagnosis.
Sidestand Illuminates when the sidestand is in the down position.
Indicator
g

Vehicle Speed When metric mode is selected, speed displays in

h kilometers per hour.
Multi-Function —
j —
Display (MFD)

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NUMBER LIGHT INDICATES CONDITION

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
k 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
l 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.

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Multi-Function Display (MFD)

The power switch must be ON to access the MFD. Use 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 switch cube.

MODES AVAILABLE
Odometer Engine Speed
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
Gear position displays at all times while the engine is running, unless a fault occurs with the gear position sensor.

Temperature
The temperature area displays ambient air temperature.

Fuel Range

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The fuel range displays the distance the motorcycle can travel on the remaining fuel in the fuel tank.

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I N S T R U M E N T C L U S T E R ( 2 0 1 7 C H I E F TA I N D A R K H O R S E )
For detailed information regarding MODE selection and Multi-Function Display operation refer to the
Indian Motorcycle Owner’s Manual.

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
High Beam if there is a problem with the low or high beam light.

The turn signal indicator flashes when the left turn signal (hazard)
is active. If there is a problem in the signal system, the lamps will
Left Turn Signal flash at twice the normal rate.

The turn signal indicator flashes when the right turn signal
(hazard) is active. If there is a problem in the signal system, the
Right Turn Signal 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

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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.

Vehicle Speed Units 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.
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
Tire Pressure Warning will also illuminate along with the Low Battery Voltage indicator
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 10
with the low battery voltage indicator when the key fob battery is
low.

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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 / R O A D M A S T E R )
SPEEDOMETER DISPLAY

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NUMBER LIGHT INDICATES CONDITION

Fuel level / Range Indicates how much fuel is remaining in the tank as well as
q — the distance the motorcycle can travel on the remaining
fuel in the fuel tank.
Vehicle speed When standard mode is selected, speed displays in miles
w per hour.
Cruise Control Amber Lamp: Cruise control is enabled, but not set. Green
Status Lamp: Cruise control is set to the desired speed.
e

Left Turn Signal The turn signal indicator flashes when the left turn signal
(hazard) is active. If there is a problem in the signal system,
r the lamps will flash at twice the normal rate.

t — Vehicle Speed Analog display of vehicle road speed in MPH or km/h.

High Beam The headlight switch is set to high beam. This indicator
y will flash if there is a problem with the low or high beam
light.

Neutral The transmission is in neutral.

u

Low Fuel Indicator This icon illuminates when approximately one gallon (3.8
L) of fuel remains in the fuel tank. the LCD display will
i switch into a Low Fuel Mileage Counter Mode to provide
the rider with mileage tracking from the time the indicator
was activated.
Sidestand Illuminates when the sidestand is in the down position.
Indicator
o

Vehicle Speed When metric mode is selected, speed displays in

a kilometers per hour.

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TACHOMETER DISPLAY

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NUMBER LIGHT INDICATES CONDITION

q — Gear Selector Indicates the current gear position.

Chassis Fault The alert symbol illuminates if a chassis fault occurs.
w

Tire Pressure (If equipped) The TPMS indicator illuminates if low tire
Monitoring System pressure is detected. It will also illuminate along with the
e (TPMS) Low Battery Voltage indicator when TPMS battery power
is low, requiring service.
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
r 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.
Tachometer Analog display of engine speed in revolutions per minute
t —
(RPM).
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
y 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.
Right Turn Signal The turn signal indicator flashes when the right turn
signal (hazard) is active. If there is a problem in the signal
u 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
i 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
dealer promptly. The light will remain on if the tilt sensor
shuts down the engine. If abnormal sensor or engine
o operation is detected the light will remain on as long as 10
the fault condition exists. Retrieve the error codes for
diagnosis.

a — Millage Indicates the total amount of miles driven

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
s 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.

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RIDE COMMAND DIAGNOSTICS / TROUBLESHOOTING

PROBLEM: BLACK SCREEN / WILL NOT POWER ON
STEP ACTION YES NO

Power cycle the bike by switching ignition on and off with main
1 power switch in fairing. Go to Step 8 Go to Step 2
Did you find and repair the condition?

Check the 5 amp fuse labeled Gauge in the main fuse box under the
left side upper panel.
2 Refer to Fuse Box Locationpage 10.57
Go to Step 9 Go to Step 3
Is the fuse blown?
Reinstall Gauge fuse and test screen for proper operation.
3 Did you find and repair the condition? Go to Step 8 Go to Step 4

1. Turn ignition on.

2. Disconnect the display from the harness.
3. Using pin 16 (Ground) as ground reference, check for battery
4 voltage on pins 31 (Switched Power) and 32 (Battery Power) of the
Go to Step 8 Go to Step 5
display connector.
Is there Battery Voltage at pins 31 and 32 with the ignition on?

Refer to the Fairing & Chassis wiring schematic in appendix and Go to Step 1
5 check circuits without voltage for continuity and proper operation. Go to Step 7 and repeat
Did you find any problems in the circuit? diagnosis

Replace display with known good display. Go to Step 1

6 Did you find and repair the condition? Go to Step 8 and repeat
diagnosis

Repair, replace, and check all affected power/ground circuits. Go to Step 1

7 Check for battery voltage at pins 31 and 32. Go to Step 8 and repeat
Is there battery voltage at pins 31 and 32 with the ignition on? diagnosis

Update display with newest software available. Confirm

Refer to the Owner’s Manual for instructions on how to update/ display
8 reflash software. operation Go to Step 6
Is display working properly? and continue
use.
1. Test circuit for continuity and/or shorts in wiring.
9 2. Fix any shorts in the wiring and reinstall new fuse. Go to Step 8 Go to Step 4
Did you find and repair the condition?

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P R O B L E M : S C R E E N M I S S I N G P I X E L S , L C D S C R E E N F L AW , S O F T W A R E G L I T C H O R P R O B L E M
STEP ACTION YES NO
Power cycle bike by switching ignition on and off with main power
1 switch in fairing. Go to Step 2 Go to Step 2
Did you find and repair the condition?

Update display with newest software available. Confirm

Refer to the Owner’s Manual for instructions on how to update/ display
2 reflash software. operation Go to Step 3
Is display working properly? and continue
use.
1. Remove and reinstall the 5amp fuse labeled Gauge in the main
fuse box under the left side upper panel.
3 Refer to Fuse Box Locationpage 10.57
Go to Step 2 Go to Step 4
Did you find and repair the condition?

Replace display with known good display.

Repeat
4 Did you find and repair the condition? Go to Step 2
Diagnosis

GPS ANTENNA TROUBLESHOOTING (2018-19 MODELS)

1. Unplug connector from GPS antenna (Refer to: Outer Fairing Removal - (Chieftain Dark Horse)page 7.52 for
location) and verify all contacts are securely seated in the connector.
2. Turn ignition on and make the following measurements on the antenna connector: 10
CONNECTION TO
WIRING VOLTAGE SPECIFICATION
MEASURE
Power Between Pins 4 and 3 12Vdc (Battery Voltage)

3. If antenna connector has 0Vdc supplied, check harness for loose connection or breaks in wiring. Check for
power at SW PWR fuse in fuse box.
4. If antenna connector shows proper voltage, check operation of GPS. If GPS still is not functioning, proceed to
step 5.
5. Turn the ignition off and make the following measurements on the antenna connector:

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6.
CONNECTION TO RESISTANCE
WIRING
MEASURE SPECIFICATION
CAN Between Pins 1 and 2 60 Ohms

7. If resistance value is out of spec, check for breaks in yellow/green CAN wiring.
8. If all values are within specification, replace GPS antenna with new unit.

GPS / CELL ANTENNA TROUBLESHOOTING (2020+ MODELS)

1. Unplug the GPS and cell connectors from the cell modem w and display. (Refer to: Outer Fairing Removal -
(Chieftain / Roadmaster)page 7.58 for location), and verify nothing is bent or damaged within the connector.
2. Plug the GPS / Cell Antenna back into the cell modem and display, making sure connectors are securely
seated, and check for functionality.
NOTICE
Must be in an area with GPS and cell signal available.

3. If GPS and or cell data is still not present, replace GPS / Cell Antenna with new unit.
4. If after replacing the GPS / Cell Antenna, there is still no cell data present, move on to cell modem
troubleshooting (if applicable).

CELL MODEM TROUBLESHOOTING (IF APPLICABLE)

Ensure the following BEFORE beginning:

• Reliable internet connection and good Verizon cell signal.

• Connect the battery to a battery tender.
• Disable the automatic power down function, Settings > Vehicle > Automatic Power Down.
• Latest version of Digital Wrench is installed on computer. Log into Polaris Dealers Website, select "Service
and Warranty" menu, then "Digital Wrench Updates".

1. Connect Digital Wrench® cable to diagnostic port on motorcycle and power on motorcycle.
2. Enter vehicle information as required.
3. Select Special Tests menu item.

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4. Select "Modem Service Procedures" menu item.

5. Select "Troubleshoot" option.

10

6. After selecting the option from step 5, follow Digital Wrench screen prompts until Digital Wrench provides a
result.
7. Verify the functionality of the cell modem.
8. If the cell modem is still not functional call Indian Motorcycle for Ride Command support.

HEADSET TROUBLESHOOTING
If headset is not functioning properly with display:

1. Check volume level on Headset.

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2. Ensure Headset has latest software. Visit Headset Manufacturer Website to verify and install most up to date
software.
3. Clear all pairings from Headset and re-pair with display
4. Pair Headset with another Bluetooth enabled device and check for proper functionality

ANDROID “OK GOOGLE” ISSUES

*Not currently available

1. Ensure Headset and Android phone are paired to the motorcycle.

2. Turn phone screen ON and unlock phone.
3. Press and hold the center button (Mute, Play/Pause) on the handlebar control.
4. Display should initiate a Voice Command session with phone.
5. Ensure Google App is selected as the default app and that your phone always remembers this selection

UNCLEAR HEADSET SOUND

1. Unpair and repair headset from Ride Command in bluetooth menu.
2. If this does not resolve the issue, clear all previously paired headsets from Ride Command, and repair the
headset.
3. If there is still unclear sound, pair different headset and see if sound quality improves.
4. If sound quality improves, previous headset was malfunctioning.

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CRUISE CONTROL • CRUISE ON / OFF — Discrete input to the VCM then

CAN message to ECM
CRUISE CONTROL OVERVIEW
• CRUISE RES / ACC — Discrete input to the VCM
The Indian Motorcycle cruise control system operates
then CAN message to ECM
in conjunction with the Electronic Throttle Control
(ETC) eliminating the need for a conventional actuator • CRUISE SET / DEC — Discrete input to the VCM
/ cable assembly. The Engine Control Module (ECM) then CAN message to ECM
uses several inputs to determine the position of the
ETC in order to maintain the desired vehicle speed. Cruise Related Inputs / Outputs (other controls):
Momentary signals are sent to the Vehicle Control
Module (VCM) from the right hand switch cube based • Brake Pressure Switch (Front & Rear) — Discrete
on operator input. The VCM converts these operator input to ECM
inputs to CAN and relays the message to the Engine
Control Module (ECM). • Clutch Switch — Discrete input to the ECM
Cruise control only operates in gears 4 — 6. • Vehicle Speed (Wheel Speed Sensors) — Discrete
inputs to ABS module and then CAN message to
Cruise Related Control Modules: 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):

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CRUISE CONTROL DIAGNOSTICS

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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 10
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?

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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?
• 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.

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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
The Chieftain and Roadmaster models are equipped with an electronically adjustable windshield which is
controlled through a switch q located on the LH switchcube.

When the windshield adjustment switch is

moved to the up or down positions it is
providing a path to ground, through the
appropriate limit switch, to an H-bridge located
in the VCM. The VCM then sends power and
ground to the windshield adjustment motor
2017
based on switch position (switching action
models
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.

2018+ For 2018+ the windshield switch is CAN to

models VCM.

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2017 Windshield Wiring Diagram

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2018+ Windshield Wiring Diagram

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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
1. Remove the outer fairing and windshield. 4. Remove the windshield lift bracket r .
• Chieftain Dark Horse: See Outer Fairing NOTICE
Removal - (Chieftain Dark Horse)page 7.52
There are two small spacers w located in the
• Chieftain / Roadmaster: See Outer Fairing windshield lift bracket. One spacer for each fastener
Removal - (Chieftain / Roadmaster)page 7.58 at the lift arms. Recover the spacers when the
fasteners are removed.
2. Raise the windshield to expose the hex-head
fasteners q on the lift arms.

5. Remove the four fasteners t securing the

3. Remove the hex-head fasteners q and fasteners e windshield cowl panel to the inner fairing and
securing the windshield lift bracket to the motor. remove cowl panel.

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6. Remove the four nuts y securing the windshield lift

motor to the mounting bracket.

7. Disconnect the electrical connector(s) and remove

motor assembly.

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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
1. If the limiter switch is being replaced, attach the 5. Install the two Lift Arm Fasteners e into the lift
switch to the motor assembly at this time. arms and Drive Motor Hinge Fastener r onto the
drive motor. Torque all fasteners to specification.
2. Plug the electrical connector(s) into the windshield
lift motor assembly and lower onto the mounting
studs.
3. Tighten nuts q to specification.
TORQUE
Windshield Motor Nuts: 36 in-lbs (4.1 Nm)

NOTICE
Refer to image below to make sure the Lift Arm
hardware stack is in the correct order.

4. Fit the windshield cowl panel into position and

install the four fasteners w securing the panel to
the inner fairing. Torque fasteners to specification.
NOTICE
It is necessary to move the windshield lift arms
toward the front of the vehicle when fitting the cowl
panel.

TORQUE
Lift Arm Fasteners: 84 in-lbs (9.5 Nm)
Drive Motor Hinge Fastener: 84 in-lbs (9.5 Nm)

6. Install the outer fairing and windshield.

• Chieftain Dark Horse: See Outer Fairing
Installation - (Chieftain Dark Horse)page 7.56
• Chieftain / Roadmaster: See Outer Fairing
Installation - (Chieftain / Roadmaster)page 7.62

7. Verify the windshield moves up and down through

the travel range.

TORQUE
Windshield Cowl Panel Fasteners: 36 in-lbs (4.1 Nm)

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CELL MODEM INSTALLATION

CELL MODEM REPLACEMENT 1. Plug in the antenna and display connectors q to
the modem.
REMOVAL
2. Install the fasteners w securing the modem to the
1. To access the Cell Modem, remove the outer fairing. Torque fasteners to specification.
fairing. See Outer Fairing Removal - (Chieftain /
Roadmaster)page 7.58 TORQUE
2. Unplug the antenna and display connectors q from Cell Modem Fasteners:
the modem. 36 in-lbs (4 N·m)

PERFORM DIGITAL WRENCH CELL MODEM ACTIVATION

(USA AND CANADA ONLY)
Ensure the following BEFORE beginning:

• Reliable internet connection and good Verizon cell

signal.
• Connect the battery to a battery tender.
• Disable the automatic power down function,
Settings > Vehicle > Automatic Power Down.
• Latest version of Digital Wrench is installed on
computer. Log into Polaris Dealers Website, select
"Service and Warranty" menu, then "Digital
3. Remove the fasteners w securing the modem to the Wrench Updates".
fairing and remove the modem.
1. Connect Digital Wrench® cable to diagnostic port
on motorcycle and power on motorcycle.
2. Enter vehicle information as required.
3. Select Special Tests menu item.
4. Select Modem Service Procedures menu item.

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5. Select Replace Modem option.

6. Follow Digital Wrench® screen prompts until

Modem Activation Completed Successful is
displayed.

7. Install the outer fairing. See Outer Fairing

Installation - (Chieftain / Roadmaster)page 7.62

CELL MODEM TROUBLESHOOTING

For Cell Modem Troubleshooting see Ride Command
Diagnostics / Troubleshootingpage 10.96

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GEAR POSITION SWITCH GEAR POSITION SWITCH REPLACEMENT

NOTICE
The gear position switch is different based off of
engine build date. These switches are not
interchangeable.

2017–19 (MULTIPLE RESISTANCE SWITCH) 2020+ (ROTARY SWITCH)

REMOVAL 2. Remove right-hand saddlebag w (if equipped).

1. Remove upper right-hand sidecover q.

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3. Remove right-hand rear tip-over bar e (if 6. Loosen clamps and remove right-hand rear
equipped). heatshield y.

4. Remove right-hand passenger footpeg r (if 7. Remove drive sprocket cover u.

equipped).

IMPORTANT
5. Remove right-hand lower sidecover t. Use of short (stub-nose) allen wrench is necessary for
bottom two bolts and front bolt.

8. From under the motorcycle, unplug gear position

connector i.

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9. Remove P-clip o securing the gear position switch 11. Remove shift drum pins s and springs d (if
wire. necessary).

NOTICE NOTE
It can be helpful to use a zip-tie to hold the belt out of Use magnet to aid in removal and re-installation of
the way during this step. pins and springs (assemble spring onto pin).

IMPORTANT 12. Inspect the shift drum pins and springs. See SHIFT
Use of 1/4" drive, deep-well, 7mm socket is DRUM SPRING / PIN INSPECTIONpage 10.124
necessary for screw removal.
GEAR POSITION SWITCH CLEANING
Using a Very-Fine abrasive pad, such as Scotch-Brite
10. Remove gear position switch a. 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.

10

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.

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INSTALLATION 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:
84 in-lbs (9.5 Nm)

5. From under the motorcycle, plug in the gear

position connector i.

TORQUE
Gear Position Switch Fasteners:
44 in-lbs (5 N·m)

IMPORTANT
3. Using a multimeter, test the switch for proper
resistance. See Gear Position Switch Testpage . Listen for an audible click to indicate the connection
is secure.

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6. Install drive sprocket cover u. Torque fasteners to 7. Install right-hand rear heatshield y. Torque clamps
specification. to specification.

NOTICE TORQUE
When re-installing, bolts must be loosely assembled Heat Shield Clamps:
into the cover before assembling onto motorcycle.

8. Install right-hand lower sidecover t.

TORQUE
Drive Sprocket Cover Fasteners:
84 in-lbs (9.5 Nm)

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9. Install right-hand passenger footpeg r (if 11. Install right-hand saddlebag w (if equipped).
equipped). Torque fastener to specification.

12. Install upper right-hand sidecover q.

TORQUE
Footpeg Fastener:
35 ft-lbs (47 N·m)

10. Install right-hand rear tip-over bar e (if

equipped). Torque fasteners to specification.

13. Road test the motorcycle to ensure the correct gear

position is indicated on the instrument cluster.

TORQUE
Tip-Over Bar Fasteners:
18 ft-lbs (24 N·m)

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GEAR POSITION SWITCH TEST

NOTICE
The gear position switch is different based off of
engine build date. These switches are not
interchangeable.

2017–19 (MULTIPLE RESISTANCE SWITCH) 2020+ (ROTARY SWITCH)

1. Disconnect the gear position switch 2–pin 4. 2017–19 models: Watch the resistance readings as
connector q located at the rear of the engine the transmission is shifted through each of the 6
below the ABS module. gear positions including Neutral. The meter
readings should match the resistance specifications
given in the following diagram.

10
2. Set multi meter to measure resistance (Ohms).
3. Connect one meter lead to each of the pins on the
switch connector.

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GEAR POSITION SWITCH VOLTAGE AND RESISTANCE

SPECIFICATIONS (2017–2019)
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

GEAR POSITION SWITCH VOLTAGE AND RESISTANCE

SPECIFICATIONS (2020+)
VOLTAGE
GEAR
NOMINAL MIN MAX
1st 0.63 0.67 0.59
N 1.00 1.04 0.96
2nd 1.38 1.42 1.34
3rd 2.13 2.17 2.09
4th 2.88 2.92 2.84
5th 3.63 3.67 3.59
6th 4.38 4.42 4.34
GEAR POSITION SWITCH TROUBLESHOOTING
GROUND INSPECTION
1. Remove the negative battery cable from the
battery and chassis ground joints.
2. Inspect the chassis pad on the frame.
SITUATION ACTION
Debris or other
Clean and remove
material is found
Remove corrosion via
brass wire brush or
Corrosion is found semi-coarse
sandpaper
Use fine abrasive pad
(400 grit or finer),
apply light pressure by
Paint Is found hand in a rotary motion
to the chassis ground
contact point.

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BATTERY CABLE INSPECTION REASSEMBLING GROUND PATH

1. Inspect battery for corrosion and debris. 1. Assemble and tighten the chassis harness first to
the pad with the ground on top.
SITUATION ACTION
TORQUE
Debris or other
Clean and remove Chassis Lug Joint Nut
material is found
60 in-lbs (7 Nm)
Remove corrosion via
brass wire brush or
Corrosion is found semi-coarse TORQUE
sandpaper
Chassis Lug Joint Fastener
84 in-lbs (10 Nm)
2. If heavy corrosion is found replace battery cable.
3. Measure the resistance of the cable and ensure it
2. Assemble the negative battery cable to the battery
measures less than one ohm.
terminal.
BATTERY TERMINAL INSPECTION TORQUE
1. Inspect and clean battery terminals. Battery Terminal Fastener:
48 in-lbs (5 N·m)
SITUATION ACTION
Debris or other
Clean and remove
material is found
Clean with a solution of
Corrosion is found baking soda and water.

CHASSIS HARNESS
1. Inspect the chassis harness lug.

SITUATION ACTION
Debris or other
Clean and remove
material is found
Remove corrosion via
brass wire brush or
Corrosion is found semi-coarse
sandpaper
Use fine abrasive pad
(400 grit or finer),
apply light pressure by
Paint Is found hand in a rotary motion 10
to the chassis ground
contact point.

2. Ensure both the top and bottom of the lug is

completely clean and clear.
3. Ensure the terminal is not bent.

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ADDITIONAL TESTING (2014–2019) 3. Measure Resistance between pin 17 on connector A

(Left Connector) and Pin 17 on Connector 1
NOTICE (Center Connector).
Perform the following if the previous section did not
resole the gear indicator issue. IMPORTANT
Only use the multimeter to make contact with the
front of the terminal. Do NOT insert the multimeter
1. Perform a gear position switch test. See Gear into the terminal, doing so may damage the harness
Position Switch Testpage 10.119. connection.
2. Disconnect VCM A and 2 left-most connectors
shown. 4. Compare resistance across these two pin in each
gear to the table below.

RESISTANCE
GEAR
NOMINAL MIN MAX
1st 261.2 248.1 274.2
N 41.6 39.5 43.7
2nd 73.2 69.5 76.8
3rd 108.9 103.5 114.4
4th 146.5 139.2 153.8
5th 196.3 186.5 206.1
6th 7.5 7.1 7.9

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ADDITIONAL TESTING (2020 +) 2. Compare Digital Wrench communicated values to

the table below.
1. Connect the unit to Digital Wrench.

VOLTAGE
GEAR
NOMINAL MIN MAX
1st 0.63 0.67 0.59
N 1.00 1.04 0.96
2nd 1.38 1.42 1.34
3rd 2.13 2.17 2.09
4th 2.88 2.92 2.84
5th 3.63 3.67 3.59
6th 4.38 4.42 4.34

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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 Replacementpage 10.113 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.

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

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SWITCH TESTING CLUTCH SWITCH TEST

1. Remove the clutch switch cover fasteners q and
BRAKE LIGHT SWITCH TEST clutch switch cover.
1. Place the motorcycle in an upright position with
front wheel clamped in a wheel vise.
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
lever released (OL).
3. Set multi meter to measure resistance.
4. Connect meter leads to each terminal of the front TIPOVER SENSOR (ANGLE SENSOR)
brake switch w . OVERVIEW OF OPERATION
5. Apply the front brake. The Tipover Sensor (TOS) is used to disable the fuel
pump, fuel injector, and ignition circuits in the event of
Resistance Specification: Continuity with pedal / a crash or tipover condition.
lever depressed
The ECM sends a 5VDC reference to the sensor and
6. Connect meter leads to each terminal of the rear monitors the output voltage. From the output signal,
brake switch e . the ECM can tell whether the TOS system is in normal
operation, if the vehicle is tipped over, or if there is an
7. Apply the rear brake. open or short in the system wiring. Only a tipover
voltage from the sensor will cause the ECM to disable
Resistance Specification: Continuity with pedal / the fuel pump and ignition circuits. If the TOS system
lever depressed 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 10
to disconnect the fuel and ignition circuits as well as
the internal drivers that control them.

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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 Replacementpage 10.40.
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.

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BREAKOUT WIRING DIAGRAMS

ANTI-LOCK BRAKE SYSTEM, WIRING DIAGRAM (2017)

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ANTI-LOCK BRAKE SYSTEM, WIRING DIAGRAM (2018+)

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CENTRAL LOCKING SYSTEM, WIRING DIAGRAM

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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 ( 2 0 1 7 )

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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 ( 2 0 1 8 + )

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KEYLESS IGNITION SYSTEM, WIRING DIAGRAM

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POWER WINDSHIELD, WIRING DIAGRAM (2017)

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POWER WINDSHIELD, WIRING DIAGRAM (2018+)

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ELECTRICAL DIAGNOSTICS
ELECTRICAL SERVICE NOTES S TAT I C A N D D Y N A M I C T E S T I N G
Keep the following notes in mind when diagnosing an There are many methods for testing a DC circuit.
electrical problem. These methods fall into one of two categories, either
static or dynamic.
• Refer to wiring diagram for stator and electrical
component resistance specifications. S TAT I C T E S T I N G
• When measuring resistance of a component that has The two most common forms of static testing are:
a low resistance value (under 10 Ohms), remember
• Resistance testing (the Ohms setting on your DMM)
to subtract meter lead resistance from the reading.
Connect leads together and record the resistance. • Measuring voltage with the circuit open, such as
The resistance of the component is equal to tested when the harness connector is off a sensor you are
value minus the lead resistance. testing. This is commonly referred to as measuring
“Available Voltage”.
• 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 These two tests will help you find the majority of
to the Owner’s Manual included with your meter. electrical issues. If they do not, we must remember
that static circuit testing does not take into account
• Voltage, amperage, and resistance values included how current actually flows in that circuit. That is only
in this manual are obtained with a Fluke™ 77 Digital accomplished with dynamic testing.
Multimeter (PV-43568). This meter is acceptable for
use when diagnosing electrical problems. Readings Before attempting dynamic testing (as it is intrusive on
obtained with other meters may differ. sealed connectors and damage could be done if not
careful), verify the following:
• Pay attention to the prefix on the meter reading (K,
M, etc.) and the position of the decimal point. • Static voltage testing advised for that circuit has
been completed, and is in spec.
• For resistance readings, isolate component to be
tested. Disconnect wire harness or power supply. • All associated circuits have under 1 ohm of
resistance from end to end. Testing Continuity /
Resistancepage 10.137
D I G I TA L M U LT I - M E T E R ( D M M ) N O T E S • All associated circuits have no shorts to ground.
Testing For A Short To Groundpage 10.138
Polaris advises to only use a high quality DMM that
meets the same standards as the Fluke™ 77 (PV- • All associated circuits have no shorts to voltage.
43568) for electrical testing. Testing For A Short To Voltagepage 10.139
Unless you are very familiar with Ohm’s Law, and have
complete information about the circuit you are trying DYNAMIC TESTING
to diagnose, test lights are likely to provide results that
would be misleading. This is especially true if any There are two types of dynamic testing we will advise
solid state component is involved, where you will to use when diagnosing electrical concerns:
almost certainly not have complete circuit information. • Current flow testing (Amperage) Testing Current
Polaris also specifically advises against the use of Flow (Amperage)page 10.140. Measuring
other circuit testing devices, including but not limited Amperage is not a common practice, as you will not 10
to: typically have a spec to compare your reading to.
Also, many components on this machine flow over 10
• Short finders Amps, which will blow the majority of DMM fuses.
• Simplified circuit testers The exception to this is a parasitic draw test refer to
Current Draw - Key Offpage .
• Fuse piggy-back devices
• Measuring voltage drop. Performing this test
Testers beside a DMM will only work in one scenario, correctly will give you understanding of how
and slight variables can provide you with misleading electrical pressure (voltage) varies in a circuit as
results. The testing practices described in this chapter current is flowing. Testing Voltage Droppage 10.141
are more certain and rely only on the DMM and your
knowledge.

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CONNECTOR PROBING GUIDELINES For a video demonstration, scan the QR code below, or
right click it and select “open in new tab”.
FRONT PROBING
Front probing is accomplished by pulling the harness
connector from the component, and then taking a
measurement from the terminal face. This is the
measurement taken in most situations.
The terminals in electrical connectors are small and
fragile. Do not probe directly with your meter leads, as
the meter leads are larger than almost all terminals.
Probing with a meter lead will likely damage the
terminal by spreading it beyond it’s design limits,
causing no tension. If there is no tension, you will have
either no connection or a poor connection.
BACK PROBING
To avoid causing damage, use of the appropriate
Back probing is typically not advisable on sealed
adapters is required. Most terminals used on Polaris
connectors, as it can easily cause damage to the wire,
machines can be tested using terminal test kit PV–
terminal, connector body, or body to wire seal.
43526. It includes male and female adapters that can
be plugged into banana connectors to adapt to your
NOTICE
meter.
There are commercially available back probe kits.
Fine, narrow needles with no coating to block current
flow also work well for back probing.

If back probing must be done to see voltage drop

while current is flowing in the circuit (dynamic
testing), ensure it is done only on connectors that are
large enough to accommodate the probe. Ensure back
probing is done gently and carefully. Ensure no
damage has been done after probing.
For a video demonstration, scan the QR code below, or
right click it and select “open in new tab”.

PV–43526 adapters are also used as known good

terminal drag testers. Insert the male tester terminal
into the female connector on the harness. There
should be a noticeable amount of force to install and
remove the tester, and you should be able to tip the
harness connector with the tester hanging from the
connector, and not have the tester fall out.
If very little or no resistance is felt, or if the tester falls
out when the connector is held upside down, this is an
indication that the female connector in the harness has
BREAK OUT
insufficient tension and will cause connection issues. This is a method of front probing to achieve the goal of
You can either replace that harness, or service it by back probing, which is to measure the circuit while it
replacing the terminal or attempting to adjust/tighten is functioning.
the tang in the female terminal. You can use test probe kit PV–43526, test leads, and
electrical tape to create a bridge with exposed testing
areas to have everything exposed but still working.
IMPORTANT
Use electrical tape to cover the exposed conductive
parts of the circuit, mainly the clamps of your test
leads. If they contact each other, circuit or
component damage could occur from a short.

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T E S T I N G C O N T I N U I T Y / R E S I S TA N C E
Testing using the Ohmmeter function of your DMM is
one of the first things you will do when troubleshooting
an electrical issue. It is especially convenient when the
wiring diagram provides a resistance spec for the
component in the circuit you are diagnosing. It can
quickly give you a good idea if you simply need to
replace a part, or if there might be another circuit
issue.
Using the following points in conjunction with your
DMM owner’s manual will ensure your resistance
testing is always accurate:
• Only measure resistance on an isolated part of the
circuit. This means if you are testing internal
resistance of a component, it cannot be connected
to the harness. If you are measuring a wire (typically
from the ECU to a sensor) both the sensor and ECU
would need to be unplugged. Most Ohmmeters
provides a precise amount of current to determine
resistance. Any other sources will make your
reading inaccurate.
• Ensure you are making good contact by using the
proper terminal adapters. Connector Probing
Guidelinespage 10.136
• If you are not using a self ranging meter, double
check your range setting.
• If your continuity is under 1 ohm, leave the harness
disconnected and move on to Testing For A Short To
Groundpage 10.138 and Testing For A Short To
Voltagepage 10.139.
For a video demonstration, scan the QR code below, or
right click it and select “open in new tab.”

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TESTING FOR A SHORT TO GROUND 9. If the DMM reads OL, there is no short to ground.
Shorts to ground happen when the current flowing in a Leave the harness disconnected on both sides, and
given circuit bypasses the load. The current flowing proceed to check for a short to voltage. Testing For
from B+ finds an easier way to return to ground (B-), so A Short To Voltagepage 10.139
much more of it can flow than the circuit is designed For a video demonstration, scan the QR code below, or
for. This causes the circuit’s protection device (either a right click it and select “open in new tab”.
fuse or circuit breaker) to open, protecting the circuit
from damage.
There are many possible causes of a short to ground,
here are some:
• The harness rubbing against a component that is
grounded, such as the frame, chassis component, or
engine.
• A component’s internal circuitry contacting its case.
• Wire-to-wire chaffing causing contact with the
conductor of a ground side circuit.
• Corrosion/moisture in a component providing a
ground path.
• Moisture in a connector body providing a ground
path.

NOTICE
This test is typically done right after checking
continuity from sensor to ECU when diagnosing an
EFI DTC. It can also be used to help diagnose
concerns about blowing fuses. Ensure you are able to
duplicate the concern before testing so that your
results point you in the right direction.Testing for
Intermittent Conditionspage 10.139

TESTING PROCEDURE
1. Consult the wiring diagram. Determine which
circuit you will be testing.
2. Ensure that any static voltage checks advised in
relation to the DTC or concern you are diagnosing
have been performed and are in spec.
3. Ensure you have checked continuity of the circuit.
Testing Continuity / Resistancepage 10.137
4. Ensure that neither end of the circuit is connected.
5. Set your DMM to Ohms.
6. Connect one meter lead securely to the battery
negative post.
7. Connect the other lead to either end of the
disconnected circuit. Ensure you are using the
correct adapter.Connector Probing
Guidelinespage 10.136
8. If there is continuity, the harness is damaged and
should be repaired or replaced.

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T E S T I N G F O R A S H O R T T O V O LTA G E TESTING FOR INTERMITTENT CONDITIONS

There are three possible short to voltage causes: Intermittent conditions are very difficult to diagnose,
as when you are testing the circuit, you may not have
1. Internal electronic component short.
the circuit failing to indicate where the issue is.
2. Harness chaffing leading to contact of the circuit Intermittent electrical failures are almost always
being diagnosed to one with B+ or a different related to a poor connection that only goes open in
reference voltage. specific situations, such as going over a certain kind of
bump, at a certain temperature, or when the machine
3. Moisture in a connector or component. is torque loaded in one way.

TESTING PROCEDURE Here is a list of possible failures that can be associated

with an intermittent electrical failure:
1. Consult the wiring diagram. Determine which
circuit you will be testing. • Loose female terminal in an electrical connector.

2. Ensure that any static voltage checks advised in NOTICE

relation to the DTC or concern you are diagnosing If the terminals in question are the correct size/
have been performed and are in spec. series, always use PV–43526 to test the drag when
3. Ensure you have checked continuity of the circuit. inserting and removing the test terminal adapters.
Testing Continuity / Resistancepage 10.137 Compare the effort to the drag against the known
good tester terminal for reference.
4. Ensure you have checked for a short to ground.
Testing For A Short To Groundpage 10.138
• Poor terminal to wire crimp.
5. Ensure that neither end of the circuit is connected.
• Terminal crimp that occurred at least partially on
6. Set your DMM to DC volts. insulation instead of the conductor wire strands.
7. Connect one meter lead securely to the battery • Terminal fretting corrosion
negative post.
• Contamination/moisture corrosion
8. Connect the other lead to either end of the
disconnected circuit. Ensure you are using the • A full or partial break of the conductor wires in the
correct adapter.Connector Probing insulation, with or without visible insulation damage.
Guidelinespage 10.136 • Improper routing, especially when it leads to
9. If there is voltage present, the harness is damaged chaffing or heat damage, especially near exhaust.
and should be repaired or replaced. You may need
to remove the protective tape and tubing to You may need to use different techniques to duplicate
inspect. these concerns. These include but are not limited to:
10. If the DMM reads 0 volts, the concern may be in a • Moving the harness by wiggling it or flexing certain
component related to the circuit. If so, checking areas.
internal continuity of non-electronic components
may reveal the concern, but diagnosis at this point • Pulling at or near the suspected connector.
may require using known good parts. • Pushing in different directions to flex the connector
For a video demonstration, scan the QR code below, or body and try to isolate poor connections.
right click it and select “open in new tab”. • Changing the temperature. This can be
10
accomplished with either heat guns or cold air guns.

WARNING
Always exercise caution when using these tools, and
use them for short periods of time when changing the
temperature of an area. Failure to do so can lead to
serious injury and/or damage to the machine.

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TESTING CURRENT FLOW (AMPERAGE) T E S T I N G PA R A S I T I C D R A W

Performing a current flow test requires the meter leads Parasitic draw is when there is excessive current flow
be inserted into the correct cavities in the meter, and with the key off.
be placed in series in the circuit to be tested. Refer to
While the most common causes of draws are
your Digital Multi Meter’s owner’s manual for potential
improperly installed accessories (tapping into un-
model specific instructions. Ensure you are using
switched B+ instead of switched) there can be
acceptable adapters to avoid damaging the connector
electronic component failures that can cause this as
terminals. See Connector Probing Guidelinespage
well.
10.136.
TESTING PROCEDURE
NOTICE
1. Remove the negative cable from the battery.
Amperage specs are generally not provided for
circuits/components. Please only perform this test 2. Connect a jumper from the negative battery cable
when advised in the manual. terminal to the negative battery post.
3. Ensure your meter leads and selector dial are set to
IMPORTANT measure amperage.
Many circuits on this machine will exceed the 10 4. Connect your red lead to the battery negative
Amp fuse in most Digital Multi Meters in normal cable terminal.
operation.
5. Connect your black lead to the battery negative
post.
6. Momentarily key the ignition switch on, then off.
IMPORTANT
Ensure all electrical components are switched off, or
damage to your jumper and/or meter will occur.

NOTICE
Wait ten minutes with the key off for the ECU to
power down to avoid a faulty readout while testing
amperage draw.

7. Wait 10 minutes before checking the value.

Vehicles will vary, but electronic components will
take time to fully go to sleep after switched power
is removed.
8. Maximum allowable is 10 milliamps. If your meter
is ranged to the 10 Amp scale, this will appear as
0.010 Amps.
9. If over 10 milliamps, go to the fuse block and start
systematically removing one fuse at a time until the
value drops, indicating the circuit that requires
attention.

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T E S T I N G V O LTA G E D R O P
NOTICE
If you disconnect the connector at the load, and
measure voltage with one lead on the power supply
wire, and one to ground, you will be measuring
available voltage. This is a static test and not dynamic
voltage drop testing. Refer to Static and Dynamic
Testingpage 10.135.

The measurement of voltage is the DIFFERENCE in

electrical pressure between the two points your DMM
leads are touching.
Most circuits will have one load. The load is the
component in the circuit that uses the current flow to
do work, such as move a solenoid or light a bulb.
Voltage coming into the load should be near battery
voltage with current flowing. There will be some loss
from moving through electrical contacts in connectors
and relays, but it will be minimal.
NOTICE
You will need to backprobe to perform this test. For
information about doing this safely, refer to
Connector Probing Guidelinespage 10.136.

Voltage should be near fully depleted by the load.

This means that when measuring on the ground side of
the circuit, immediately after the load, back to battery
negative, you should have near zero pressure
difference (voltage).
If you do have a difference in pressure, this means
there is something adding resistance to the circuit
such as corrosion.
For a video demonstration, scan the QR code below, or
right click it and select “open in new tab”.

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NOTES

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A Wiring Diagrams
Topics Covered in this Appendix

A.1 Wiring Diagrams

Main wiring diagrams can be found tucked into the back of the printed manual.
Click on the links below to view wiring diagrams electronically.

2017–2018: Click HERE

2019: Click HERE

2020: Click HERE

2021: Click HERE

143
 INDEX

A Rocker Assembly ........................................... 8.54-8.55

ABS
Saddlebag .................................................... 7.19-7.20 I-
Seat (All Models Except Roadmaster) ........................ 7.9
Trouble Code List..................................................9.17
ABS Battery Voltage Fault ...........................................9.17
Seat (Chieftain) .....................................................7.11 X
Seat (Roadmaster) .................................................7.10
ABS Module Shock, Rear ................................................... 8.51-8.52
Replacement ........................................................9.20 Side Panels............................................................ 7.8
ABS System Starter Motor / Solenoid .........................................10.8
Special Tools ......................................................... 9.4 Stator ..................................................................10.9
Air Box Suspension, Front ..................................................8.10
Assembly View .....................................................4.12 Swingarm.............................................................8.56
Installation ............................................................ 3.6 Torque Compensator .............................................. 5.6
Removal................................................................ 3.4 Transmission ......................................................... 6.9
Air Filter Triple Clamp ................................................. 8.11-8.12
Replacement ........................................................2.20 Trunk ........................................................... 7.12-7.13
Alarm System Wheel (Cast), Front ........................................ 8.13-8.14
Overview ........................................................... 10.46 Wheel (Spoked), Front ...........................................8.15
Alarm, Operation / Diagnostics .............................. 10.103 Authentication
Angle Sensor Key Fob ............................................................. 10.44
Testing ............................................................ 10.125 Axle Inspection
Assembly View Front ...................................................................8.23
ABS Module..........................................................9.12 Axle, Rear
Air Box ................................................................4.12 Inspection ............................................................8.68
Balance Shaft ........................................................6.12
Battery Box......................................................... 10.11
Brake Caliper, Front...............................................9.10
Brake Caliper, Rear ...............................................9.11 B
Brake Line Routing.................................................. 9.7 Balance Shaft
Cam Chain ...........................................................3.48 Assembly View .....................................................6.12
Camshafts ............................................................3.49 Installation ...........................................................6.17
Clutch .................................................................. 5.8 Removal...............................................................6.16
Clutch Pinion Shaft.................................................. 5.5 Special Tools ......................................................... 6.3
Crankcase........................................................ 6.6-6.7 Specifications ........................................................ 6.4
Cylinder ..............................................................3.97 Battery
Cylinder Head ......................................................3.51 Assembly View ................................................... 10.11
Exhaust.............................................................. 3.113 Current Drain Test ............................................... 10.33
Fairing (Chieftain / Roadmaster) ..............................7.17 Inspection .......................................................... 10.19
Fairing (Chieftain Dark Horse).................................7.16 Installation ..................................................2.47, 10.13
Fairing (Chieftain) .................................................7.18 Load Test ........................................................... 10.25
Fenders ........................................................... 7.4-7.5 Maintenance.........................................................2.42
Floorboards........................................................... 7.7 Removal......................................................2.46, 10.12
Foot Pegs .............................................................. 7.7 Safety Precautions .................................................10.5
Fork ....................................................................8.10 Battery Box
Frame................................................................... 7.6 Assembly View ................................................... 10.11
Front Brake............................................................ 9.5 Installation ......................................................... 10.15
Front Master Cylinder ............................................. 9.8 Removal............................................................. 10.14
Front Wheel (Cast) ......................................... 8.13-8.14 Battery Charging.............................................2.43, 10.16
Front Wheel (Spoked) ............................................8.15 Battery Maintenance ........................................2.43, 10.16
Front Wheel Speed Sensor......................................9.13 Bearing Clearance Inspection ....................................6.32
Fuel System ........................................................... 4.9 Bearing Selection
Fuel Tank .............................................................4.11 Connecting Rod ....................................................6.33
Handlebar............................................................. 8.9 Belt
Handlebar Controls ........................................... 8.7-8.8 Adjustment...........................................................2.52
Lifters / Pushrods ..................................................3.50 Alignment ............................................................2.52
Lower Fairing........................................................7.15 Inspection .................................................... 2.48, 8.57
Lubrication System ................................................3.33 Installation ...........................................................8.57
Motor Mounts .......................................................3.11 Removal...............................................................8.57
Nacelle (Vintage / Springfield) ................................7.21 Specifications .......................................................2.49
Oil Cooler ............................................................3.29 Tension Measurement ............................................2.50
Oil Filter Adapter ..................................................3.30 Belt Tension
Piston ..................................................................3.97 Specification.........................................................2.51
Primary Cover ....................................................... 5.4 Body
Rear Master Cylinder.............................................. 9.9 Service Notes ........................................................ 7.3
Rear Suspension.............................. 8.47, 8.49, 8.51-8.52 Special Tools ......................................................... 7.3
Rear Wheel ..........................................................8.53 Brake Bleeding Precautions........................................9.21
Rear Wheel Speed Sensor.......................................9.14 Brake Disc, Front
Regulator / Rectifier............................................. 10.10 Removal / Installation.............................................8.24

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Brake Disc, Rear Brake System, Rear Brake Pads

Removal / Installation.............................................8.70 Replacement ........................................................9.26
Brake Fluid Brake System, Rear Brakes
Changing.............................................................9.22 Bleeding ..............................................................9.22
Brake Fluid Replacement ...........................................9.21 Brake System, Rear Caliper
Brake Lever Assembly View .....................................................9.11
Inspection, Front ...................................................2.31 Brakes
Lubrication, Front ..................................................2.31 ABS Trouble Codes................................................9.17
Reach, Front .........................................................2.32 ABS Troubleshooting..............................................9.17
Brake Lever Reserve Inspection ..................................9.24 Brake Pad Inspection, Front.....................................2.36
Brake Light Brake Pad Inspection, Rear .....................................2.37
Operation Overview ............................................ 10.78 Brake Pedal, Inspection ..........................................2.32
Removal / Installation........................................... 10.78 Brake Pedal, Lubrication.........................................2.32
Brake Light Switch CHMSL Replacement ........................................... 10.80
Testing ............................................................ 10.125 Fluid Level Inspection ............................................2.35
Brake Light, Center................................................. 10.80 Front Brake Lever, Inspection ..................................2.31
Brake Line Routing Front Brake Lever, Lubrication .................................2.31
Assembly View ...................................................... 9.7 Front Brake Lever, Reach ........................................2.32
Brake Pads, Front Braking System
Replacement ........................................................9.25 ABS Overview of Operation.....................................9.16
Brake Pads, Rear ABS System Components ........................................9.16
Replacement ........................................................9.26 Break-In, Engine ......................................................2.19
Brake Pedal Breather
Inspection ............................................................2.32 Inspection ............................................................2.37
Lubrication...........................................................2.32
Brake System
ABS Brake Fluid Change .........................................9.22
ABS General Information ........................................9.15
C
ABS Module Replacement .......................................9.20 Caliper, Front
ABS System Safety Precautions ................................9.15 Assembly View .....................................................9.10
ABS Wiring Diagram ................................ 10.127-10.128 Installation ...........................................................9.32
Front Caliper Installation ........................................9.32 Rebuilding ...........................................................9.30
Front Caliper Service .............................................9.30 Removal...............................................................9.30
Front Master Cylinder ............................................. 9.8 Caliper, Rear
Front Master Cylinder Service .................................9.28 Assembly View .....................................................9.11
Lever Reserve Inspection........................................9.24 Installation ...........................................................9.36
Precautions ..........................................................9.21 Rebuilding ...........................................................9.34
Rear Caliper Installation .........................................9.36 Removal...............................................................9.34
Rear Caliper Service..............................................9.34 Cam Chain
Rear Master Cylinder.............................................. 9.9 Assembly View .....................................................3.48
Rear Master Cylinder Service..................................9.33 Installation ...........................................................3.62
Service Notes ........................................................ 9.3 Removal...............................................................3.61
Service Specifications ............................................. 9.4 Cam Chain Cover
Special Tools ......................................................... 9.4 Installation ...........................................................3.55
Troubleshooting....................................................9.37 Removal...............................................................3.55
Vacuum Bleeder....................................................9.21 Cam Chain Guide
Wheel Speed Sensor Adjustment (Air Gap) ...............9.19 Installation ...........................................................3.60
Wheel Speed Sensor Replacement ...........................9.18 Removal...............................................................3.59
Brake System Disc, Rear Cam Chain Tensioner
Removal / Installation.............................................8.70 Inspection ............................................................3.57
Brake System, ABS Module Installation ...........................................................3.58
Assembly View .....................................................9.12 Removal...............................................................3.56
Brake System, Disc Cam Chain, Inner Cover
Inspection ............................................................9.27 Installation ...........................................................6.19
Brake System, Front Removal...............................................................6.16
Assembly View ...................................................... 9.5 Camshaft
Disc Removal / Installation ......................................8.24 Carrier Assembly..................................................3.69
Brake System, Front Brake Pads Carrier Disassembly ..............................................3.66
Replacement ........................................................9.25 Carrier Installation ................................................3.72
Brake System, Front Brakes Carrier Removal....................................................3.65
Bleeding ..............................................................9.23 Inspection ............................................................3.68
Brake System, Front Caliper Removal - In Bike...................................................3.73
Assembly View .....................................................9.10 Synchronization ....................................................3.69
Brake System, Line Routing Timing......................................................... 3.53, 3.69
Assembly View ...................................................... 9.7 Camshaft Bearings
Brake System, Rear Assembly View .....................................................3.49
Assembly View ...................................................... 9.6 Camshaft Carrier

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Assembly.............................................................3.69 Specifications ........................................................ 6.4

Disassembly .........................................................3.66 Controller Area Network I-
Installation ...........................................................3.72 Resistance Values ..................................................4.62
Removal...............................................................3.65 Controls X
Camshafts Assembly View ................................................. 8.7-8.8
Installation - In Bike ...............................................3.76 Conversion Chart
Camshafts, Assembly View ........................................3.49 Metric .................................................................1.63
CAN Diagnostics ......................................................4.62 Conversion Charts....................................................1.64
Carbon Canister ......................................................2.38 Measurement........................................................1.66
Cell Modem SAE .....................................................................1.63
Installation ....................................................... 10.111 Temperature.........................................................1.65
Removal........................................................... 10.111 CPS
Troubleshooting................................................ 10.112 Test / Replace .......................................................4.57
Center Brake Light ................................................. 10.80 Crankcase
Charging System Assembly.............................................................6.40
Output Test......................................................... 10.33 Assembly View ...................................................... 6.6
Service Notes .......................................................10.5 Assembly, Left Side................................................6.37
Service Specifications ............................................10.7 Assembly, Right Side .............................................6.37
Special Tools ........................................................10.6 Disassembly .........................................................6.23
Troubleshooting.................................................. 10.32 Fastener Location ................................................... 6.8
Cleaning............................................................. 10.113 Resealing .............................................................6.40
Clutch Separation............................................................6.23
Assembly.............................................................5.20 Torque Sequence ................................................... 6.8
Assembly View ...................................................... 5.8 Crankcase Emission Control ......................................1.46
Disassembly .........................................................5.17 Crankcase Ventilation
Inspection ............................................................5.19 Inspection ............................................................2.37
Installation ...........................................................5.21 Crankshaft
Pinion Shaft Bearing Inspection................................5.10 Assembly View ...................................................... 6.7
Pinion Shaft Installation ..........................................5.11 Cleaning..............................................................6.36
Pinion Shaft Removal..............................................5.10 Inspection ............................................................6.34
Pinion Shaft Seal Replacement .................................5.10 Installation ...........................................................6.38
Rack, Removal / Installation ....................................5.16 Locking for Service................................................3.54
Removal...............................................................5.16 Main Bearing Inspection .........................................6.36
Service Notes ........................................................ 5.2 Main Bearing Oil Clearance ....................................6.36
Special Tools ......................................................... 5.2 Removal...............................................................6.29
Specifications ........................................................ 5.3 Service Notes ........................................................ 6.3
Troubleshooting....................................................5.26 Special Tools ......................................................... 6.3
Clutch Cable Specifications ........................................................ 6.4
Lubrication...........................................................2.29 Troubleshooting....................................................6.44
Removal / Installation.............................................8.20 Crankshaft Position Sensor
Clutch Lever Test / Replace .......................................................4.57
Free Play Adjustment .............................................2.30 Cross Over Pipe
Lubrication...........................................................2.30 Installation ......................................................... 3.120
Clutch Pinion Shaft Removal............................................................. 3.116
Assembly View ...................................................... 5.5 Cruise Control
Clutch Rack Diagnostics ...................................................... 10.102
Removal / Installation.............................................5.16 Overview / Operation ........................................ 10.101
Clutch Switch Troubleshooting................................................ 10.102
Circuit Test......................................................... 10.29 Current Drain
Removal / Installation........................................... 10.29 Testing .............................................................. 10.33
Testing ............................................................ 10.125 Cylinder
Coil, Ignition Assembly View .....................................................3.97
Removal / Installation........................................... 10.53 Bore Measurement............................................... 3.101
Compression Test Inspection .......................................................... 3.100
Engine.................................................................2.41 Installation ......................................................... 3.110
Compression Test (Wet) Misfire .................................................................4.60
Engine.................................................................2.42 Removal...............................................................3.99
Connecting Rod Service Notes .......................................................3.94
Bearing Clearance Inspection .................................6.32 Special Tools ........................................................3.95
Bearing Inspection ................................................6.31 Specifications .......................................................3.96
Bearing Selection ..................................................6.33 Stud Replacement ............................................... 3.109
Inspection ...................................................3.106, 6.30 Warpage Measurement ........................................ 3.103
Inspection, Big End................................................6.31 Cylinder / Piston
Installation ...........................................................6.34 Troubleshooting.................................................. 3.111
Removal...............................................................6.30 Cylinder Deactivation ...............................................4.61
Side Clearance .....................................................6.30 Cylinder Head
Connecting Rods Assembly.............................................................3.89

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Assembly View .....................................................3.51 E

Disassembly .........................................................3.82
Inspection ............................................................3.83 ECM
Installation ...........................................................3.90 Connector Map .....................................................4.30
Removal...............................................................3.79 Connectors ..........................................................4.41
Special Tools ........................................................3.45 Disconnect ...........................................................4.41
Cylinder Head / Valve Train Pinout Chart .........................................................4.30
Service Notes .......................................................3.44 Pinout Testing .......................................................4.40
Cylinder Head / Valves Reflash Procedure .................................................4.67
Specifications .......................................................3.46 Removal / Installation.............................................4.41
Troubleshooting....................................................3.91 ECM Replacement Information ...................................4.63
Cylinder Head Temperature Sensor EFI
Replacement ........................................................4.43 Service Notes ........................................................ 4.3
Test.....................................................................4.43 Service Precautions ................................................ 4.5
Cylinder Studs Special Tools ......................................................... 4.4
Replacement ...................................................... 3.109 Specifications ........................................................ 4.4
Electrical
Connector Probing Guidelines ............................ 10.136
Continuity / Resistance....................................... 10.137
D Digital Multi-Meter (DMM).................................. 10.135
Detonation Sensor Service Notes ................................................... 10.135
Test / Replace .......................................................4.58 Static and Dynamic Testing ................................. 10.135
Diagnostic Trouble Codes (DTC) ................................4.32 Testing Current Flow (Amperage) ........................ 10.140
Digital Wrench Testing For A Short To Ground ............................. 10.138
Communication Errors ...........................................4.63 Testing For A Short To Voltage ............................. 10.139
Diagnostic Connector ............................................4.64 Testing for Intermittent Conditions ....................... 10.139
ECM Reflash .........................................................4.67 Testing Parasitic Draw ........................................ 10.140
ECM Replacement.................................................4.63 Testing Voltage Drop ......................................... 10.141
Feature Map .........................................................4.66 Electrical System
Guided Diagnostics ...............................................4.63 Service Notes ..................................................... 10.54
Overview .............................................................4.63 Special Tools ...................................................... 10.54
Serial Number Location ..........................................4.64 Electronic Fuel Injection (EFI)
Update Information................................................4.63 Sensor Locations ...................................................4.13
Update Process .....................................................4.65 Electronic Throttle Control Module
Version Updates....................................................4.64 Removal...............................................................4.59
Discs, Brake Emission Control Systems ..........................................1.46
Inspection ............................................................9.27 Emission Sources .....................................................1.46
Drill Sizes Engine
Metric .................................................................1.63 Compression Test..................................................2.41
SAE .....................................................................1.63 Compression Test (Wet) .........................................2.42
Drive Belt Installation ...........................................................3.19
Adjustment...........................................................2.52 Limiting / Misfire ...................................................4.60
Alignment ............................................................2.52 Locking the Crankshaft...........................................3.54
Inspection .................................................... 2.48, 8.57 Oil / Filter Change.................................................2.20
Installation ...........................................................8.57 Oil Level ..............................................................2.24
Removal...............................................................8.57 Primary Drive Gear ................................................ 5.7
Specifications .......................................................2.49 Primary Drive Gear Installation ...............................5.24
Tension Measurement ............................................2.50 Primary Drive Gear Removal...................................5.24
Tension Specifications............................................2.51 Specifications ........................................................ 3.9
Drive Gear Timing.................................................................3.53
Inspection ............................................................6.20 Engine Break-In Procedure ........................................2.19
Installation ...........................................................6.21 Engine Number Location ............................................ 1.3
Removal...............................................................6.20 Engine Removal
Drive Sprocket Preliminary Steps ..................................................3.13
Inspection ............................................................8.60 Removing Engine from Frame .................................3.15
Installation ...........................................................8.61 Service Notes ........................................................ 3.8
Removal...............................................................8.58 Special Tools ........................................................3.10
Drive Sprocket, Cover EVAP System ...........................................................2.38
Removal / Installation.............................................8.58 Evaporative Emissions Control ...................................1.46
Driven Sprocket Evaporative Emissions System....................................2.38
Bearing Replacement.............................................8.63 Evaporative System
Inspection ............................................................8.62 Line Routing, 49 State .............................................. 4.7
Installation ...........................................................8.65 Line Routing, CA .................................................... 4.8
Removal...............................................................8.62 Exhaust
Dynamic Assembly View ................................................... 3.113
Testing ............................................................ 10.135 Installation .................................................3.119-3.120
Muffler Removal .................................................. 3.115

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Removal.................................................... 3.116, 3.118 Removal...............................................................7.42

Exhaust Emission Control ..........................................1.46 Front Fender I-
Installation .................................................... 7.34-7.35
Removal....................................................... 7.33, 7.35 X
F Front Fork
Inspection ............................................................8.30
Fairing (Chieftain / Roadmaster) Front Wheel
Assembly View .....................................................7.17 Bearing Inspection ................................................8.24
Fairing (Chieftain / Roadmaster), Inner Inspection ............................................................8.23
Installation ...........................................................7.61 Removal / Installation.............................................8.22
Removal...............................................................7.60 Front Wheel (Cast)
Fairing (Chieftain / Roadmaster), Outer Assembly View .............................................. 8.13-8.14
Installation ...........................................................7.62 Front Wheel (Spoked)
Removal...............................................................7.58 Assembly View .....................................................8.15
Fairing (Chieftain Dark Horse) Front Wheel & Suspension
Assembly View .....................................................7.16 Troubleshooting....................................................8.42
Fairing (Chieftain Dark Horse), Inner Front Wheell
Installation ...........................................................7.55 Bearing Replacement.............................................8.25
Removal...............................................................7.54 Fuel Injection
Fairing (Chieftain Dark Horse), Outer Overview of Operation ...........................................4.29
Installation ...........................................................7.56 Fuel Injector
Removal...............................................................7.52 Installation ...........................................................4.49
Fairing (Chieftain) Removal...............................................................4.49
Assembly View .....................................................7.18 Resistance Test .....................................................4.49
Fault Codes .............................................................4.32 Fuel Level Sensor
Fender, Front Resistance Test .....................................................4.25
Installation .................................................... 7.34-7.35 Fuel Line
Removal....................................................... 7.33, 7.35 Routing, 49 State..................................................... 4.7
Fender, Rear Routing, CA ........................................................... 4.8
Installation ...........................................................7.41 Fuel Pressure
Removal...............................................................7.40 Inspection ............................................................4.15
Fenders Specification.........................................................4.15
Assembly View ................................................. 7.4-7.5 Test.....................................................................4.15
Final Drive Fuel Pump
Troubleshooting....................................................8.82 Current Draw Test .................................................4.27
Floorboards Installation ...........................................................4.21
Assembly View ...................................................... 7.7 Pressure Test ........................................................4.15
Installation ...........................................................7.24 Removal...............................................................4.19
Removal...............................................................7.23 Supply Voltage Test ...............................................4.26
Flywheel Fuel Rail
Installation ...........................................................5.25 Installation ...........................................................4.50
Removal......................................................5.25, 10.38 Removal...............................................................4.44
Foot Pegs Fuel System
Assembly View ...................................................... 7.7 Assembly View ...................................................... 4.9
Foot Pegs (Passenger) Depressurization ...................................................4.16
Installation ...........................................................7.26 EFI Overview........................................................4.29
Removal...............................................................7.26 Inspection ............................................................2.39
Fork Line Routing, 49 State .............................................. 4.7
Assembly.............................................................8.31 Line Routing, CA .................................................... 4.8
Assembly View .....................................................8.10 Priming ...............................................................4.28
Disassembly .........................................................8.27 Service Notes ........................................................ 4.3
Installation ...........................................................8.36 Service Precautions ................................................ 4.5
Removal...............................................................8.25 Special Tools ......................................................... 4.4
Fork Lock Specifications ........................................................ 4.4
Removal / Installation.............................................8.39 Troubleshooting....................................................4.69
Frame Fuel Tank
Assembly View ...................................................... 7.6 Assembly View .....................................................4.11
Front Casting, Installation .......................................7.44 Installation ...........................................................4.24
Front Casting, Removal...........................................7.42 Mounting .............................................................4.11
Service Notes ........................................................ 7.3 Removal...............................................................4.17
Special Tools ......................................................... 7.3 Vent Inspection (49 State) .......................................2.38
Front Axle Vent Inspection (CA)..............................................2.38
Inspection ............................................................8.23 Fuse Box
Front Brake Fuse Application Chart................................ 10.58, 10.60
Assembly View ...................................................... 9.5 Location...............................................................2.54
Front Casting (Main Frame) Locations ........................................................... 10.57
Installation ...........................................................7.44 Fuses

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Location...............................................................2.54 Test Flowchart..................................................... 10.49

Replacement ........................................................2.54 Testing Precautions.............................................. 10.48
Troubleshooting Basics ........................................ 10.48
Inspection .................................................... 2.39, 10.124
G Rear Axle .............................................................8.68
Installation
Gear Position Switch ............................................. 10.113 Cylinder ............................................................ 3.110
Neutral Indicator Test........................................... 10.26 Engine.................................................................3.19
Test................................................................. 10.119 Muffler .............................................................. 3.122
Troubleshooting................................................ 10.120 Piston ................................................................ 3.108
Gear Ratios .............................................................. 6.4 Piston Ring ......................................................... 3.107
General Information Instrument Cluster
Engine.................................................................3.44 Overview, Chief Classic / Chief Vintage / Chief Dark
Tire Changing.......................................................8.99 Horse / Springfield ............................................ 10.85
Gross Vehicle Weight Rating (GVWR) ..........................1.40 Overview, Chieftain Dark Horse............................. 10.90
Guided Diagnostics ..................................................4.63 Instrument Panel
Removal / Installation.............................................7.47
Instrument Panel (Chieftain Dark Horse)
H Removal / Installation.............................................7.57
Intake Manifold
Halogen Headlight Lens Removal / Installation.............................................4.14
Compliance Markings .......................................... 10.67
Handlebar
Assembly View ...................................................... 8.9 K
Removal / Installation..................................... 8.16, 8.18
Head Light Key Fob
Assembly View ................................................... 10.55 Authentication .................................................... 10.44
Head Pipe Operation and Programming................................. 10.42
Installation ......................................................... 3.119 Overview ........................................................... 10.41
Removal............................................................. 3.118 Troubleshooting.................................................. 10.44
Headlight Knock Sensor
Aim Inspection......................................................2.55 Test / Replace .......................................................4.58
Bulb Replacement ............................................... 10.66
Warning / MIL 2014 ............................................. 10.72
Warning 2015 ..................................................... 10.72 L
Headlight Aim
Adjustment...........................................................2.56 License Plate Light
Headlight Lens Assembly View ................................................... 10.56
Replacement, Fairing Models ................................ 10.68 Removal / Installation........................................... 10.78
Replacement, Non-Fairing Models ......................... 10.69 Lifter
Highway Bars Installation ...........................................................3.64
Installation ...........................................................7.29 Lifters
Removal...............................................................7.29 Assembly View .....................................................3.50
Horn Removal...............................................................3.63
Removal / Installation.................................. 10.75, 10.77 Lock Replacement
Horn Service Trunk ..................................................................7.38
Breakout Diagram....................................... 10.74, 10.76 Lower Fairing
General Overview ...................................... 10.73, 10.75 Assembly View .....................................................7.15
Lower Fairing (Roadmaster)
Installation ...........................................................7.31
I Removal...............................................................7.30
Lubricants ................................................................ 2.5
Idle Speed Lubrication System
Adjustment...........................................................2.24 Assembly View .....................................................3.33
Ignition Coil
Power and Ground Signal Test ............................... 10.51
Removal / Installation........................................... 10.53
Resistance Test ................................................... 10.52
M
Ignition System Main Bearing
Service Notes ..................................................... 10.47 Inspection ............................................................6.36
Service Specifications .......................................... 10.47 Oil Clearance Inspection ........................................6.36
Special Tools ...................................................... 10.47 Maintenance
Test 1: Battery Voltage Inspection........................... 10.50 Engine Break-In Procedure .....................................2.19
Test 2: Spark....................................................... 10.50 Service Notes .......................................................2.19
Test 3: Ignition Cable Resistance............................ 10.50 Special Tools ........................................................2.19
Test 4: Ignition Coil Power and Ground Signal .......... 10.51 Specifications ........................................................ 2.3
Test 5: Ignition Coil Resistance .............................. 10.52 Maintenance Interval Chart......................................... 2.6

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Manufacturer Label Location ....................................... 1.3 P

Master Cylinder, Front
P-Codes..................................................................4.32
I-
Assembly View ...................................................... 9.8
Rebuilding ...........................................................9.28 Passenger Foot Pegs / Blanks (Dark Horse)
Removal / Installation.............................................7.23
X
Removal...............................................................9.28
Master Cylinder, Rear PCV System
Assembly View ...................................................... 9.9 Inspection ............................................................2.37
Rebuilding ...........................................................9.33 Periodic Maintenance ................................................ 2.6
Removal...............................................................9.33 Pinion Shaft, Clutch
Misfire Detection ......................................................4.60 Bearing Inspection ................................................5.10
Model Number Decoder............................................. 1.2 Installation ...........................................................5.11
Model Number Location ............................................. 1.3 Removal...............................................................5.10
Motor Mounts Seal Replacement..................................................5.10
Assembly View .....................................................3.11 Piston
Muffler Assembly View .....................................................3.97
Installation ......................................................... 3.122 Clearance Worksheet........................................... 3.102
Removal............................................................. 3.115 Inspection .......................................................... 3.105
Installation ......................................................... 3.108
Profile & Orientation ..............................................3.98
Removal............................................................. 3.104
N Service Notes .......................................................3.94
Nacelle Special Tools ........................................................3.95
Installation ...........................................................7.50 Specifications .......................................................3.96
Removal...............................................................7.48 Piston Pin
Nacelle (Vintage / Springfield) Inspection .......................................................... 3.106
Assembly View .....................................................7.21 Piston Ring
Noise Emission Control .............................................1.46 Inspection .......................................................... 3.105
Installation ......................................................... 3.107
Profile & Orientation ..............................................3.98
Removal............................................................. 3.104
O Power Windshield
Oil Change Motor, Installation (Chieftain / Roadmaster)........... 10.110
Checking Oil Level ................................................2.24 Motor, Removal (Chieftain Dark Horse / Chieftain /
Procedure ............................................................2.20 Roadmaster) ................................................... 10.108
Oil Cooler Operation (Chieftain / Roadmaster)...................... 10.105
Assembly View .....................................................3.29 Primary Cover
Inspection ............................................................3.42 Assembly View ...................................................... 5.4
Installation ...........................................................3.43 Installation ...........................................................5.14
Removal...............................................................3.41 Removal................................................................ 5.9
Oil Filter Adapter Primary Drive
Assembly View .....................................................3.30 Service Notes ........................................................ 5.2
Oil Level Special Tools ......................................................... 5.2
Check .................................................................2.24 Specifications ........................................................ 5.3
Oil Pressure Switch Troubleshooting....................................................5.26
Test.....................................................................3.35 Primary Drive Gear ................................................... 5.7
Oil Pump 2018, 2019 engines ................................................5.24
Installation ...........................................................3.38 2018, 2019,2020 engines.......................................... 5.7
Removal...............................................................3.37 Installation ...........................................................5.24
Oiling System Removal...............................................................5.24
Assembly View .....................................................3.29 Priming the Fuel System ............................................4.28
Oil Flow Diagram ..................................................3.31 Programming
Oil Pressure Test ...................................................3.35 Key Fob ............................................................. 10.42
Service Notes .......................................................3.24 Pushrods
Special Tools ........................................................3.26 Assembly View .....................................................3.50
Specifications .......................................................3.27
Troubleshooting....................................................3.25
Operation R
Key Fob ............................................................. 10.42
Output Shaft Seal Rear Axle
Replacement ........................................................8.61 Inspection ............................................................8.68
Overview Rear Brake
Alarm System ..................................................... 10.46 Assembly View ...................................................... 9.6
Key Fob ............................................................. 10.41 Rear Fender
Owner’s Manuals Installation ...........................................................7.41
Part Numbers .......................................................1.41 Removal...............................................................7.40
Rear Sprocket
Inspection ............................................................8.62

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Installation ...........................................................8.65 Body .................................................................... 7.3

Removal...............................................................8.62 Brake System ......................................................... 9.3
Rear Suspension Clutch .................................................................. 5.2
Assembly View ............................... 8.47, 8.49, 8.51-8.52 Crankshaft ............................................................ 6.3
Rear Wheel Cylinder ..............................................................3.94
Bearing Inspection ................................................8.69 Cylinder Head / Valve Train ....................................3.44
Bearing Replacement.............................................8.70 EFI ....................................................................... 4.3
Inspection ............................................................8.68 Electrical System................................................. 10.54
Removal / Installation.............................................8.66 Engine Removal ..................................................... 3.8
Rear Wheel and Suspension Front Suspension .................................................... 8.4
Special Tools ........................................................8.44 Front Wheel .......................................................... 8.4
Reflash Authorization ................................................4.67 Fuel System ........................................................... 4.3
Regulated Voltage Test............................................ 10.33 Ignition System ................................................... 10.47
Regulator / Rectifier Maintenance.........................................................2.19
Assembly View ................................................... 10.10 Oiling System .......................................................3.24
Bracket, Replacement .......................................... 10.40 Piston ..................................................................3.94
Connector Inspection........................................... 10.39 Primary Drive ........................................................ 5.2
Diode Leakage Test ............................................. 10.39 Rear Suspension....................................................8.44
Replacement ...................................................... 10.40 Rear Wheel ..........................................................8.44
Replacement ....................................................... 10.113 Starting System .....................................................10.5
Ride Command Tires....................................................................8.83
Troubleshooting.................................................. 10.96 Transmission ......................................................... 6.3
Ride Command System Wheels ................................................................8.83
Installation ...........................................................7.66 Service Specifications
Removal...............................................................7.64 Brake System ......................................................... 9.4
Ride Height Charging System...................................................10.7
Adjustment (Air Shock) ..........................................2.62 Front Suspension .................................................... 8.5
Adjustment (Chief Models) .....................................2.61 Front Wheel .......................................................... 8.5
Inspection ............................................................2.60 Ignition System ................................................... 10.47
Rings Rear Suspension....................................................8.45
End Gap Measurement......................................... 3.105 Rear Wheel ..........................................................8.45
Installation ......................................................... 3.107 Starting System .....................................................10.7
Profile & Orientation ..............................................3.98 Shift Drum
Removal............................................................. 3.104 Assembly View .....................................................6.11
Rocker Arm Inspection ............................................................6.27
Inspection ............................................................3.81 Removal...............................................................6.26
Removal...............................................................3.80 Shift Drum Pin ...................................................... 10.124
Rocker Assembly Shift Drum Spring ................................................. 10.124
Assembly View .............................................. 8.54-8.55 Shift Fork
Assembly View .....................................................6.11
Removal...............................................................6.26
S Shift Pedal
Adjustment...........................................................2.34
Saddlebag Inspection ............................................................2.33
Assembly View .............................................. 7.19-7.20 Shift Ratchet
Seat Inspection ............................................................5.11
Assembly View ................................................. 7.4-7.5 Installation ...........................................................5.13
Seat (all except Roadmaster) Removal...............................................................5.11
Removal / Installation.............................................7.26 Shift Shaft Seal
Seat (All Models Except Roadmaster) Replacement ........................................................5.14
Assembly View ...................................................... 7.9 Shifting
Seat (Chieftain) Troubleshooting....................................................5.26
Assembly View .....................................................7.11 Shock
Seat (Dark Horse) Analysis ......................................................... 2.65, 8.6
Removal / Installation.............................................7.28 Shock Absorber
Seat (Roadmaster) Inspection ............................................................8.71
Assembly View .....................................................7.10 Installation ...........................................................8.73
Removal / Installation.............................................7.27 Removal...............................................................8.71
Security System, Operation / Diagnostics ................. 10.103 Shock, Rear
Sensor Diagnostics ...................................................4.39 Assembly View .............................................. 8.51-8.52
Sensors Preload Adjustment (Air Shock) ...............................2.62
Location...............................................................4.13 Preload Adjustment (Chief Models) ..........................2.61
Service Intervals Preload Inspection.................................................2.60
Maintenance.......................................................... 2.6 Side Cover (Lower)
Service Manuals Removal / Installation.............................................7.22
Part Numbers .......................................................1.41 Side Cover (Upper)
Service Notes Removal / Installation.............................................7.22

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Side Panels Inspection ............................................................8.62

Assembly View ...................................................... 7.8 Installation ...........................................................8.65 I-
Side Stand Switch Removal...............................................................8.62
Testing ............................................................ 10.126 Stake Nut X
Sidestand Installation ...........................................................6.43
Inspection ............................................................2.57 Starter
Lubrication...........................................................2.57 Solenoid, Ground Circuit Test................................ 10.25
Removal / Installation.............................................2.57 Starter Motor
Spark Plug Assembly View .....................................................10.8
Gap.....................................................................2.40 Current Draw Test ............................................... 10.30
Inspection ............................................................2.40 Inspection ............................................................6.20
Installation ...........................................................2.41 Installation ..................................................6.21, 10.31
Removal...............................................................2.40 Removal......................................................6.20, 10.31
Special Tools ...........................................................1.48 Safety Information ............................................... 10.20
ABS System ........................................................... 9.4 Starter Solenoid
Balance Shaft ......................................................... 6.3 Ground Circuit Test ............................................. 10.25
Body .................................................................... 7.3 Positive Circuit Test ............................................. 10.30
Brake System ......................................................... 9.4 Starting System ...................................................... 10.24
By System ............................................................1.47 Circuit Operation ........................................10.21-10.22
Charging System...................................................10.6 Diagnostic Table ................................................. 10.20
Clutch .................................................................. 5.2 Service Notes .......................................................10.5
Crankshaft ............................................................ 6.3 Service Specifications ............................................10.7
Cylinder ..............................................................3.95 Special Tools ........................................................10.6
Cylinder Head / Valves ..........................................3.45 Troubleshooting, No Crank ................................... 10.23
EFI ....................................................................... 4.4 Troubleshooting, Starter Drive............................... 10.24
Electrical System................................................. 10.54 Wiring Diagram ..........................................10.21-10.22
Engine Removal ....................................................3.10 Static
Frame................................................................... 7.3 Testing ............................................................ 10.135
Front Suspension .................................................... 8.4 Stator
Front Wheel .......................................................... 8.4 Assembly View .....................................................10.9
Fuel System ........................................................... 4.4 Ground Continuity Test ........................................ 10.36
Ignition System ................................................... 10.47 Installation ......................................................... 10.38
Locating...............................................................1.47 Output Test......................................................... 10.35
Maintenance.........................................................2.19 Removal............................................................. 10.37
Oiling System .......................................................3.26 Resistance Test ................................................... 10.36
Ordering Information.............................................1.47 Steering Head
Piston ..................................................................3.95 Bearing Adjustment ...............................................8.40
Primary Drive ........................................................ 5.2 Bearing Inspection ................................................2.59
Rear Wheel and Suspension ....................................8.44 Suspension
Starting System .....................................................10.6 Shock Analysis................................................ 2.65, 8.6
Tire Pressure Monitoring System (TPMS) ...................8.84 Suspension, Front
Tires....................................................................8.84 Assembly View .....................................................8.10
Transmission ......................................................... 6.3 Fork Assembly ......................................................8.31
Wheels ................................................................8.84 Fork Installation ....................................................8.36
Specifications Fork Removal........................................................8.25
Balance Shaft ......................................................... 6.4 Service Notes ........................................................ 8.4
Clutch .................................................................. 5.3 Service Specifications ............................................. 8.5
Connecting Rods.................................................... 6.4 Special Tools ......................................................... 8.4
Crankshaft ............................................................ 6.4 Suspension, Front Fork
Cylinder ..............................................................3.96 Disassembly .........................................................8.27
Cylinder Head / Valves ..........................................3.46 Suspension, Rear
EFI ....................................................................... 4.4 Rocker Assembly ........................................... 8.54-8.55
Engine.................................................................. 3.9 Service Notes .......................................................8.44
Fuel System ........................................................... 4.4 Service Specifications ............................................8.45
Maintenance.......................................................... 2.3 Troubleshooting....................................................8.81
Oiling System .......................................................3.27 Swing Arm
Piston ..................................................................3.96 Inspection ............................................................2.59
Primary Drive ........................................................ 5.3 Swingarm
Speedometer Assembly View .....................................................8.56
Display .............................................................. 10.92 Bushing / Bearing Replacement ...............................8.76
Sprocket Installation ...........................................................8.78
Inspection, Rear ....................................................2.53 Removal...............................................................8.74
Sprocket, Drive Switch Cube
Inspection ............................................................8.60 Replacement ...................................................... 10.83
Installation ...........................................................8.61
Removal...............................................................8.58
Sprocket, Driven

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T Torque Specifications
Master .................................................................1.52
Tachometer TPMS
Display .............................................................. 10.94 Overview .............................................................8.88
Tail Light Sensor Replacement ..............................................8.89
Assembly View ................................................... 10.56 TPMS (Chieftain / Roadmaster)
Operation Overview ............................................ 10.78 Activation.............................................................8.96
Removal / Installation........................................... 10.78 TPMS (Chieftain Dark Horse)
Throttle Body Activation.............................................................8.93
Removal...............................................................4.59 TPMS (Springfield)
Timing Marks ..........................................................3.53 Activation.............................................................8.90
Tipover Switch Trademark Information ................................................. 2
Testing ............................................................ 10.125 Transmission
Tire & Wheel Assembly View ...................................................... 6.9
Troubleshooting.................................................. 8.115 Gear Ratios ........................................................... 6.4
Tire Changing Gear Train............................................................6.13
General Information ..............................................8.99 Inspection ............................................................6.27
Tire Pressure Monitoring System Installation ...........................................................6.39
Overview .............................................................8.88 Power Flow...........................................................6.13
Sensor Replacement ..............................................8.89 Removal...............................................................6.26
Tire Pressure Monitoring System (Chieftain / Roadmaster) Service Notes ........................................................ 6.3
Activation.............................................................8.96 Special Tools ......................................................... 6.3
Tire Pressure Monitoring System (Chieftain Dark Horse) Troubleshooting....................................................6.44
Activation.............................................................8.93 Triple Clamp
Tire Pressure Monitoring System (Springfield) Assembly View .............................................. 8.11-8.12
Activation.............................................................8.90 Bearing Adjustment ...............................................8.40
Tire Pressure Monitoring System (TPMS) Installation ...........................................................8.40
Special Tools ........................................................8.84 Removal...............................................................8.38
Tire Wear Patterns ....................................................8.87 Troubleshootin
Cupping ..............................................................8.87 Cylinder / Piston ................................................. 3.111
Tires Troubleshooting
Balance Dots..................................... 8.106, 8.108, 8.110 Brake System ........................................................9.37
Balancing ........................................................... 8.112 Crankshaft ...........................................................6.44
Directional Arrows............................. 8.106, 8.108, 8.110 Cylinder Head / Valves ..........................................3.91
Inflation / Precautions ........................ 8.106, 8.108, 8.110 Final Drive ...........................................................8.82
Information ........................................................... 1.3 Front Wheel & Suspension ......................................8.42
Inspection .................................................... 2.25, 8.84 Key Fob ............................................................. 10.44
Ozone Cracking ....................................................8.87 Misfire Detection ...................................................4.60
Pressure....................................................... 2.25, 8.84 Rear Suspension....................................................8.81
Repair Precautions............................................... 8.104 Rear Wheel ..........................................................8.81
Service Notes .......................................................8.83 Ride Command ................................................... 10.96
Size Specifications ......................................... 2.25, 8.84 Tire & Wheel ...................................................... 8.115
Special Tools ........................................................8.84 Transmission ........................................................6.44
Specifications ........................................................ 1.3 Trunk
Tread Wear ..........................................................8.87 Assembly View .............................................. 7.12-7.13
Valve Stem Installation, Metal ................................ 8.105 Interior Lamp Replacement................................... 10.80
Valve Stem Installation, Rubber ............................. 8.105 Lock Replacement .................................................7.38
Valve Stem, Inspection ......................................... 8.105 Trunk (Roadmaster)
Tires (Chieftain / Roadmaster) Installation ...........................................................7.37
Installation ......................................................... 8.106 Removal...............................................................7.36
Removal............................................................. 8.100 Turn Signal
Tires (Classic / Vintage) Front, Removal / Installation (Chieftain) .................. 10.81
Installation ......................................................... 8.108 Front, Removal / Installation (Classic / Vintage) ....... 10.81
Removal............................................................. 8.101 Operation Overview ............................................ 10.81
Tires (Dark Horse) Rear, Removal / Installation (All Models) ................. 10.82
Installation ......................................................... 8.110
Removal............................................................. 8.102
TMAP Sensor
Overview .............................................................4.42 V
Replacement ........................................................4.42 Vacuum Bleeder.......................................................9.21
Tools, Special ..........................................................1.48 Valve Cover
Torque Compensator Installation ...........................................................3.78
2017 engines ......................................................... 5.6 Removal...............................................................3.77
Assembly View ...................................................... 5.6 Valve Guide
Inspection ............................................................5.22 Removal / Installation.............................................3.86
Installation ...........................................................5.23 Valve Seat
Removal...............................................................5.22 Inspection ............................................................3.87

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Reconditioning .....................................................3.88 Wiring Diagram

Valve Stem ABS System ............................................ 10.127-10.128 I-
Inspection .......................................................... 8.105 Central Locking System...................................... 10.129
Installation, Metal ................................................ 8.105 Keyless Ignition System ...................................... 10.132 X
Installation, Rubber ............................................. 8.105 Power Windshield ............................................. 10.134
Valve Train Power WIndshield ............................................. 10.133
Special Tools ........................................................3.45 Starting System ....................................... 10.130-10.131
Valves Wiring Diagrams.......................................................143
Assembly View .....................................................3.51
Inspection ............................................................3.84
Wear Patterns .......................................................3.85
VCM
Service Notes ..................................................... 10.62
Vehicle Control Module
Removal / Installation........................................... 10.62
Vehicle Control Module (VCM)
Connector Map ................................................... 10.63
Service Notes ..................................................... 10.62
Vehicle Identification Number ..................................... 1.2
VIN/PIN Decoder ...................................................... 1.2
VIN/PIN Location....................................................... 1.3
Voltage Output Test ................................................ 10.33
Voltage Regulator
Assembly View ................................................... 10.10

W
Wheel
Inspection .......................................................... 8.104
Lacing ............................................................... 8.114
Spoke Inspection...................................................2.66
Spoke Tightening ................................................ 8.113
Wheel (Cast), Front
Assembly View .............................................. 8.13-8.14
Wheel (Spoked), Front
Assembly View .....................................................8.15
Wheel Bearings
Inspection, Front ...................................................2.59
Wheel Speed Sensor
Adjustment (Air Gap).............................................9.19
Replacement ........................................................9.18
Wheel Speed Sensor, Front
Assembly View .....................................................9.13
Wheel Speed Sensor, Rear
Assembly View .....................................................9.14
Wheel Truing ........................................................ 8.113
Wheel, Front
Bearing Inspection ................................................8.24
Bearing Replacement.............................................8.25
Inspection ............................................................8.23
Removal / Installation.............................................8.22
Service Notes ........................................................ 8.4
Service Specifications ............................................. 8.5
Special Tools ......................................................... 8.4
Wheel, Rear
Assembly View .....................................................8.53
Bearing Inspection ................................................8.69
Bearing Replacement.............................................8.70
Inspection ............................................................8.68
Removal / Installation.............................................8.66
Service Notes .......................................................8.44
Service Specifications ............................................8.45
Troubleshooting....................................................8.81
Wheels
Service Notes .......................................................8.83
Special Tools ........................................................8.84

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