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2017 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'.
Consumers, please provide your feedback in writing to: Indian Motorcycle Company ATTN: Service Publications
Department, 2100 Hwy 55, Medina, MN 55340.

Publication Printed April 2017 (PN 9927618 R03)

© Copyright 2017 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
Throughout this manual, important information is brought to your attention by the following symbols:

WARNING

SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator,
bystander or person(s) inspecting or servicing the vehicle.

CAUTION

SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the
vehicle.

CAUTION

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.

NOTE

NOTE 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 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 8/1/2016 Initial release
R02 1/20/2017 Add Roadmaster Classic models
R03 4/2/2017 Add Chieftain Limited and Elite models

2017 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

CHAPTER 1 1
GENERAL / SPECIFICATIONS
VEHICLE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MANUFACTURER LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
TIRE INFORMATION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2017 CHIEF CLASSIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2017 CHIEF DARK HORSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
2017 CHIEF VINTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12
2017 SPRINGFIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.16
2017 CHIEFTAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20
2017 CHIEFTAIN DARK HORSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24
2017 CHIEFTAIN LIMITED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.28
2017 CHIEFTAIN ELITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.32
2017 ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.36
2017 ROADMASTER CLASSIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.40
VEHICLE LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.43
GROSS VEHICLE WEIGHT RATING (GVWR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.43
PUBLICATIONS & TECHNICAL LITERATURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.44
PUBLICATIONS PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.44
REFINISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.45
PAINT COLORS BY MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.45
EMMISIONS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.48
EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.48
EMISSION SOURCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.48
EXHAUST EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.48
NOISE EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.48
CRANKCASE EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.48
EVAPORATIVE EMISSION CONTROL (CALIFORNIA AND INTERNATIONAL MODELS) . . . . . . . . . . . . . . .1.48
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.49
USING SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.49
TOOL ORDERING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.50
SPECIAL TOOLS INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.50
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.54
MASTER TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.54
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.57
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.57
DECIMAL EQUIVALENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.58
FAHRENHEIT TO CELSIUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.59
MEASUREMENT CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.59

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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 MARKET COLOR
BRAKE HP CONFIG
1st digit 2nd/ 4th digit* 5th digit* 6th digit* 7th digit* 8th digit 9th digit** 10th digit
3rd
digit

N= 17 = C= Cruiser C = Chief A = Standard A = 1811cc A = Full-size A = 49 State (49S) A = Thunder Black
Indian 2017 M = Midsize V = Chief ABS (111ci) V-Twin B = 50 State (50S) B = Springfield Blue
Motor- T = Touring Vintage B = Standard C = Canadian (CAN) C = Ivory Cream
cycle C= Chieftain Non-ABS E = EU (WVTA) D = Indian Red /
H = Springfield C = Classic ABS J = Japan (SVA) Thunder Black
R = Roadmaster D = Dark Horse K = Braxil CKD E = Indian Red /
B = Roadmaster ABS (BRZ) Cream
Classic V = Vintage X = China (XNA) F = Springfield Blue
ABS / Cream
G = Willow Green /
Cream
H = Black Smoke
R = Indian Red
S = Black Hills
Silver
T = Vogue Silver w/
Blk Graphic
V = Matte Sunset
Red / Matte Black
Z = Unpainted

* = digits that would transfer to 17 digit VIN and are used in digits 4–8 respectively.
** = 9th digit will be used on color / featured versions of models (not including base).
First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN.

E N G I N E N U M B E R L O C AT I O N
The engine number q is stamped into the bottom of
the RH engine case.. The stamping identifies the
engine model and serial number.

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 )
D E S I G N AT I O N
Example: 56KTCAAA0E3000024
Vehicle Descriptors Vehicle Identifiers
World Mfg. ID Check
Chas- Type Disp Mfg
HP Series Digit MY* Individual Serial No.
sis
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

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GENERAL / SPECIFICATIONS

V I N L O C AT I O N
The vehicle identification number q is stamped on the
right side of the steering head. 1

M A N U FA C T U R E R L A B E L
The manufacturer label q located on the left side of
the steering head contains the following information:
Vehicle Identification Number (VIN)
Gross Vehicle Weight Rating (GVWR)
Gross Axle Weight Rating (GAWR)
Tire Type and Load Information.

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

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GENERAL / SPECIFICATIONS

G E N E R A L S P E C I F I C AT I O N S
2017 CHIEF CLASSIC
Model Numbers
2017
N17CCCAAAD N17CCCAACK
N17CCCAAAK N17CCCAACZ
N17CCCAAAZ N17CCCAAED
N17CCCAABD N17CCCAAEK
N17CCCAABK N17CCCAAKD
N17CCCAABZ N17CCCAAKK
N17CCCAACD

Chassis
CATEGORY SPECIFICATION
Dry Weight 751 lbs (341 kg)
Wet Weight 783 lbs (356 kg)
Gross Vehicle Weight Rating 1260 lbs (572 kg)
Gross Axle Weight Rating, Front 485 lbs (220 kg)
Gross Axle Weight Rating, Rear 775 lbs (352 kg)
Maximum Load 477 lbs (216 kg)
Overall Length 103.5 in (2630 mm)
Overall Width 39.4 in (1000 mm)
Overall Height 46.3 in (1176 mm)
Seat Height 26.0 in (660 mm)
Ground Clearance 5.5 in (139.8 mm)
Total Storage Capacity NA
Passenger Capacity 0
Wheelbase 68.1 in (1730 mm)
Rake / Trail 29° / 6.1 in (155.0 mm)

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GENERAL / SPECIFICATIONS

Engine
CATEGORY SPECIFICATION
1
Engine Number 1205441
Engine Type Thunder Stroke 111
Engine Configuration 49° OHV Pushrod V-Twin
Engine Wet Weight 297 lbs (134.7 kg)
Engine Displacement 111 cid (1811 cc)
Engine Cooling System Air / Oil
Compression Ratio 9.5:1
Compression Pressure 90–110 psi (620–758 kPa)
Valve Train 2 Valves per cylinder / Hydraulic Lifters
Bore x Stroke 101 mm x 113 mm
Idle Speed / Fast Idle Speed 800 RPM ± 50 RPM (warm)
Oil Capacity 5.5 qts (5.2 L)
Oil Type SAE 20W40 (recommended)
Lubrication System Semi-Dry Sump
Spark Plug Type / Gap DCPR8E / 0.034 in (0.9 mm)
Exhaust System Two O2 Sensors (one in each pipe) / Single three-way
catalyst

Fuel System
CATEGORY SPECIFICATION
Fuel System Type Electronic Fuel Injection (ME17)
Fuel Delivery Electronic Fuel Pump (in tank)
Fuel Pressure 58 psi (400 kPa)
Throttle Body Bore Size 2.125 in (54 mm)
Fuel Capacity 5.5 gal (20.8 L)
Fuel Reserve Capacity 1.0 gal (3.8 L)
Fuel Type 91 Octane recommended ((R+M/2) method)

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GENERAL / SPECIFICATIONS

Electrical
CATEGORY SPECIFICATION
Stator Rated Output 710W @ 2000 RPM
Battery 12V / 18 AH / 310 CCA, Sealed Glass Mat
Headlights H4 12V 60/55W Long Life
Auxiliary Lights H8 35W
Tail / Brake LED (non-serviceable)
Turn Signals LED (non-serviceable)
Starting System Electric Start
Ignition System Bosch ME-17 (ECM Controlled)
Instrument Type Multifunction Instrument Cluster
DC Outlet Standard 12V (Accessory)

Drivetrain
CATEGORY SPECIFICATION
Transmission Type 6 Speed Overdrive, Constant Mesh
Clutch Type Wet, Multi-Plate, Coil Spring
Primary Drive Type Wet, Gear Drive w/Torque Compensator
Primary Reduction Ratio 1.56:1
Final Drive Type / Ratio Belt / 2.2:1
Belt Type / Belt Width 24 mm Carbon Fiber Reinforced Belt
Gear Shift Pattern 1 Down, 5 Up
Transmission Gear Ratios:
1st 2.73:1
2nd 1.86:1
3rd 1.38:1
4th 1.10:1
5th .94:1
6th .81:1

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GENERAL / SPECIFICATIONS

Suspension
CATEGORY SPECIFICATION
1
Front Suspension Type Conventional Telescopic Fork
Front Travel 4.68 in (11.9 cm)
Front Tube Diameter 46 mm
Rear Shock Type Single, Monotube Gas with Adjustable Preload
Rear Swingarm Type Cast Aluminum
Rear Travel 3.7 in (9.4 cm)

Wheels / Brakes
CATEGORY SPECIFICATION
Front Tire Type / Size Dunlop Elite 3 – 130/90B16
Front Wheel Type / Size Cast - 16 in X 3.5 in
Front Tire Air Pressure 36 PSI (248 kPa)
Front Brake, Type Dual Floating Disc / 4 Piston Calipers
Rear Tire Dunlop American Elite – 180/65B16
Rear Wheel Cast - 16 in X 5 in
Rear Tire Air Pressure 40 PSI (276 kPa)
Rear Brake, Type Single Floating Disc / 2 Piston Caliper
Brake Fluid Type DOT 4

All specifications are for standard Indian Chief Classic models. Specifications may change with the addition of
custom order options and / or accessories. Indian Motorcycle Company reserves the right without prior notice to
discontinue at any time at its discretion any of the items herein or change specifications or designs without
incurring any obligation to the customer.

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GENERAL / SPECIFICATIONS

2017 CHIEF DARK HORSE
Model Numbers
2017
N17CCDAAAH
N17CCDAABH
N17CCDAACH
N17CCDAAEH

Chassis
CATEGORY SPECIFICATION
Dry Weight 751 lbs (341 kg)
Wet Weight 783 lbs (356 kg)
Gross Vehicle Weight Rating 1260 lbs (572 kg)
Gross Axle Weight Rating, Front 485 lbs (220 kg)
Gross Axle Weight Rating, Rear 775 lbs (352 kg)
Maximum Load 477 lbs (216 kg)
Overall Length 103.5 in (2630 mm)
Overall Width 39.4 in (1000 mm)
Overall Height 46.3 in (1176 mm)
Seat Height 26.0 in (660 mm)
Ground Clearance 5.5 in (139.8 mm)
Total Storage Capacity NA
Passenger Capacity 0
Wheelbase 68.1 in (1730 mm)
Rake / Trail 29° / 6.1 in (155.0 mm)

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9 mm) Exhaust System Two O2 Sensors (one in each pipe) / Single three-way catalyst Fuel System CATEGORY SPECIFICATION Fuel System Type Electronic Fuel Injection (ME17) Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 58 psi (400 kPa) Throttle Body Bore Size 2.2 L) Oil Type SAE 20W40 (recommended) Lubrication System Semi-Dry Sump Spark Plug Type / Gap DCPR8E / 0.125 in (54 mm) Fuel Capacity 5.034 in (0.0 gal (3.7 kg) Engine Displacement 111 cid (1811 cc) Engine Cooling System Air / Oil Compression Ratio 9.9 .5:1 Compression Pressure 90–110 psi (620–758 kPa) Valve Train 2 Valves per cylinder / Hydraulic Lifters Bore x Stroke 101 mm x 113 mm Idle Speed / Fast Idle Spd 800 RPM ± 50 RPM (warm) Oil Capacity 5. GENERAL / SPECIFICATIONS Engine CATEGORY SPECIFICATION 1 Engine Number 1205442 Engine Type Thunder Stroke 111 Engine Configuration 49° OHV Pushrod V-Twin Engine Wet Weight 297 lbs (134.5 gal (20.5 qts (5.8 L) Fuel Type 91 Octane recommended ((R+M/2) method) 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1.8 L) Fuel Reserve Capacity 1.

10:1 5th .GENERAL / SPECIFICATIONS Electrical CATEGORY SPECIFICATION Stator Rated Output 610W @ 3500 RPM Battery 12V / 18 AH / 310 CCA. Coil Spring Primary Drive Type Wet.94:1 6th .56:1 Final Drive Type / Ratio Belt / 2. 5 Up Transmission Gear Ratios: 1st 2.2:1 Belt Type / Belt Width 24 mm Carbon Fiber Reinforced Belt Gear Shift Pattern 1 Down.86:1 3rd 1.10 © Copyright .81:1 9927618 R03 . Gear Drive w/Torque Compensator Primary Reduction Ratio 1. Sealed Glass Mat Headlights H4 12V 60/55W Long Life Auxiliary Lights H8 35W Tail / Brake LED (non-serviceable) Turn Signals LED (non-serviceable) Starting System Electric Start Ignition System Bosch ME-17 (ECM Controlled) Instrument Type Multifunction Instrument Cluster DC Outlet Standard 12V (Accessory) Drivetrain CATEGORY SPECIFICATION Transmission Type 6 Speed Overdrive.38:1 4th 1. Constant Mesh Clutch Type Wet.2017 Indian Motorcycle (Full-Size) Service Manual 1. Multi-Plate.73:1 2nd 1.

7 in (9.68 in (11. Indian Motorcycle Company reserves the right without prior notice to discontinue at any time at its discretion any of the items herein or change specifications or designs without incurring any obligation to the customer.4 cm) Wheels / Brakes CATEGORY SPECIFICATION Front Tire Type / Size Dunlop Elite 3– 130/90B16 Front Wheel Type / Size Cast / 16 in X 3. Type Dual Floating Disc / 4 Piston Calipers Rear Tire Dunlop American Elite – 180/65B16 Rear Wheel Cast / 16 in X 5 in Rear Tire Air Pressure 40 PSI (276 kPa) Rear Brake.5 in Front Tire Air Pressure 36 PSI (248 kPa) Front Brake.9 cm) Front Tube Diameter 46 mm Rear Shock Type Single.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1.11 . Type Single Floating Disc / 2 Piston Caliper Brake Fluid Type DOT 4 All specifications are for standard Indian Dark Horse models. 9927618 R03 . GENERAL / SPECIFICATIONS Suspension CATEGORY SPECIFICATION 1 Front Suspension Type Conventional Telescopic Fork Front Travel 4. Specifications may change with the addition of custom order options and / or accessories. Monotube Gas with Adjustable Preload Rear Swingarm Type Cast Aluminum Rear Travel 3.

Front 485 lbs (220 kg) Gross Axle Weight Rating.1 in (155.1 in (1730 mm) Rake / Trail 29° / 6.7 in (2634 mm) Overall Width 39.5 in (140 mm) Total Storage Capacity 15 lbs (6.4 in (1000 mm) Overall Height 58.8 kg) Passenger Capacity 1 Wheelbase 68.0 mm) 9927618 R03 .12 © Copyright .GENERAL / SPECIFICATIONS 2 0 1 7 C H I E F V I N TA G E Model Numbers 2017 N17CCVAAAA N17CCVAACE N17CCVAAAE N17CCVAACF N17CCVAAAF N17CCVAACG N17CCVAAAG N17CCVAACZ N17CCVAAAZ N17CCVAAEA N17CCVAABA N17CCVAAEE N17CCVAABE N17CCVAAEF N17CCVAABF N17CCVAAEG N17CCVAABG N17CCVAAKA N17CCVAABZ N17CCVAAKE N17CCVAACA Chassis CATEGORY SPECIFICATION Dry Weight 824 lbs (374 kg) Wet Weight 856 lbs (388 kg) Gross Vehicle Weight Rating 1260 lbs (572 kg) Gross Axle Weight Rating. Rear 775 lbs (352 kg) Maximum Load 404 lbs (183 kg) Overall Length 103.0 in (660 mm) Ground Clearance 5.2017 Indian Motorcycle (Full-Size) Service Manual 1.7 in (1490 mm) Seat Height 26.

8 L) Fuel Type 91 Octane recommended ((R+M/2) method) 9927618 R03 .5 gal (20. GENERAL / SPECIFICATIONS Engine CATEGORY SPECIFICATION 1 Engine Number 1205441 Engine Type Thunder Stroke 111 Engine Configuration 49° OHV Pushrod V-Twin Engine Wet Weight 297 lbs (134.5:1 Compression Pressure 90–110 psi (620–758 kPa) Valve Train 2 Valves per cylinder / Hydraulic Lifters Bore x Stroke 101 mm x 113 mm Idle Speed / Fast Idle Spd 800 RPM ± 50 RPM (warm) Oil Capacity 5.2 L) Oil Type SAE 20W40 (recommended) Lubrication System Semi-Dry Sump Spark Plug Type / Gap DCPR8E / 0.7 kg) Engine Displacement 111 cid (1811 cc) Engine Cooling System Air / Oil Compression Ratio 9.9 mm) Exhaust System Two O2 Sensors (one in each pipe) / Single three-way catalyst Fuel System CATEGORY SPECIFICATION Fuel System Type Electronic Fuel Injection (ME17) Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 58 psi (400 kPa) Throttle Body Bore Size 2.125 in (54 mm) Fuel Capacity 5.13 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1.034 in (0.0 gal (3.5 qts (5.8 L) Fuel Reserve Capacity 1.

Coil Spring Primary Drive Type Wet.73:1 2nd 1.14 © Copyright .56:1 Final Drive Type / Ratio Belt / 2.86:1 3rd 1.94:1 6th . 5 Up Transmission Gear Ratios: 1st 2. Constant Mesh Clutch Type Wet. Gear Drive w/Torque Compensator Primary Reduction Ratio 1.GENERAL / SPECIFICATIONS Electrical CATEGORY SPECIFICATION Stator Rated Output 710W @ 2000 RPM Battery 12V / 18 AH / 310 CCA.2:1 Belt Type / Belt Width 24 mm Carbon Fiber Reinforced Belt Gear Shift Pattern 1 Down. Sealed Glass Mat Headlights H4 12V 60/55W Long Life Auxiliary Lights H8 35W Tail / Brake LED (non-serviceable) Turn Signals LED (non-serviceable) Starting System Electric Start Ignition System Bosch ME-17 (ECM Controlled) Instrument Type Multifunction Instrument Cluster DC Outlet Standard 12V Drivetrain CATEGORY SPECIFICATION Transmission Type 6 Speed Overdrive.38:1 4th 1.10:1 5th . Multi-Plate.81:1 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual 1.

Monotube Gas with Adjustable Preload Rear Swingarm Type Cast Aluminum Rear Travel 3. Specifications may change with the addition of custom order options and / or accessories. Type Single Floating Disc / 2 Piston Caliper Brake Fluid Type DOT 4 All specifications are for standard Indian Chief Vintage models.15 . GENERAL / SPECIFICATIONS Suspension CATEGORY SPECIFICATION 1 Front Suspension Type Conventional Telescopic Fork Front Travel 4.4 cm) Wheels / Brakes CATEGORY SPECIFICATION Front Tire Type / Size Dunlop American Elite – 130/90B16 Front Wheel Type / Size Spoked / 16 in X 3.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1.68 in (11.7 in (9.5 in Front Tire Air Pressure 36 PSI (248 kPa) Front Brake. Indian Motorcycle Company reserves the right without prior notice to discontinue at any time at its discretion any of the items herein or change specifications or designs without incurring any obligation to the customer.9 cm) Front Tube Diameter 46 mm Rear Shock Type Single. 9927618 R03 . Type Dual Floating Disc / 4 Piston Calipers Rear Tire Dunlop American Elite – 180/65B16 Rear Wheel Spoked / 16 in X 5 in Rear Tire Air Pressure 40 PSI (276 kPa) Rear Brake.

Rear 885 lbs (401 kg) Maximum Load 523 lbs (237 kg) Overall Length 101.GENERAL / SPECIFICATIONS 2017 SPRINGFIELD Model Numbers 2017 N17THAAAAA N17THAAACL N17THAAAAL N17THAAACM N17THAAAAM N17THAAACR N17THAAAAR N17THAAACZ N17THAAAAZ N17THAAAEA N17THAAABA N17THAAAEL N17THAAABL N17THAAAEM N17THAAABM N17THAAAER N17THAAABR N17THAAAKA N17THAAABZ N17THAAAKL N17THAAACA Chassis CATEGORY SPECIFICATION Dry Weight 830 lbs (376 kg) Wet Weight 862 lbs (391 kg) Gross Vehicle Weight Rating 1385 lbs (628 kg) Gross Axle Weight Rating.0 in (990 mm) Overall Height 56.6 in (142 mm) Total Storage Capacity 22 lbs (10.7 in (2583 mm) Overall Width 39.2017 Indian Motorcycle (Full-Size) Service Manual 1.16 © Copyright .8 in (1442 mm) Seat Height 26.0 in (660 mm) Ground Clearance 5. Front 500 lbs (227 kg) Gross Axle Weight Rating.0 kg) Passenger Capacity 1 Wheelbase 67 in (1701 mm) Rake / Trail 25° / 5.0 mm) 9927618 R03 .2 in (133.

034 in (0.9 mm) Exhaust System Two O2 Sensors (one in each pipe) / Single three-way catalyst Fuel System CATEGORY SPECIFICATION Fuel System Type Electronic Fuel Injection (ME17) Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 58 psi (400 kPa) Throttle Body Bore Size 2.2 L) Oil Type SAE 20W40 (recommended) Lubrication System Semi-Dry Sump Spark Plug Type / Gap DCPR8E / 0.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1.125 in (54 mm) Fuel Capacity 5.8 L) Fuel Reserve Capacity 1. GENERAL / SPECIFICATIONS Engine CATEGORY SPECIFICATION 1 Engine Number 1205441 Engine Type Thunder Stroke 111 V-Twin Engine Configuration 49° OHV Pushrod V-Twin Engine Wet Weight 297 lbs (134.17 .8 L) Fuel Type 91 Octane recommended ((R+M/2) method) 9927618 R03 .0 gal (3.5 gal (20.7 kg) Engine Displacement 111 cid (1811 cc) Engine Cooling System Air / Oil Compression Ratio 9.5 qts (5.5:1 Compression Pressure 90–110 psi (620–758 kPa) Valve Train 2 Valves per cylinder / Hydraulic Lifters Bore x Stroke 101 mm x 113 mm Idle Speed / Fast Idle Spd 800 RPM ± 50 RPM (warm) Oil Capacity 5.

10:1 5th . 5 Up Transmission Gear Ratios: 1st 2. Sealed Glass Mat Headlights H4 12V 60/55W Long Life Auxiliary Lights H8 35W Tail / Brake LED (non-serviceable) Turn Signals LED (non-serviceable) Starting System Electric Start Ignition System Bosch ME-17 (ECM Controlled) Instrument Type Multifunction Instrument Cluster DC Outlet Standard 12V Drivetrain CATEGORY SPECIFICATION Transmission Type 6 Speed Overdrive.GENERAL / SPECIFICATIONS Electrical CATEGORY SPECIFICATION Stator Rated Output 710W @ 2000 RPM Battery 12V / 18 AH / 310 CCA.86:1 3rd 1.2:1 Belt Type / Belt Width 24 mm Carbon Fiber Reinforced Belt Gear Shift Pattern 1 Down.2017 Indian Motorcycle (Full-Size) Service Manual 1.94:1 6th . Gear Drive w/Torque Compensator Primary Reduction Ratio 1. Coil Spring Primary Drive Type Wet. Multi-Plate.56:1 Final Drive Type / Ratio Belt / 2.73:1 2nd 1. Constant Mesh Clutch Type Wet.38:1 4th 1.18 © Copyright .81:1 9927618 R03 .

9 cm) Front Tube Diameter 46 mm Rear Shock Type Single. Type Single Floating Disc / 2 Piston Caliper Brake Fluid Type DOT 4 All specifications are for standard Indian Springfield models.5 in Front Tire Air Pressure 46 PSI (317 kPa) Front Brake.4 cm) Wheels / Brakes CATEGORY SPECIFICATION Front Tire Type / Size Dunlop Elite 3– 130/90B16 Front Wheel Type / Size Cast / 16 in X 3.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1. Monotube Air Adjustable Shock Rear Swingarm Type Cast Aluminum Rear Travel 4.5 in (11.7 in (11. Indian Motorcycle Company reserves the right without prior notice to discontinue at any time at its discretion any of the items herein or change specifications or designs without incurring any obligation to the customer. 9927618 R03 . GENERAL / SPECIFICATIONS Suspension CATEGORY SPECIFICATION 1 Front Suspension Type Conventional Telescopic Fork Front Travel 4.19 . Type Dual Floating Disc / 4 Piston Calipers Rear Tire Dunlop Elite 3 – 180/60R16 Rear Wheel Cast / 16 in X 5 in Rear Tire Air Pressure 41 PSI (283 kPa) Rear Brake. Specifications may change with the addition of custom order options and / or accessories.

2 in (2571 mm) Overall Width 39.7 in (1668 mm) Rake / Trail 25° / 5.2017 Indian Motorcycle (Full-Size) Service Manual 1.6 in (142 mm) Total Storage Capacity 45 lbs (20 kg) Passenger Capacity 1 Wheelbase 65.0 mm) 9927618 R03 .6 in (1388 mm) Seat Height 26.20 © Copyright .GENERAL / SPECIFICATIONS 2 0 1 7 C H I E F TA I N Model Numbers 2017 N17TCAAAA1 N17TCAAAC1 N17TCAAAA6 N17TCAAAC6 N17TCAAAAP N17TCAAACP N17TCAAAAS N17TCAAACS N17TCAAAAT N17TCAAACT N17TCAAAAZ N17TCAAACZ N17TCAAAB1 N17TCAAAE1 N17TCAAAB6 N17TCAAAE6 N17TCAAABP N17TCAAAEP N17TCAAABS N17TCAAAES N17TCAAABT N17TCAAAET N17TCAAABZ N17TCAAAKS Chassis CATEGORY SPECIFICATION Dry Weight 828 lbs (376 kg) Wet Weight 860 lbs (391 kg) Gross Vehicle Weight Rating 1385 lbs (628 kg) Gross Axle Weight Rating. Front 500 lbs (227 kg) Gross Axle Weight Rating.4 in (1000 mm) Overall Height 54.0 in (660 mm) Ground Clearance 5. Rear 885 lbs (402 kg) Maximum Load 525 lbs (238 kg) Overall Length 101.9 in (150.

5 gal (20.2 L) Oil Type SAE 20W40 (recommended) Lubrication System Semi-Dry Sump Spark Plug Type / Gap DCPR8E / 0.034 in (0.21 .0 gal (3.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1.7 kg) Engine Displacement 111 cid (1811 cc) Engine Cooling System Air / Oil Compression Ratio 9. GENERAL / SPECIFICATIONS Engine CATEGORY SPECIFICATION 1 Engine Number 1205440 Engine Type Thunder Stroke 111 V-Twin Engine Configuration 49° OHV Pushrod V-Twin Engine Wet Weight 297 lbs (134.5:1 Compression Pressure 90–110 psi (620–758 kPa) Valve Train 2 Valves per cylinder / Hydraulic Lifters Bore x Stroke 101 mm x 113 mm Idle Speed / Fast Idle Spd 800 RPM ± 50 RPM (warm) Oil Capacity 5.8 L) Fuel Reserve Capacity 1.125 in (54 mm) Fuel Capacity 5.8 L) Fuel Type 91 Octane recommended ((R+M/2) method) 9927618 R03 .9 mm) Exhaust System Two O2 Sensors (one in each pipe) / Single three-way catalyst Fuel System CATEGORY SPECIFICATION Fuel System Type Electronic Fuel Injection (ME17) Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 58 psi (400 kPa) Throttle Body Bore Size 2.5 qts (5.

10:1 5th .73:1 2nd 1.81:1 9927618 R03 .22 © Copyright .56:1 Final Drive Type / Ratio Belt / 2. Sealed Glass Mat Headlights H4 12V 60/55W Long Life Auxiliary Lights H8 35W Tail / Brake LED (non-serviceable) Turn Signals LED (non-serviceable) Starting System Electric Start Ignition System Bosch ME-17 (ECM Controlled) Instrument Type Multifunction Instrument Cluster DC Outlet Standard 12V Drivetrain CATEGORY SPECIFICATION Transmission Type 6 Speed Overdrive. 5 Up Transmission Gear Ratios: 1st 2.94:1 6th . Constant Mesh Clutch Type Wet. Gear Drive w/Torque Compensator Primary Reduction Ratio 1.GENERAL / SPECIFICATIONS Electrical CATEGORY SPECIFICATION Stator Rated Output 710W @ 2000 RPM Battery 12V / 18 AH / 310 CCA.2:1 Belt Type / Belt Width 24 mm Carbon Fiber Reinforced Belt Gear Shift Pattern 1 Down.38:1 4th 1.2017 Indian Motorcycle (Full-Size) Service Manual 1.86:1 3rd 1. Coil Spring Primary Drive Type Wet. Multi-Plate.

9 cm) Front Tube Diameter 46 mm Rear Shock Type Single. Specifications may change with the addition of custom order options and / or accessories. GENERAL / SPECIFICATIONS Suspension CATEGORY SPECIFICATION 1 Front Suspension Type Conventional Telescopic Fork Front Travel 4. Type Single Floating Disc / 2 Piston Caliper Brake Fluid Type DOT 4 All specifications are for standard Indian Chieftain models.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1. Monotube Air Adjustable Shock Rear Swingarm Type Cast Aluminum Rear Travel 4. 9927618 R03 .5 in (11.4 cm) Wheels / Brakes CATEGORY SPECIFICATION Front Tire Type / Size Dunlop Elite 3– 130/90B16 Front Wheel Type / Size Cast / 16 in X 3.7 in (11.5 in Front Tire Air Pressure 36 PSI (248 kPa) Front Brake. Type Dual Floating Disc / 4 Piston Calipers Rear Tire Dunlop Elite 3– 180/60R16 Rear Wheel Cast / 16 in X 5 in Rear Tire Air Pressure 41 PSI (282 kPa) Rear Brake.23 . Indian Motorcycle Company reserves the right without prior notice to discontinue at any time at its discretion any of the items herein or change specifications or designs without incurring any obligation to the customer.

6 in (142 mm) Total Storage Capacity 22 lbs (10.2 in (2571 mm) Overall Width 39. Front 500 lbs (227 kg) Gross Axle Weight Rating.6 in (1388 mm) Seat Height 26.7 in (1668 mm) Rake / Trail 25° / 5.GENERAL / SPECIFICATIONS 2 0 1 7 C H I E F TA I N D A R K H O R S E Model Numbers 2017 N17TCDAAAH N17TCDAABH N17TCDAACH N17TCDAAEH Chassis CATEGORY SPECIFICATION Dry Weight 799 lbs (362 kg) Wet Weight 831 lbs (377 kg) Gross Vehicle Weight Rating 1385 lbs (628 kg) Gross Axle Weight Rating.24 © Copyright .2017 Indian Motorcycle (Full-Size) Service Manual 1.0 mm) 9927618 R03 . Rear 885 lbs (401 kg) Maximum Load 554 lbs (251 kg) Overall Length 101.0 in (660 mm) Ground Clearance 5.9 in (150.4 in (1000 mm) Overall Height 54.0 kg) Passenger Capacity 1 Wheelbase 65.

125 in (54 mm) Fuel Capacity 5.8 L) Fuel Reserve Capacity 1.25 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1.7 kg) Engine Displacement 111 cid (1811 cc) Engine Cooling System Air / Oil Compression Ratio 9.5:1 Compression Pressure 90–110 psi (620–758 kPa) Valve Train 2 Valves per cylinder / Hydraulic Lifters Bore x Stroke 101 mm x 113 mm Idle Speed / Fast Idle Spd 800 RPM ± 50 RPM (warm) Oil Capacity 5. GENERAL / SPECIFICATIONS Engine CATEGORY SPECIFICATION 1 Engine Number 1205534 Engine Type Thunder Stroke 111 V-Twin Engine Configuration 49° OHV Pushrod V-Twin Engine Wet Weight 297 lbs (134.8 L) Fuel Type 91 Octane recommended ((R+M/2) method) 9927618 R03 .0 gal (3.5 gal (20.5 qts (5.034 in (0.9 mm) Exhaust System Two O2 Sensors (one in each pipe) / Single three-way catalyst Fuel System CATEGORY SPECIFICATION Fuel System Type Electronic Fuel Injection (ME17) Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 58 psi (400 kPa) Throttle Body Bore Size 2.2 L) Oil Type SAE 20W40 (recommended) Lubrication System Semi-Dry Sump Spark Plug Type / Gap DCPR8E / 0.

Sealed Glass Mat Headlights H4 12V 60/55W Long Life Auxiliary Lights H8 35W Tail / Brake LED (non-serviceable) Turn Signals LED (non-serviceable) Starting System Electric Start Ignition System Bosch ME-17 (ECM Controlled) Instrument Type Multifunction Instrument Cluster DC Outlet Standard 12V Drivetrain CATEGORY SPECIFICATION Transmission Type 6 Speed Overdrive. Multi-Plate.56:1 Final Drive Type / Ratio Belt / 2.26 © Copyright .10:1 5th . 5 Up Transmission Gear Ratios: 1st 2.38:1 4th 1. Coil Spring Primary Drive Type Wet.86:1 3rd 1. Gear Drive w/Torque Compensator Primary Reduction Ratio 1.GENERAL / SPECIFICATIONS Electrical CATEGORY SPECIFICATION Stator Rated Output 710W @ 2000 RPM Battery 12V / 18 AH / 310 CCA.73:1 2nd 1. Constant Mesh Clutch Type Wet.2017 Indian Motorcycle (Full-Size) Service Manual 1.94:1 6th .81:1 9927618 R03 .2:1 Belt Type / Belt Width 24 mm Carbon Fiber Reinforced Belt Gear Shift Pattern 1 Down.

Specifications may change with the addition of custom order options and / or accessories.27 . GENERAL / SPECIFICATIONS Suspension CATEGORY SPECIFICATION 1 Front Suspension Type Conventional Telescopic Fork Front Travel 4.7 in (11. Type Single Floating Disc / 2 Piston Caliper Brake Fluid Type DOT 4 All specifications are for standard Indian Chieftain models.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1. 9927618 R03 . Indian Motorcycle Company reserves the right without prior notice to discontinue at any time at its discretion any of the items herein or change specifications or designs without incurring any obligation to the customer. Monotube Air Adjustable Shock Rear Swingarm Type Cast Aluminum Rear Travel 4.5 in (11. Type Dual Floating Disc / 4 Piston Calipers Rear Tire Dunlop Elite 3– 180/60R16 Rear Wheel Cast / 16 in X 5 in Rear Tire Air Pressure 41 PSI (282 kPa) Rear Brake.5 in Front Tire Air Pressure 36 PSI (248 kPa) Front Brake.9 cm) Front Tube Diameter 46 mm Rear Shock Type Single.4 cm) Wheels / Brakes CATEGORY SPECIFICATION Front Tire Type / Size Dunlop Elite 3– 130/90B16 Front Wheel Type / Size Cast / 16 in X 3.

GENERAL / SPECIFICATIONS 2 0 1 7 C H I E F TA I N L I M I T E D Model Numbers 2017 N17TCNAAAA N17TCNAAAT N17TCNAAAP N17TCNAABT N17TCNAABP N17TCNAACT N17TCNAACP N17TCNAAET N17TCNAAEP N17TCNAAAS N17TCNAAA6 N17TCNAABS N17TCNAAB6 N17TCNAACS N17TCNAAC6 N17TCNAAES N17TCNAAE6 Chassis CATEGORY SPECIFICATION Dry Weight 817 lbs (371 kg) Wet Weight 849 lbs (385 kg) Gross Vehicle Weight Rating 1385 lbs (628 kg) Gross Axle Weight Rating. Front 500 lbs (227 kg) Gross Axle Weight Rating. Rear 885 lbs (402 kg) Maximum Load 536 lbs (243 kg) Overall Length 98.0 mm) 9927618 R03 .7 in (1668 mm) Rake / Trail 25° / 5.9 in (150.7 in (2506 mm) Overall Width 39.2017 Indian Motorcycle (Full-Size) Service Manual 1.0 in (660 mm) Ground Clearance 5.6 in (1388 mm) Seat Height 26.28 © Copyright .4 in (1000 mm) Overall Height 54.6 in (142 mm) Total Storage Capacity 45 lbs (20 kg) Passenger Capacity 1 Wheelbase 65.

8 L) Fuel Type 91 Octane recommended ((R+M/2) method) 9927618 R03 .0 gal (3.7 kg) Engine Displacement 111 cid (1811 cc) Engine Cooling System Air / Oil Compression Ratio 9.125 in (54 mm) Fuel Capacity 5.5 gal (20.2 L) Oil Type SAE 20W40 (recommended) Lubrication System Semi-Dry Sump Spark Plug Type / Gap DCPR8E / 0.034 in (0.8 L) Fuel Reserve Capacity 1.9 mm) Exhaust System Two O2 Sensors (one in each pipe) / Single three-way catalyst Fuel System CATEGORY SPECIFICATION Fuel System Type Electronic Fuel Injection (ME17) Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 58 psi (400 kPa) Throttle Body Bore Size 2.29 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1.5 qts (5. GENERAL / SPECIFICATIONS Engine CATEGORY SPECIFICATION 1 Engine Number 1205440 Engine Type Thunder Stroke 111 V-Twin Engine Configuration 49° OHV Pushrod V-Twin Engine Wet Weight 297 lbs (134.5:1 Compression Pressure 90–110 psi (620–758 kPa) Valve Train 2 Valves per cylinder / Hydraulic Lifters Bore x Stroke 101 mm x 113 mm Idle Speed / Fast Idle Spd 800 RPM ± 50 RPM (warm) Oil Capacity 5.

73:1 2nd 1.2:1 Belt Type / Belt Width 24 mm Carbon Fiber Reinforced Belt Gear Shift Pattern 1 Down. 5 Up Transmission Gear Ratios: 1st 2. Constant Mesh Clutch Type Wet.81:1 9927618 R03 . Multi-Plate. Sealed Glass Mat Headlights H4 12V 60/55W Long Life Auxiliary Lights H8 35W Tail / Brake LED (non-serviceable) Turn Signals LED (non-serviceable) Starting System Electric Start Ignition System Bosch ME-17 (ECM Controlled) Instrument Type Multifunction Instrument Cluster DC Outlet Standard 12V Drivetrain CATEGORY SPECIFICATION Transmission Type 6 Speed Overdrive.2017 Indian Motorcycle (Full-Size) Service Manual 1.GENERAL / SPECIFICATIONS Electrical CATEGORY SPECIFICATION Stator Rated Output 710W @ 2000 RPM Battery 12V / 18 AH / 310 CCA. Gear Drive w/Torque Compensator Primary Reduction Ratio 1.86:1 3rd 1.38:1 4th 1. Coil Spring Primary Drive Type Wet.10:1 5th .94:1 6th .56:1 Final Drive Type / Ratio Belt / 2.30 © Copyright .

GENERAL / SPECIFICATIONS Suspension CATEGORY SPECIFICATION 1 Front Suspension Type Conventional Telescopic Fork Front Travel 4. Type Single Floating Disc / 2 Piston Caliper Brake Fluid Type DOT 4 All specifications are for Indian Chieftain Limited models.31 .9 cm) Front Tube Diameter 46 mm Rear Shock Type Single. Type Dual Floating Disc / 4 Piston Calipers Rear Tire Type / Size Dunlop Elite 3– 180/60R16 Rear Wheel Cast / 16 in X 5 in Rear Tire Air Pressure 41 PSI (282 kPa) Rear Brake. Indian Motorcycle Company reserves the right without prior notice to discontinue at any time at its discretion any of the items herein or change specifications or designs without incurring any obligation to the customer.7 in (11. Specifications may change with the addition of custom order options and / or accessories.5 in (11.5 in Front Tire Air Pressure 36 PSI (248 kPa) Front Brake.4 cm) Wheels / Brakes CATEGORY SPECIFICATION Front Tire Type / Size Dunlop American Elite – 130/60B19 Front Wheel Type / Size Cast / 19 in X 3. Monotube Air Adjustable Shock Rear Swingarm Type Cast Aluminum Rear Travel 4. 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1.

GENERAL / SPECIFICATIONS 2 0 1 7 C H I E F TA I N E L I T E Model Numbers 2017 N17TCEAAA4 Chassis CATEGORY SPECIFICATION Dry Weight 831 lbs (377 kg) Wet Weight 863 lbs (392 kg) Gross Vehicle Weight Rating 1385 lbs (628 kg) Gross Axle Weight Rating. Rear 885 lbs (402 kg) Maximum Load 522 lbs (237 kg) Overall Length 98. Front 500 lbs (227 kg) Gross Axle Weight Rating.9 in (150.7 in (1668 mm) Rake / Trail 25° / 5.0 mm) 9927618 R03 .32 © Copyright .7 in (2506 mm) Overall Width 39.6 in (142 mm) Total Storage Capacity 45 lbs (20 kg) Passenger Capacity 1 Wheelbase 65.0 in (1448 mm) Seat Height 26.2017 Indian Motorcycle (Full-Size) Service Manual 1.0 in (660 mm) Ground Clearance 5.4 in (1000 mm) Overall Height 57.

7 kg) Engine Displacement 111 cid (1811 cc) Engine Cooling System Air / Oil Compression Ratio 9.8 L) Fuel Type 91 Octane recommended ((R+M/2) method) 9927618 R03 .034 in (0.2 L) Oil Type SAE 20W40 (recommended) Lubrication System Semi-Dry Sump Spark Plug Type / Gap DCPR8E / 0.5 gal (20.33 .8 L) Fuel Reserve Capacity 1.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1. GENERAL / SPECIFICATIONS Engine CATEGORY SPECIFICATION 1 Engine Number 1205440 Engine Type Thunder Stroke 111 V-Twin Engine Configuration 49° OHV Pushrod V-Twin Engine Wet Weight 297 lbs (134.125 in (54 mm) Fuel Capacity 5.9 mm) Exhaust System Two O2 Sensors (one in each pipe) / Single three-way catalyst Fuel System CATEGORY SPECIFICATION Fuel System Type Electronic Fuel Injection (ME17) Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 58 psi (400 kPa) Throttle Body Bore Size 2.5:1 Compression Pressure 90–110 psi (620–758 kPa) Valve Train 2 Valves per cylinder / Hydraulic Lifters Bore x Stroke 101 mm x 113 mm Idle Speed / Fast Idle Spd 800 RPM ± 50 RPM (warm) Oil Capacity 5.0 gal (3.5 qts (5.

73:1 2nd 1.56:1 Final Drive Type / Ratio Belt / 2. Multi-Plate.81:1 9927618 R03 . Gear Drive w/Torque Compensator Primary Reduction Ratio 1.2017 Indian Motorcycle (Full-Size) Service Manual 1. Sealed Glass Mat Headlights LED (non-serviceable) H4 12V 60/55W Long Life (INT’L) Auxiliary Lights H8 35W Tail / Brake LED (non-serviceable) Turn Signals LED (non-serviceable) Starting System Electric Start Ignition System Bosch ME-17 (ECM Controlled) Instrument Type Multifunction Instrument Cluster DC Outlet Standard 12V Drivetrain CATEGORY SPECIFICATION Transmission Type 6 Speed Overdrive.2:1 Belt Type / Belt Width 24 mm Carbon Fiber Reinforced Belt Gear Shift Pattern 1 Down. Constant Mesh Clutch Type Wet.34 © Copyright .GENERAL / SPECIFICATIONS Electrical CATEGORY SPECIFICATION Stator Rated Output 710W @ 2000 RPM Battery 12V / 18 AH / 310 CCA.86:1 3rd 1. Coil Spring Primary Drive Type Wet.10:1 5th .38:1 4th 1.94:1 6th . 5 Up Transmission Gear Ratios: 1st 2.

5 in Front Tire Air Pressure 36 PSI (248 kPa) Front Brake. Type Dual Floating Disc / 4 Piston Calipers Rear Tire Type / Size Dunlop Elite 3– 180/60R16 Rear Wheel Cast / 16 in X 5 in Rear Tire Air Pressure 41 PSI (282 kPa) Rear Brake. Specifications may change with the addition of custom order options and / or accessories.9 cm) Front Tube Diameter 46 mm Rear Shock Type Single. 9927618 R03 .7 in (11.5 in (11.35 . Type Single Floating Disc / 2 Piston Caliper Brake Fluid Type DOT 4 All specifications are for Indian Chieftain Elite models.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1. Indian Motorcycle Company reserves the right without prior notice to discontinue at any time at its discretion any of the items herein or change specifications or designs without incurring any obligation to the customer. Monotube Air Adjustable Shock Rear Swingarm Type Cast Aluminum Rear Travel 4. GENERAL / SPECIFICATIONS Suspension CATEGORY SPECIFICATION 1 Front Suspension Type Conventional Telescopic Fork Front Travel 4.4 cm) Wheels / Brakes CATEGORY SPECIFICATION Front Tire Type / Size Dunlop American Elite – 130/60B19 Front Wheel Type / Size Cast / 19 in X 3.

7 in (1491 mm) Seat Height 26.5 in (140 mm) Total Storage Capacity 85 lbs (36 kg) Passenger Capacity 1 Wheelbase 65.5 in (673. Rear 885 lbs (401 kg) Maximum Load 441 lbs (200 kg) Overall Length 104.36 © Copyright .1 mm) Ground Clearance 5.GENERAL / SPECIFICATIONS 2017 ROADMASTER Model Numbers 2017 N17TRAAAAA N17TRAAACB N17TRAAAAB N17TRAAACG N17TRAAAAG N17TRAAACV N17TRAAAAV N17TRAAACX N17TRAAAAX N17TRAAACZ N17TRAAAAZ N17TRAAAEA N17TRAAABA N17TRAAAEB N17TRAAABB N17TRAAAEG N17TRAAABG N17TRAAAEV N17TRAAABV N17TRAAAEX N17TRAAABX N17TRAAAKA N17TRAAABZ N17TRAAAKD N17TRAAACA Chassis CATEGORY SPECIFICATION Dry Weight 912 lbs (414 kg) Wet Weight 944 lbs (428 kg) Gross Vehicle Weight Rating 1385 lbs (628 kg) Gross Axle Weight Rating. Front 500 lbs (227 kg) Gross Axle Weight Rating.0 mm) 9927618 R03 .6 in (2656 mm) Overall Width 39.4 in (1000 mm) Overall Height 58.2017 Indian Motorcycle (Full-Size) Service Manual 1.9 in (150.7 in (1668 mm) Rake / Trail 25° / 5.

2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1.5 gal (20.125 in (54 mm) Fuel Capacity 5.034 in (0.2 L) Oil Type SAE 20W40 (recommended) Lubrication System Semi-Dry Sump Spark Plug Type / Gap DCPR8E / 0.7 kg) Engine Displacement 111 cid (1811 cc) Engine Cooling System Air / Oil Compression Ratio 9.8 L) Fuel Reserve Capacity 1.37 .9 mm) Exhaust System Two O2 Sensors (one in each pipe) / Single three-way catalyst Fuel System CATEGORY SPECIFICATION Fuel System Type Electronic Fuel Injection (ME17) Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 58 psi (400 kPa) Throttle Body Bore Size 2.8 L) Fuel Type 91 Octane recommended ((R+M/2) method) 9927618 R03 .5 qts (5. GENERAL / SPECIFICATIONS Engine CATEGORY SPECIFICATION 1 Engine Number 1205440 Engine Type Thunder Stroke 111 Engine Configuration 49° OHV Pushrod V-Twin Engine Wet Weight 297 lbs (134.5:1 Compression Pressure 90–110 psi (620–758 kPa) Valve Train 2 Valves per cylinder / Hydraulic Lifters Bore x Stroke 101 mm x 113 mm Idle Speed / Fast Idle Spd 800 RPM ± 50 RPM (warm) Oil Capacity 5.0 gal (3.

Sealed Glass Mat Headlights H4 12V 60/55W Long Life Auxiliary Lights H8 35W Tail / Brake LED (non-serviceable) Turn Signals LED (non-serviceable) Starting System Electric Start Ignition System Bosch ME-17 (ECM Controlled) Instrument Type Multifunction Instrument Cluster DC Outlet Standard 12V (Accessory) Drivetrain CATEGORY SPECIFICATION Transmission Type 6 Speed Overdrive. 5 Up Transmission Gear Ratios: 1st 2.81:1 9927618 R03 .10:1 5th .73:1 2nd 1.94:1 6th . Gear Drive w/Torque Compensator Primary Reduction Ratio 1.2017 Indian Motorcycle (Full-Size) Service Manual 1. Constant Mesh Clutch Type Wet. Coil Spring Primary Drive Type Wet.38:1 4th 1. Multi-Plate.2:1 Belt Type / Belt Width 24 mm Carbon Fiber Reinforced Belt Gear Shift Pattern 1 Down.GENERAL / SPECIFICATIONS Electrical CATEGORY SPECIFICATION Stator Rated Output 710W @ 2000 RPM Battery 12V / 18 AH / 310 CCA.38 © Copyright .86:1 3rd 1.56:1 Final Drive Type / Ratio Belt / 2.

7 in (9.5 in Front Tire Air Pressure 36 PSI (248 kPa) Front Brake.68 in (11. Type Dual Floating Disc / 4 Piston Calipers Rear Tire Dunlop Elite 3– 180/60R16 Rear Wheel Cast / 16 in X 5 in Rear Tire Air Pressure 41 PSI (283 kPa) Rear Brake. 9927618 R03 . Specifications may change with the addition of custom order options and / or accessories.9 cm) Front Tube Diameter 46 mm Rear Shock Type Single.39 . GENERAL / SPECIFICATIONS Suspension CATEGORY SPECIFICATION 1 Front Suspension Type Conventional Telescopic Fork Front Travel 4.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1. Monotube Gas with Adjustable Preload Rear Swingarm Type Cast Aluminum Rear Travel 3.4 cm) Wheels / Brakes CATEGORY SPECIFICATION Front Tire Type / Size Dunlop Elite 3– 130/90B16 Front Wheel Type / Size Cast / 16 in X 3. Indian Motorcycle Company reserves the right without prior notice to discontinue at any time at its discretion any of the items herein or change specifications or designs without incurring any obligation to the customer. Type Single Floating Disc / 2 Piston Caliper Brake Fluid Type DOT 4 All specifications are for standard Indian Roadmaster models.

40 © Copyright .7 in (1491 mm) Seat Height 26. Front 500 lbs (227 kg) Gross Axle Weight Rating.7 in (1668 mm) Rake / Trail 25° / 5. Rear 885 lbs (401 kg) Maximum Load 489 lbs (222 kg) Overall Length 103.0 mm) 9927618 R03 .5 in (140 mm) Total Storage Capacity 56 lbs (25 kg) Passenger Capacity 1 Wheelbase 65.1 mm) Ground Clearance 5.2017 Indian Motorcycle (Full-Size) Service Manual 1.5 in (673.5 in (2630 mm) Overall Width 39.GENERAL / SPECIFICATIONS 2017 ROADMASTER CLASSIC Model Numbers 2017 N17TRLAAAA N17TRLAABA N17TRLAACA N17TRLAAEA N17TRLAAAG N17TRLAABG N17TRLAACG N17TRLAAEG N17TRLAAAE N17TRLAABE N17TRLAACE N17TRLAAEE Chassis CATEGORY SPECIFICATION Dry Weight 864 lbs (392 kg) Wet Weight 896 lbs (406 kg) Gross Vehicle Weight Rating 1385 lbs (628 kg) Gross Axle Weight Rating.4 in (1000 mm) Overall Height 58.9 in (150.

0 gal (3.125 in (54 mm) Fuel Capacity 5.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1.41 . GENERAL / SPECIFICATIONS Engine CATEGORY SPECIFICATION 1 Engine Number 1205440 Engine Type Thunder Stroke 111 Engine Configuration 49° OHV Pushrod V-Twin Engine Wet Weight 297 lbs (134.2 L) Oil Type SAE 20W40 (recommended) Lubrication System Semi-Dry Sump Spark Plug Type / Gap DCPR8E / 0.8 L) Fuel Reserve Capacity 1.8 L) Fuel Type 91 Octane recommended ((R+M/2) method) 9927618 R03 .7 kg) Engine Displacement 111 cid (1811 cc) Engine Cooling System Air / Oil Compression Ratio 9.9 mm) Exhaust System Two O2 Sensors (one in each pipe) / Single three-way catalyst Fuel System CATEGORY SPECIFICATION Fuel System Type Electronic Fuel Injection (ME17) Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 58 psi (400 kPa) Throttle Body Bore Size 2.034 in (0.5:1 Compression Pressure 90–110 psi (620–758 kPa) Valve Train 2 Valves per cylinder / Hydraulic Lifters Bore x Stroke 101 mm x 113 mm Idle Speed / Fast Idle Spd 800 RPM ± 50 RPM (warm) Oil Capacity 5.5 qts (5.5 gal (20.

42 © Copyright .94:1 6th . Coil Spring Primary Drive Type Wet. Sealed Glass Mat Headlights H4 12V 60/55W Long Life Auxiliary Lights H8 35W Tail / Brake LED (non-serviceable) Turn Signals LED (non-serviceable) Starting System Electric Start Ignition System Bosch ME-17 (ECM Controlled) Instrument Type Multifunction Instrument Cluster DC Outlet Standard 12V (Accessory) Drivetrain CATEGORY SPECIFICATION Transmission Type 6 Speed Overdrive.56:1 Final Drive Type / Ratio Belt / 2.GENERAL / SPECIFICATIONS Electrical CATEGORY SPECIFICATION Stator Rated Output 710W @ 2000 RPM Battery 12V / 18 AH / 310 CCA.10:1 5th .73:1 2nd 1. Multi-Plate.81:1 9927618 R03 . Constant Mesh Clutch Type Wet.2:1 Belt Type / Belt Width 24 mm Carbon Fiber Reinforced Belt Gear Shift Pattern 1 Down. 5 Up Transmission Gear Ratios: 1st 2.2017 Indian Motorcycle (Full-Size) Service Manual 1.38:1 4th 1.86:1 3rd 1. Gear Drive w/Torque Compensator Primary Reduction Ratio 1.

to ensure you do not exceed the WARNING maximum load capacity.4 cm) Wheels / Brakes CATEGORY SPECIFICATION Front Tire Type / Size Dunlop Elite 3– 130/90B16 Front Wheel Type / Size Cast / 16 in X 3. apparel • weight of any accessories and their contents The maximum load capacity of your motorcycle is the • weight of any additional cargo on the motorcycle maximum weight you may add to your motorcycle without exceeding the GVWR.43 .9 cm) Front Tube Diameter 46 mm Rear Shock Type Single. include the following: Exceeding the gross vehicle weight rating of your • operator body weight motorcycle can reduce stability and handling and • passenger body weight could cause loss of control.68 in (11. 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 ) When determining the weight you will be adding to your motorcycle. NEVER exceed the gross • weight of all riders’ apparel and items in or on vehicle weight rating of your motorcycle. Monotube Gas with Adjustable Preload Rear Swingarm Type Cast Aluminum Rear Travel 3. Refer to Information label section in this manual for location on the motorcycle.5 in Front Tire Air Pressure 36 PSI (248 kPa) Front Brake. 9927618 R03 . GENERAL / SPECIFICATIONS Suspension CATEGORY SPECIFICATION 1 Front Suspension Type Conventional Telescopic Fork Front Travel 4. This capacity is determined by calculating the difference between your motorcycle’s GVWR and wet weight. Type Dual Floating Disc / 4 Piston Calipers Rear Tire Dunlop Elite 3– 180/60R16 Rear Wheel Cast / 16 in X 5 in Rear Tire Air Pressure 41 PSI (283 kPa) Rear Brake.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1. Indian Motorcycle Company reserves the right without prior notice to discontinue at any time at its discretion any of the items herein or change specifications or designs without incurring any obligation to the customer.7 in (9. Refer to the specification section of this manual or the Manufacturing Information / VIN label on the motorcycle frame for model-specific information. Specifications may change with the addition of custom order options and / or accessories. Type Single Floating Disc / 2 Piston Caliper Brake Fluid Type DOT 4 All specifications are for Indian Roadmaster Classic models.

The part numbers are listed in the following table.com/ Service Manuals and Owner’s Manuals can be purchased through any authorized Indian motorcycle dealer.S.2017 Indian Motorcycle (Full-Size) Service Manual 1.GENERAL / SPECIFICATIONS 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 Some Indian Motorcycle publications. http://www.) Chieftain 9927618 9927464 9927431 Chieftain 9927690 Darkhorse Roadmaster 9927431 Springfield 9927432 Classic 9927429 Vintage Chief 9927430 Darkhorse 2017 Indian Motorcycle Chieftain / (CAN) Limited / 9927618 9927466 9925931 Elite Chieftain 9927690 Darkhorse Roadmaster 9927431 Springfield 9927432 Classic 9927429 Vintage Chief 9927430 Darkhorse 2017 Indian Motorcycle Chieftain / (INT’L) Limited / 9927618 9927468 9927431 Elite Chieftain 9927690 Darkhorse Roadmaster 9927431 Springfield 9927432 9927618 R03 .44 © Copyright . such as Owner’s Manuals and Parts Books may be available on-line at the Indian Motorcycle website. MODEL YEAR / SERVICE MANUAL OWNER’S MANUAL PARTS BOOK MODEL MARKET PART NUMBERS PART NUMBERS PART NUMBERS Classic 9927429 Vintage Chief 9927430 Darkhorse 2017 Indian Motorcycle (U.indianmotorcycle.

45 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1. GENERAL / SPECIFICATIONS REFINISHING PA I N T C O L O R S B Y M O D E L 1 2017 CHIEF CLASSIC 2017 CHIEFTAIN MODEL PAINT MODEL PAINT PAINT COLOR PAINT COLOR NUMBER CODE NUMBER CODE N17CCCAAAK N17TCAAAA1 N17CCCAABK N17TCAAAB1 Thunder Black Pearl P-666 N17CCCAACK Pearl White P-566 N17TCAAAC1 N17CCCAAEK N17TCAAAE1 N17CCCAAKK N17TCAAAA6 N17CCCAAAD N17TCAAAB6 White Smoke P-675 N17CCCAABD N17TCAAAC6 Burgundy Metallic / P-629 N17CCCAACD N17TCAAAE6 Thunder Black P-266 N17CCCAAED N17TCAAAAS N17CCCAAKD N17TCAAABS N17CCCAAAZ N17TCAAACS Silver Smoke P-581 N17CCCAABZ Unpainted NA N17TCAAAES N17CCCAACZ N17TCAAAKS N17TCAAAAT 2017 CHIEF DARK HORSE N17TCAAABT Star Silver / P-354 / N17TCAAACT Thunder Black P-266 MODEL PAINT PAINT COLOR N17TCAAAET NUMBER CODE N17TCAAAAP N17CCDAAAH N17TCAAABP Wildfire Red / P-676 / N17CCDAABH Thunder Black Smoke P-463 N17TCAAACP Thunder Black P-266 N17CCDAACH N17TCAAAEP N17CCDAAEH N17TCAAAAZ 2017 CHIEF VINTAGE N17TCAAABZ Unpainted NA N17TCAAACZ MODEL PAINT PAINT COLOR NUMBER CODE 2017 CHIEFTAIN DARK HORSE N17CCVAAAA N17CCVAABA MODEL PAINT PAINT COLOR N17CCVAACA Thunder Black P-266 NUMBER CODE N17CCVAAEA N17TCDAAAH N17CCVAAKA N17TCDAABH N17CCVAAAE Thunder Black Smoke P-463 N17TCDAACH N17CCVAABE Indian Red / N17TCDAAEH P-639 / N17CCVAACE Ivory Cream P-646 N17CCVAAEE N17CCVAAKE 2017 CHIEFTAIN LIMITED N17CCVAAAG MODEL PAINT PAINT COLOR N17CCVAABG Willow Green / P-670 / NUMBER CODE N17CCVAACG Ivory Cream P-646 N17TCNAAAA Thunder Black P-266 N17CCVAAEG N17TCNAAAP N17CCVAAAF Springfield Blue / N17TCNAABP Wildfire Red / P-676 / N17CCVAABF P-640 / Ivory Cream N17TCNAACP Thunder Black P-266 N17CCVAACF P-646 N17TCNAAEP N17CCVAAEF N17CCVAAAZ N17TCNAAA6 N17CCVAABZ Unpainted NA N17TCNAAB6 White Smoke P-675 N17CCVAACZ N17TCNAAC6 N17TCNAAE6 9927618 R03 .

46 © Copyright .2017 Indian Motorcycle (Full-Size) Service Manual 1.GENERAL / SPECIFICATIONS 2017 CHIEFTAIN LIMITED 2017 ROADMASTER CLASSIC MODEL PAINT MODEL PAINT PAINT COLOR PAINT COLOR NUMBER CODE NUMBER CODE N17TCNAAAT N17TRLAAAA N17TCNAABT Star Silver / P-354 / N17TRLAABA Thunder Black P-266 N17TCNAACT Thunder Black P-266 N17TRLAACA N17TCNAAET N17TRLAAEA N17TCNAAAS N17TRLAAAG N17TCNAABS N17TRLAABG Willow Green / P-670 / Silver Smoke P-581 Ivory Cream N17TCNAACS N17TRLAACG P-646 N17TCNAAES N17TRLAAEG N17TRLAAAE 2017 CHIEFTAIN ELITE N17TRLAABE Indian Red / P-639 / N17TRLAACE Ivory Cream P-646 MODEL PAINT PAINT COLOR N17TRLAAEE NUMBER CODE Red Candy / N17TCEAAA4 P-1627 Thunder Black 2017 ROADMASTER MODEL PAINT PAINT COLOR NUMBER CODE N17TRAAAAA N17TRAAABA N17TRAAACA Thunder Black P-266 N17TRAAAEA N17TRAAAKA N17TRAAAAG N17TRAAABG Willow Green / P-670 / N17TRAAACG Ivory Cream P-646 N17TRAAAEG N17TRAAAAV N17TRAAABV Burgundy Metallic P-629 N17TRAAACV N17TRAAAEV N17TRAAAAX N17TRAAABX Thunder Black / P-266 / N17TRAAACX Ivory Cream P-646 N17TRAAAEX N17TRAAAAB N17TRAAABB Steel Gray / P-266 / N17TRAAACB Thunder Black P-692 / N17TRAAAEB N17TRAAAKB N17TRAAAAZ N17TRAAABZ Unpainted NA N17TRAAACZ 9927618 R03 .

47 . GENERAL / SPECIFICATIONS 2017 SPRINGFIELD MODEL PAINT COLOR PAINT 1 NUMBER CODE N17THAAAAA N17THAAABA N17THAAACA Thunder Black P-266 N17THAAAEA N17THAAAKA N17THAAAAR N17THAAABR Indian Red P-639 N17THAAACR N17THAAAER N17THAAAAL N17THAAABL Steel Gray/ P-692 / N17THAAACL Burgundy Metallic P-629 N17THAAAEL N17THAAAKL N17THAAAAM N17THAAABM Blue Sapphire / P-598 / N17THAAACM Silver Star P-354 N17THAAAEM N17THAAAAZ N17THAAABZ Unpainted NA N17THAAACZ 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1.

manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful life. Among those acts presumed to constitute tampering are the acts listed below: 3. S. The Electronic Control Module produce photochemical smog. Removal of. header pipes or any other component which conducts exhaust gases. The Electronic Fuel Injection (EFI) and Electronic Throttle Control (ETC) systems control idle speed. or 2. 5. no adjustments should be made to the system. 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.730 mi) after the through the air cleaner into the combustion chamber. charcoal inside the canister temporarily stores fuel Hydrocarbons must be controlled because under system vapors until the engine is started and the some conditions hydrocarbons react with sunlight to motorcycle is driven. Activated monoxide and hydrocarbons during operation. Lack of proper maintenance. time of sale to the ultimate purchaser. 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 M O D E L S ) EMISSION SOURCES California and International models are equipped with An internal combustion engine produces carbon an Evaporative Emissions Canister q. The use of the motorcycle after such device or element of design has been removed or rendered inoperative. when operated and maintained according to the instructions provided.GENERAL / SPECIFICATIONS E M M I S I O N S I N F O R M AT I O N EMISSION CONTROL SYSTEMS 6. 4. Replacing any moving part of the motorcycle or The U. 9927618 R03 . baffles. 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. and that motorcycles built after CRANKCASE EMISSION CONTROL The crankcase emission control system is comprised January 1. NOISE EMISSION CONTROL Tampering with Noise Control Systems is Prohibited.48 © Copyright .000 km (3. 1983 comply with applicable noise emission of a closed system that routes crankcase emissions standards for one year or 6. or puncturing the muffler. Federal law prohibits the following acts or causing thereof: 1. repair or replacement. The removal or rendering inoperative by any person other than for purposes of maintenance. and engine intake vacuum draws vapors out of the canister.2017 Indian Motorcycle (Full-Size) Service Manual 1. under certain conditions. If components are replaced that affect idle speed. Carbon monoxide must (ECM) automatically opens a Purge Control Valve be controlled because it is toxic. 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. Removal or puncturing of any part of the intake system.

9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1. The Special Tools section at the of causing damage to the motorcycle during service. service technicians representation of the special tools used throughout can maximize efficiency and minimize the likelihood this service manual.49 . beginning of each chapter provides a short list of the tools required to perform procedures specific to that chapter. GENERAL / SPECIFICATIONS 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.

2017 Indian Motorcycle (Full-Size) Service Manual 1. SPECIAL TOOLS INDEX ABS Tool (Brake Lever Reserve) Battery Tester Bearing Removal Kit PV-50104 PU-50296 PF-51324 9927618 R03 . Bosch Automotive Service Solutions.GENERAL / SPECIFICATIONS 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. by phone at 1-800-328-6657 or on-line via your dealer website. if available. Dealers may order special tools through Indian Motorcycle’s official tool supplier. Indian Motorcycle recommends use of the Special Tools referenced in the chapters of this service manual when servicing any Indian Motorcycle product. while other tools may be substituted with a similar tool.50 © Copyright .

51 . GENERAL / SPECIFICATIONS Belt Tension Meter Body Panel Tool Kit Cartridge Shaft Tool PV-43532 PV-49955 PV-49452 1 Crankcase Tool Clutch Shaft Holding Tool Crankshaft Locking Pin PF-51234 PF-51232 PF-52135 Crankshaft Rotation Tool Damper Rod Holder Electrical Tester Kit PF-51239 PV-49453 PV-43526 Engine Stand Adapter Fork Spring Compressor Adapter Fork Oil Level Tool PF-51240 PV-49464 PV-59000A 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1.

2017 Indian Motorcycle (Full-Size) Service Manual 1.52 © Copyright .GENERAL / SPECIFICATIONS 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 Output Shaft Seal Tool Relay Bypass Tool Shock Air Pump PF-51243 PU-49466 PV-48909 9927618 R03 .

GENERAL / SPECIFICATIONS Shock Spanner Wrench Smartlink Module Kit Spanner Socket (Stem) PV-46993 PU-47471 PV-43508 1 Swingarm Bushing Tool TPMS Activation Tool USB to Serial Adapter PF-51237 PF-51288 PU-50621 Cam Installation Tool PF-51455 9927618 R03 .53 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1.

Brake Disc fasteners 22 ft-lbs (30 Nm) Step 3: 40 ft-lbs (54 Brake Lever Cap fastener 70 in-lbs (8 Nm) Nm) Cylinder Head Banjo 18 ft-lbs (24 Nm) Cylinder fasteners 25 ft-lbs (34 Nm) Brake Line Studs Mounting 84 in-lbs (10 Nm) Cylinder fasteners Head 71 in-lbs (8 Nm) Brake Pad Retaining Pin 120 in-lbs (14 Nm) Temperature Sensor Brake Pedal Pad fasteners 84 in-lbs (10 Nm) Display Bracket fasteners (top) 36 in-lbs (4 Nm) Brake Pressure Switches 18 ft-lbs (24 Nm) Display Bracket fasteners (bottom) 84 in-lbs (10 Nm) Bearing Retainer Detent Roller fastener 89 in-lbs (10 Nm) 62 in-lbs (7 Nm) Plate 45 ft-lbs (60 Nm) Down Tube fasteners fasteners Drive Motor Hinge fasteners 84 in-lbs (10 Nm) Camshaft Carrier Carrier 15 ft-lbs (20 Nm) fasteners Cover 84 in-lbs (10 Nm) Carrier fasteners Bearing 52 ft-lbs (70 Nm) Sprocket Nut 180 ft-lbs (244 Nm) fasteners Drive Sprocket Sprocket Nut Chain Cover 15 ft-lbs (20 Nm) Retainer 88 in-lbs (10 Nm) Cam Chain Tensioner fasteners Plate 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual 1.54 © Copyright .GENERAL / SPECIFICATIONS REFERENCE M A S T E R T O R Q U E TA B L E ITEM TORQUE ITEM TORQUE ABS Module Bracket fasteners 84 in-lbs (10 Nm) Chain Guide 71 in-lbs (8 Nm) fasteners ABS Pulse Ring / Brake Disc 22 ft-lbs (30 Nm) fasteners Tensioner 15 ft-lbs (20 Nm) fastener Bracket 88 in-lbs (10 Nm) fasteners Camshaft Sprocket fasteners 52 ft-lbs (70 Nm) Cover 84 in-lbs (10 Nm) Cable Air Box fasteners Adjuster Jam 48 in-lbs (5 Nm) Retainer Nut 86 in-lbs (10 Nm) fastener Cable Guide 84 in-lbs (10 Nm) Filter fastener 62 in-lbs (7 Nm) fasteners Lever Cap 70 in-lbs (8 Nm) Air Filter Adapter fastener Plate 31 in-lbs (4 Nm) Pinion Shaft fasteners Clutch Lever 88 in-lbs (10 Nm) Auxiliary Light Bar Bracket fasteners 18 ft-lbs (24 Nm) fastener 31 in-lbs (4 Nm) Spring 89 in-lbs (10 Nm) Baffle Plate fasteners fasteners Drive Gear 10 ft-lbs (14 Nm) 125 ft-lbs (170 Nm) Stake Nut fasteners Balance Shaft Switch Cover Driven Gear 6 in-lbs (1 Nm) 59 ft-lbs (80 Nm) fasteners fastener Switch 6 in-lbs (1 Nm) Box 84 in-lbs (10 Nm) fastener fasteners Battery to Connecting Rod Bearing Cap 22 ft-lbs (30 Nm) Battery Starter Motor 63 in-lbs (7 Nm) fastener Nut Console Bracket fasteners 43 in-lbs (5 Nm) Terminal 40 in-lbs (5 Nm) Console Panel fasteners 84 in-lbs (10 Nm) Fasteners Crankcase fasteners 22 ft-lbs (30 Nm) Bezel fasteners 36 in-lbs (4 Nm) Crankshaft Position Sensor 89 in-lbs (10 Nm) Bezel fasteners (Vintage/Springfield) 12 in-lbs (1 Nm) Crankshaft Sprocket fastener 52 ft-lbs (70 Nm) Blind Plug 15 ft-lbs (20 Nm) Step 1: 22 ft-lbs (30 Brake Bleeder fasteners 48 in-lbs (5 Nm) Nm) Brake Caliper Cover Acorn Nut 18 in-lbs (2 Nm) Cylinder Step 2: Back nuts off Head Nuts completely.

2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1.55 . GENERAL / SPECIFICATIONS ITEM TORQUE ITEM TORQUE ECM fasteners 36 in-lbs (4 Nm) 18 ft-lbs (24 Nm) Heat Shield Clamps 31 in-lbs (4 Nm) 1 Front Lower Engine Mounts 35 ft-lbs (48 Nm) Rear 75 ft-lbs (102 Nm) fasteners Highway Bar Upper 18 ft-lbs (24 Nm) Evaporative Emissions Canister 84 in-lbs (10 Nm) fasteners fasteners Hinge fasteners 45 in-lbs (5 Nm) Exhaust Clamps 31 ft-lbs (42 Nm) Horn to Bracket Nut 84 in-lbs (10 Nm) Clamp 36 in-lbs (4 Nm) fasteners Ignition Coil 84 in-lbs (10 Nm) Inner Ignition Cover fasteners 84 in-lbs (10 Nm) Mounting 12 ft-lbs (16 Nm) Fairing Intake Manifold Boots 89 in-lbs (10 Nm) Nuts Outer Intake Manifold Clamps 20 in-lbs (2 Nm) Mounting 36 in-lbs (4 Nm) Knock Sensor 15 ft-lbs (20 Nm) Nuts 84 in-lbs (10 Nm) Latch Assembly fasteners 65 in-lbs (7 Nm) Fender fasteners Pivot Latch Striker fasteners 36 in-lbs (4 Nm) 18 ft-lbs (24 Nm) fasteners LED Trunk Light fasteners 36 in-lbs (4 Nm) Floorboard Support 35 ft-lbs (48 Nm) Left Hand Lower Side Cover fasteners 84 in-lbs (10 Nm) fastener Blank 35 ft-lbs (48 Nm) License Plate Bracket fasteners 84 in-lbs (10 Nm) fastener Foot Peg License Plate Light fasteners 15 in-lbs (2 Nm) Mounting 35 ft-lbs (48 Nm) fasteners Lift Arm fasteners 84 in-lbs (10 Nm) Fork Cartridge fastener 17 ft-lbs (23 Nm) Lifter Block fasteners 89 in-lbs (10 Nm) Fork Clamp fasteners 18 ft-lbs (24 Nm) Lifter Retaining Plate fasteners 62 in-lbs (7 Nm) Fork Cap to Jam Nut 11 ft-lbs (15 Nm) Lock Actuator fasteners 13 ft-lbs (18 Nm) Fork Cap to Outer Tube 16 ft-lbs (22 Nm) Lower Belt Guard 96 in-lbs (11 Nm) Frame Down Tube fasteners 45 ft-lbs (60 Nm) Luggage Rack fasteners 12 in-lbs (1 Nm) Front Axle 52 ft-lbs (71 Nm) Master Cylinder Jam Nut 35 ft-lbs (48 Nm) Front Axle Pinch fasteners 18 ft-lbs (24 Nm) Main Plate Mounting fasteners 88 in-lbs (10 Nm) Front Caliper Body fasteners 20 ft-lbs (27 Nm) Lower 75 ft-lbs (102 Nm) Midcast fasteners Front Caliper Stud 35 ft-lbs (48 Nm) Upper 35 ft-lbs (48 Nm) Front Fender fasteners 18 ft-lbs (24 Nm) Muffler Hanger fasteners 18 ft-lbs (24 Nm) Front Master Cylinder 70 in-lbs (8 Nm) Mounting 84 in-lbs (10 Nm) fastener Front Master Cylinder Cover 14 in-lbs (2 Nm) fasteners Oil Cooler Supply/ Return Line 84 in-lbs (10 Nm) Fuel Injector Retaining fasteners 89 in-lbs (10 Nm) fasteners Fuel Pump Nut 24 in-lbs (3 Nm) Adapter 88 in-lbs (10 Nm) Fuel Tank Mounting fasteners 18 ft-lbs (25 Nm) Oil Filter fasteners 63 in-lbs (7 Nm) Filter Fitting 22 ft-lbs (30 Nm) Fuse Box fastener Gear Position Switch 43 in-lbs (5 Nm) Oil Jet fasteners 62 in-lbs (7 Nm) Grip Retaining fastener 35 in-lbs (4 Nm) Drain Plug 15 ft-lbs (20 Nm) Ground Wire fastener 84 in-lbs (10 Nm) Inlet Screen 88 in-lbs (10 Nm) Gusset Plate 55 ft-lbs (75 Nm) Oil Pan Scavenge Tube 88 in-lbs (10 Nm) Head Pipe Nuts 15 ft-lbs (20 Nm) Mounting Head Pipe Trim Cover fasteners 84 in-lbs (10 Nm) fasteners Assembly 88 in-lbs (10 Nm) Bracket 12 in-lbs (1 Nm) fasteners fastener Oil Pump Headlight Pickup Carrier 88 in-lbs (10 Nm) 75 in-lbs (8 Nm) fasteners fasteners 9927618 R03 .

Spool fasteners 25 ft-lbs (34 Nm) 84 in-lbs (10 Nm) S.S.56 © Copyright . Front 36 in-lbs (4 Nm) Seat Fasteners 18 ft-lbs (24 Nm) Upper Pushrod fastener 55 ft-lbs (75 Nm) Seat Fasteners (Except Darkhorse) 84 in-lbs (10 Nm) Valve Cover fasteners 89 in-lbs (10 Nm) Seat fasteners 14 in-lbs (2 Nm) Valve Stem Lock Nut 13 in-lbs (2 Nm) Shift Rod Jam Nuts 84 in-lbs (10 Nm) Valve Stem Nut 44 in-lbs (5 Nm) Shifter Toe Pedal 18 ft-lbs (24 Nm) VCM Mounting Plate fastener 84 in-lbs (10 Nm) Shock Absorber fasteners 55 ft-lbs (75 Nm) Wheel Speed Sensor 96 in-lbs (11 Nm) Shock Air Line Jam Nut 20 ft-lbs (27 Nm) Wheel Spoke 69 in-lbs (8 Nm) Bumper 84 in-lbs (10 Nm) Mounting fastener 36 in-lbs (4 Nm) Windshield fasteners Pivot 37 ft-lbs (50 Nm) Motor Nuts 36 in-lbs (4 Nm) Side Stand fastener Switch 43 in-lbs (5 Nm) fasteners 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual 1. Then Back 12 in-lbs (1 Nm) Rear fasteners Trunk Rocker Arm fastener 22 ft-lbs (30 Nm) Base 13 ft-lbs (18 Nm) fasteners Saddlebag Mounting Cylinder 25 in-lbs (34 Nm) fasteners Turn Signal fastener 18 ft-lbs (24 Nm) Saddlebag fasteners 84 in-lbs (10 Nm) Turn Signal fastener.) Starter Motor fasteners 89 in-lbs (10 Nm) Passenger to Driver Seat fasteners 84 in-lbs (10 Nm) Starter Solenoid Mounting fasteners 84 in-lbs (10 Nm) (Except Darkhorse) Pressure Plate fasteners 88 in-lbs (10 Nm) Starter Terminal (B+) Nut 60 in-lbs (7 Nm) Primary Cover fasteners 15 ft-lbs (20 Nm) Stator fasteners 88 in-lbs (10 Nm) Steering Lock fasteners 18 ft-lbs (24 Nm) Step 1: 15 ft-lbs (20 Nm) Steering Stem Adjuster Nut 29 ft-lbs (39 Nm) Rear Axle Nut Step 2: 65 ft-lbs (88 Strap fasteners 8 ft-lbs (11 Nm) Nm) Strut Cover fasteners 84 in-lbs (10 Nm) Rear Caliper Mounting fasteners 31 ft-lbs (42 Nm) Swing-arm Nut 65 ft-lbs (88 Nm) Rear Caliper Slide fasteners 20 ft-lbs (27 Nm) Swing-arm Shaft (Initial Torque) 8 ft-lbs (11 Nm) Rear Head Pipe Hanger fasteners 18 ft-lbs (24 Nm) Swing-arm Shaft Jam Nut 75 ft-lbs (102 Nm) Rear Lower Subframe fasteners 18 ft-lbs (24 Nm) Switch Cubes 31 in-lbs (4 Nm) Rear Master Cylinder Cover 7 in-lbs (1 Nm) fasteners Switch Cubes (2018 models) 7 in-lbs (1 Nm) Rear Nacelle Cover fasteners 36 in-lbs (4 Nm) Tail Light fastener 84 in-lbs (10 Nm) Rear Subframe fasteners 35 ft-lbs (48 Nm) Throttle Body fasteners 89 in-lbs (10 Nm) Bracket 84 in-lbs (10 Nm) TMAP Sensor fastener 62 in-lbs (7 Nm) fasteners Rectifier Tone Ring fasteners 18 ft-lbs (24 Nm) Crankcase 89 ft-lbs (10 Nm) fasteners Torque Compensator fastener 83 ft-lbs (112 Nm) Ride Command Display Fasteners 36 in-lbs (4 Nm) Torque Compensator Locking Plate 88 in-lbs (10 Nm) fastener Right Hand Sprocket Cover fastener 84 in-lbs (10 Nm) TPMS Sensor fastener 44 in-lbs (5 Nm) Riser fasteners 60 ft-lbs (81 Nm) Triple Clamp Nut.GENERAL / SPECIFICATIONS ITEM TORQUE ITEM TORQUE Oil Pressure Sensor 88 in-lbs (10 Nm) Solenoid Terminal (B+) Nut 60 in-lbs (7 Nm) Oil Pressure Sensor Adapter 15 ft-lbs (20 Nm) Spark Plug 13 ft-lbs (17 Nm) Oxygen Sensors 14 ft-lbs (19 Nm) Speedometer Bracket fasteners 15 in-lbs (2 Nm) P-Clamp fasteners (Brake Line / W. Top 72 ft-lbs (98 Nm) 18 ft-lbs (24 Nm) Triple Clamp Pinch fasteners 18 ft-lbs (24 Nm) Riser Clamp fasteners Tighten Front fasteners First.

406 13/32 #12-24 #17 1 1/2-12 1 27/64 12x1.277 9/32 #5-40 #38 7/8-14 13/16 #5-44 #37 1-8 7/8 8x1.57 .0995 3/32 #1-64 #53 1/2-20 29/64 3x. FRAC- SIZE LENT TION #0-80 3/64 1/2-13 27/64 3x.3437 11/32 #8-36 #29 1 1/4-7 1 7/64 10x1.3125 5/16 #8-32 #29 1 1/8-12 1 3/64 10x1.25 11/32 0.70 #30 0.265 17/64 #6-32 #36 1-12 59/64 9x1.0937 3/32 #1-72 #53 9/16-12 31/64 4x.50 13/32 0.25 17/64 0.00 J 0.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1.339 11/32 #10-24 #24 1 1/4-12 1 11/64 11x1.3125 5/16 #6-40 #33 1 1/8-7 63/64 9x1.125 1/8 #2-64 #50 5/8-11 17/32 5x.166 11/64 #3-48 5/64 5/8-18 37/64 5x.75 1/8 0.60 3/32 0.00 #9 0.161 5/32 #3-56 #45 3/4-10 21/32 6x1.50 3/8 0.196 13/64 #4-40 #43 3/4-16 11/16 7x1.50 R 0.375 3/8 #10-32 #21 1 1/2-6 1 11/32 12x1.00 5/16 0.00 16/64 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 9927618 R03 .25 5/16 0.75 13/32 0.50 #39 0.234 15/64 #4-48 #42 7/8-9 49/64 8x1.90 #20 0.80 #19 0.1285 1/8 #2-56 #51 9/16-18 33/64 4x. GENERAL / SPECIFICATIONS 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.

5156 in 17/32 in = .3543 in] 23/64 in = .1719 in 57/64 in = .9063 in 13/64 in = .1969 in] 29/32 in = .0312 in [1 mm = .3438 in [9 mm = .9219 in 7/32 in = .5512 in] 9/16 in = .8661 in] 5/32 in = .3281 in 11/32 in = .3937 in] 13/32 in = .9843 in] 17/64 in = .0 in 19/64 in = .3125 in [8mm= .1875 in [5 mm = .1406 in 55/64 in = .7656 in 1/16 in = .9688 in [25 mm = .7969 in 3/32 in = .5625 in 37/64 in = .9055 in] 3/16 in = .7188 in 9927618 R03 .7874 in] 5/64 in = .8906 in [23 mm = .625 in [16mm=.0394 in] 3/4 in = .4331 in] 7/16 in = .1575 in] 7/8 in = .3594 in 3/8 in = .2969 in 5/16 in = .6406 in 21/32 in = .2656 in [7 mm = .4219 in [11 mm =.6719 in 11/16 in = .8594 in [22 mm = .7087 in] 23/32 in = .1094 in [3 mm = .8281 in 1/8 in = .0781 in [2 mm = .2344 in [6 mm = .75 in 3/64 in = .5118 in] 33/64 in = .875 in 11/64 in = .GENERAL / SPECIFICATIONS D E C I M A L E Q U I VA L E N T S 1/64 in = .4844 in 1/2 in = .9449 in] 15/64 in = .5469 in [14 mm = .8438 in 9/64 in = .9844 in 9/32 in = .375 in 25/64 in = .1250 in 27/32 in = .0469 in 49/64 in = .4375 in 29/64 in = .2756 in] 63/64 in = .6094 in 5/8 in = .6563 in [17 mm = .6693 in] 43/64 in = .2031 in 59/64 in = .0156 in 47/64 in = .1181 in] 53/64 in = .6875 in 45/64 in = .0625 in 25/32 in = .7480 in] 1/32 in = .4724 in] 31/64 in = .25 in 31/32 in = .5313 in 35/64 in = .8125 in [21 mm =.9531 in 1/4 in = .4531 in 15/32 in = .0938 in 13/16 in = .2813 in 1 in = 1.3906 in [10 mm = . 8268 in] 7/64 in = . 6299 in] 41/64 in = .58 © Copyright .7031 in [18 mm = .2362 in] 61/64 in = .4688 in [12 mm = .3150 in] 21/64 in = .5906 in] 19/32 in = .0787 in] 51/64 in = .7344 in [19 mm = .2188 in 15/16 in = .5938 in 39/64 in = .4063 in 27/64 in = .5 in [13mm = .7813 in [20 mm = .1563 in [4 mm = .5781 in [15 mm = .2017 Indian Motorcycle (Full-Size) Service Manual 1.9375 in [24 mm = .

GENERAL / SPECIFICATIONS FA H R E N H E I T T O C E L S I U S MEASUREMENT CONVERSION CHART oC to oF: 9 (oC + 40) ¸ 5 .833 quarts US quarts x.54 = cm 122 50 mile x 1.137 = liters (l) = Imperial liters (l) x.946 = liters liters x 1.035 = Ounces (oz) 167 75 = Fluid Ounces cc’s x.0115 = kg-m 50 10 Nm x.454 = kg 194 90 kg x 2.57 = CCs 158 70 grams (g) x.233 = ft-lbs 68 20 77 25 kg-m x 86.88 quarts Imperial quarts x 1.6 = km 131 55 km x.785 = liter 9927618 R03 .568 = liters (l) liters (l) x 1.057 = US quarts US gallon x 3.2046 = lbs 203 95 = Cubic Cubic Inches x 16.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 1.03381 (oz) 176 80 185 85 lbs x. 40=oC MEASURE BY ft-lbs x 12 = in-lbs DEGREES F DEGREES C in-lbs x.03937 = in 113 45 in x 2.76 = Imperial pints Imperial quarts x 1.061 = Cubic Inches Centimeters Imperial pints x.4 = mm 104 40 mm x.201 = US quarts = Imperial US quarts x.6214 = mile 140 60 Ounces (oz) x 28.0833 = ft-lbs 32 0 ft-lbs x 1.796 = in-lbs 86 30 kg-m x 10 = Nm 95 35 in x 25.59 .356 = Nm 41 5 in-lbs x.7376 = ft-lbs 59 15 kg-m x 7.40 = oF UNIT OF MULTIPLIED COVERTS TO 1 oF to oC: 5 (o F + 40) ¸ 9 .35 = grams (g) 149 65 Fluid Ounce x 29.387 212 100 Centimeters Cubic x.

145 per square inch (kPa) (psi) Kilo pascals = Kilograms (kPa) x .GENERAL / SPECIFICATIONS UNIT OF MULTIPLIED COVERTS TO MEASURE BY liter x .60 © Copyright .14159) x R2 x H (height) = Cylinder Volume 9927618 R03 .1 (kPa) p (3.895 (kPa) (psi) = Pounds force Kilo pascals x .264 = US gallon Pounds force = Kilo pascals per square inch x 6.01 force per cm2 Kilograms force = Kilo pascals per cm2 x 98.2017 Indian Motorcycle (Full-Size) Service Manual 1.

. . . . . . . . . . . . . . . . . . .8 SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 CLUTCH CABLE INSPECTION / LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . .23 SPARK PLUG INSPECTION / GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE CHAPTER 2 MAINTENANCE MAINTENANCE QUICK REFERENCE GUIDE . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 IDLE SPEED / FAST IDLE SPEED .2. . . . . . . . . . . . . . . . . . .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. . . . . . . . . .26 BATTERY CHARGING . . . . . . .15 BRAKE PEDAL LUBRICATION . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . .9 ENGINE OIL & FILTER CHANGE. . . . . . . . . . . . .2. . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 INDIAN MOTORCYCLE SERVICE PRODUCTS AND LUBRICANTS . . . . . . . . . . . . . . . . .18 FRONT BRAKE PAD INSPECTION . . . . . . .17 BRAKE FLUID LEVEL INSPECTION . . . . . . . . . . . . 2. . .8 MAINTENANCE PROCEDURES . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . .27 9927618 R03 . . . . . . . . . . . . . . . . . . . . .13 FRONT BRAKE LEVER INSPECTION . . 2. . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 SPARK PLUG INSTALLATION . 2. . . . . . . . . . . . . . . .24 ENGINE COMPRESSION TEST . . . . . . . . . . . . . 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 SPARK PLUG REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2. . . . .2. . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . .21 EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA AND INTERNATIONAL MODELS) . . . . . . . . . . . . . . . . . . . .13 CLUTCH LEVER FREE PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 FUEL TANK VENT INSPECTION (49 STATE) . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .20 CRANKCASE VENTILATION SYSTEM. . . . . . . . . . . 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 FRONT BRAKE LEVER LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 SHIFT PEDAL INSPECTION / LUBRICATION . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . 2.26 BATTERY STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . .8 SERVICE NOTES .12 CLUTCH LEVER LUBRICATION . . . . . . . . . . . .10 TIRE PRESSURE / SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 BREAK-IN PROCEDURE . . . . . . .19 REAR BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 ENGINE COMPRESSION TEST (WET) . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 SHIFT PEDAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 ENGINE OIL LEVEL . . . .3 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 FRONT BRAKE LEVER REACH . . . . 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 AIR FILTER REPLACEMENT . . . . . . . . . . . . . .1 . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . .26 BATTERY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 FUEL SUPPLY HOSE (FUEL RAIL) INSPECTION . . . . . . . . . . . . . . . . .MAINTENANCE . . . . . . . . . . . . . . . . . . . . .5 PERIODIC MAINTENANCE INTERVAL TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 BRAKE PEDAL INSPECTION . . . . . . . . . . . .

. . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . .2017 Indian Motorcycle (Full-Size) Service Manual 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPRINGFIELD / CHIEFTAIN / ROADMASTER . . . . . . . . . . . . . . . .37 REAR SHOCK PRELOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . .SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . .37 REAR SHOCK PRELOAD INSPECTION . . . . . . . . . . . . . . .CHIEF MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 DRIVE BELT DEFLECTION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 SIDESTAND INSPECTION . . .36 STEERING HEAD / FRONT WHEEL INSPECTION . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 DRIVE BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32 FUSE REPLACEMENT . . . . . . . . .36 SWINGARM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . .2 © Copyright . . . . . . . . . . . .28 DRIVE BELT TENSION MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAINTENANCE DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 SIDESTAND REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 DRIVE BELT SPECIFICATIONS . . . . . .CHECK WHEEL SPOKES . . . . . . . . . .2. . .2. . .30 DRIVE BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . .40 9927618 R03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 DRIVE BELT FREQUENCY TENSION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 REAR SHOCK PRELOAD ADJUSTMENT .32 HEADLIGHT AIM INSPECTION . . . . . . . . .2. . . . . . . . . . . . . .2. . . . . . . . . . .34 HEADLIGHT AIM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . .

04 in (1. See adjustment procedure outlined in this — Load) chapter Spark Plug Type / Gap NGK DCPR8E / GAP — .16 in (4.5 mm) .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: 1.3“ (34 mm) or 11 notches up on belt guard. Front . Ride Height (Rear Spring Pre.20 in (5.5 mm) Clutch Lever Freeplay .3 .0 mm) .6 mm) Valve Lash (Int.04 in (1. Front .25 in (6.28 in (7 mm) .5–1.18 in (4. / Ex. MAINTENANCE MAINTENANCE QUICK REFERENCE GUIDE S P E C I F I C AT I O N S .0 mm) Brake Disc Thickness.063 in (1. Rear .26 in (6. Chieftain / Roadmaster / Springfield: 1.0 mm) .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2.) NOT ADJUSTABLE (Lash is self-adjusting via — hydraulic lifters) 9927618 R03 .034 in (0. Rear . Lubrication @ 60 PSI (414 kPa) ± 15% 30 PSI (207 kPa) 3000 rpm Engine at operating temperature.059” (0.019–.0 mm) Minimum Brake Disc Thickness.1“ (28 mm) — lbs force) or 8 notches up on belt guard.M A I N T E N A N C E General Specifications ITEM STANDARD SERVICE LIMIT Battery Type / CCA 12 Volt / 18 AH / 310 CCA — 2 Brake Pad Thickness. Fuel Pressure (KOEO) 58 psi (400 kPa) 51 psi (350 kPa) Idle Speed / Fast Idle Speed 800 RPM ±50 RPM Oil Pressure.9 mm) — FRONT: All Models (EXCEPT Springfield): 36 PSI (248 — kPa) Springfield: 46 PSI (317 kPa) Tire Pressure REAR: — Chief Classic / Chief Vintage / Chief Dark Horse: 40 PSI (276 kPa) Springfield / Chieftain Dark Horse / Chieftain / Roadmaster / : 41 PSI (282 kPa) Tire Tread Depth (Minimum) — .5 mm) Brake Pad Thickness.

8 L) / Reserve 1. Seat Fasteners 18 ft-lbs (24 Nm) Spark Plugs 13 ft-lbs (17 Nm) Fluid Specifications DESCRIPTION FLUID TYPE CAPACITY Brake Hydraulic Fluid DOT 4 — Engine / Transmission Oil Semi-Synthetic 20W40 Engine Oil 5.8 L) 9927618 R03 .4 © Copyright .0 gal (3.8 oz (557 cc) per leg Roadmaster / Springfield) Fuel 91 Octane (Recommended) 5.1 Nm)63 in-lbs (7 Nm) Brake Bleeder Fasteners (Caliper) 48 in-lbs (5 Nm) Drive Sprocket Nut 180 ft-lbs (244 Nm) Drive Sprocket Nut Retainer Plate 88 in-lbs (10 Nm) Fuel Tank Mounting Fasteners 18 ft-lbs (25 Nm) Master Cylinder Cover Fasteners (Front) 14 in-lbs (2 Nm) Oil Drain Plugs (2) 15 ft-lbs (20 Nm) Oil Filter Approximately 3/4 turn after sealing ring has contacted the filter adapter.2017 Indian Motorcycle (Full-Size) Service Manual 2.5 gal (20.MAINTENANCE Torque Specifications DESCRIPTION TORQUE SPECIFICATIONS Air Filter Cover Fastener — M6 x 1.0 x 10 84 in-lbs (10 Nm) (QTY.2 L) Fork Oil (Classic / Vintage / Indian Motorcycle Fork Oil 20.3) Battery Terminal Nuts 40 in-lbs (5 Nm) Battery Cable to Starter Motor 63 in-lbs (7.5 Qts (5.3 oz (599 cc) per leg Dark Horse) Fork Oil (Chieftain / Indian Motorcycle Fork Oil 18.

DOT 4 12 oz 2880016 Carbon Cleaner.5 . MAINTENANCE INDIAN MOTORCYCLE SERVICE PRODUCTS AND LUBRICANTS MAINTENANCE PRODUCT PART NUMBERS PRODUCT PART NUMBER All Purpose Grease 14 oz 2872187 Anti-Freeze. 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) 15W-60 2880191 quart 2880187 Synthetic 15W-60 Engine Lubricant (Scout) 55 gal drum 2880188 Semi-Synthetic 20W-40 Engine Lubricant (Thunder quart 2880012 Stroke Engines) 55 gal drum 2880013 Synthetic Transmission oil quart 2880014 9927618 R03 . 50/50 Extended Life (Scout) 1 quart (32 oz) 2880966 2 Brake Fluid.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2.

adjust.Replace at specified interval or annually. R Fuel pumps built after 11/11/ 2015 do not have a replaceable fuel filter.2017 Indian Motorcycle (Full-Size) Service Manual 2.000 (40.000 (64.000) 15.000) 50. correct or replace if necessary) R .Inspect (tighten. Fuel System I I I I I I I I I I I I Key Fob Battery** Oil Lines / Oil System Inspection I I I I I I I I I I I I Spark Plugs I I R I Operation Codes: I .000) 25.000) 40.000) 35.000 (16.Perform * .000) 500 (800) Air Filter I I I I R I I R I I R I Crankcase Ventilation System I I I I I I I I I I I I Drive Belt I I I I I I I R I I I I Engine Compression I I I I I I Engine Mount Fasteners I Engine Oil* R R R R R R R R R R R Engine Oil Filter* R R R R R R R R R R R Evaporative Emission Control System (CA.000 (24.000) 2.000 (80. clean.000 (48.000 (72. If driven in extreme conditions.Replace/Rebuild L .000 (52.500 (4.000) 45. Only) I I I I I I I I I I I I Exhaust System I I I I I I I I I I I I Fuel Filter Replacement Applies only to fuel pumps built before 11/10/2015.6 © Copyright .Lubricate with proper lubricant as directed P .000) 30.MAINTENANCE P E R I O D I C M A I N T E N A N C E I N T E R VA L TA B L E ENGINE MILES (KILOMETERS) 10.000 (32.000) 20.000) 5. ** .000 (8.Replace at specified interval or every 2 years 9927618 R03 .

000) 40.000) 15. MAINTENANCE CHASSIS MILES (KILOMETERS) 10.000) 45.000) 25.000 (24. If driven in extreme conditions.Lubricate with proper lubricant as directed P .000 (80.000) 30.Perform * .000 (52.000) 20.000) 50.000) 2 500 (800) Battery I I I I I I I I I I I I Brake Fluid** I I I R I R I R I R I R Brake Pads I I I I I I I I I I I I Clutch Lever L I L I L I L I L I L Clutch Cable Freeplay I I I I I I I I I I I I Control Cable Ends I I L I L I L I L I L Fasteners I I I I I I I I I I I I Front Brake Lever L I L L L L L L L L L L Front Fork Oil** I I I R I I R I I R I Front Forks and Front Axle I I I I I I I I I I I I Gear Shift Pedal I I I I I I I I I I I I Head Light I I I I I I I Rear Brake Pedal I I I I I I I I I I I I Rear Shock Absorber I I I I I I I I I I I R Rear Wheel Alignment I I I I I I I I I I I I Road Test P P P P P P P P P P P P Sidestand L I I L I L I L I L I L Steering Bearings I I I I I I I I I I I I Suspension Linkage.Replace at specified interval or every 2 years 9927618 R03 .000 (32.Replace/Rebuild L .000 (16.000) 35.000) 2.000 (48. clean.7 .000 (72. ** .000 (40. adjust.000) 5.500 (4. correct or replace if necessary) R .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2.000 (64.000 (8. Rear I I I I I I I I I I I I Swing Arm and Rear Axle I I I I I I I I I I I I Tires / Wheels I I I I I I I I I I I I Operation Codes: I .Inspect (tighten.Replace at specified interval or annually.

procedures carefully.service-solutions. understand and replacement parts. 500 Miles Perform the break-in maintenance (805 km) procedure outlined in the Periodic Maintenance Interval Table located in this chapter. 301–500 Miles Do not operate for extended (484–805 km) periods above 3/4 throttle. adjustment and lubrication of important Motorcycles are manufactured using the best possible components are explained in the periodic maintenance chart. critical engine parts wear and polish to necessary. Drive slowly until the engine warms up. Follow all break-in operations. clean. SPECIAL TOOLS TOOL DESCRIPTION PART NUMBER Observe the following precautions during the break-in period: Brake Lever Reserve PV-50104 Tool • Upon initial start-up.8 © Copyright . use genuine Indian Motorcycle follow all break-in procedures to ensure the long-term parts available from your Indian Motorcycle dealer. adjust and replace parts as in period. 91–300 Miles Do not operate for extended (146–483 km) periods above 1/2 throttle or at any one throttle position. 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. Battery Tester PU-50296 • Avoid fast starts with wide open throttle. Vary engine speed frequently.com/ 0–90 Miles Do not operate for extended (0–145 km) periods above 1/3 throttle or at any one throttle position. During this break- Inspect. Belt Tension Meter PV-43532 • Avoid running the engine at extremely low RPM in Oil Filter Wrench PU-50105 higher gears (lugging the engine). 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual 2. Vary engine speed frequently. but the final machining process is the break-in. do not allow the engine to idle for long periods as overheating can occur. performance and durability of the engine. materials and manufacturing techniques. IMPORTANT CAUTION Service and adjustments are critical. Shock Air Pump PV-48909 Break-In Guidelines Shock Spanner Wrench PV-46993 ODOMETER BREAK-IN PROCEDURE Bosch Automotive Service Solutions: 1-800-328- 6657 or https://polaris. Avoid full throttle operation and other condition that may place an excessive load on the engine during the break-in period. have a qualified dealer perform these serious damage to the engine. Indian Inspection. When inspection reveals the need for correct operating clearances. Read.MAINTENANCE 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. lubricate.

1. 1.9 . Remove three fasteners e securing air filter element r to air box backing plate and remove filter. more frequent servicing is required. reversing the removal procedure. Remove both drain plugs and sealing washers. Place a small amount of oil on the seal of the new filter and spin on until the filter seal contacts the sealing surface. WARNING The air filter element cannot be cleaned. 5. 4. Start and run the engine until it reaches normal operating temperature. 9. Place an oil drain pan under both the SCAVENGE q and STORAGE w drain plugs. Allow oil to drain completely. 8. Replace the HOT COMPONENTS Wear insulated gloves and/ 2 filter when necessary. or allow engine and exhaust to cool before handling these parts. 2. 7.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2. Clean the oil filter sealing surface and surrounding area. Installation of new filter is performed by plugs. If the motorcycle is operated in wet or dusty conditions. TORQUE Oil Filter: Approximately 3/4 turn after seal has contacted the filter adapter. Remove air box cover fasteners q and air box cover w. 2. TORQUE TORQUE Scavenge and Storage Drain Plugs: 15 ft-lbs (20 Nm) Air Filter Fasteners e : 62 in-lbs (7 Nm) Air Box Cover Fasteners q : 84 in-lbs (10 Nm) 9927618 R03 . 3. Remove oil filter. Use new sealing washers and reinstall both drain 3. 6. Securely support the motorcycle in an upright (vertical) position. drain and dispose of oil and filter properly. Torque to specification. Tighten oil filter to specification. Stop the engine. MAINTENANCE 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 Engine MUST BE WARM while performing the follow- NOTE ing procedure.

Place the machine on a level area and hold it in an engine.0 US quarts of Indian Motorcycle 20W40 engine oil.95 L). With the motorcycle in an upright (vertical) ADD to FULL is 1 qt (. 14. 13. using a funnel. as this can result in overfilling. when checking oil level.MAINTENANCE 10. DO NOT ADD oil to bring to FULL mark on a upright (centered) position.2017 Indian Motorcycle (Full-Size) Service Manual 2.10 © Copyright . NOTE 4. add Indian ENGINE OIL LEVEL Motorcycle 20W-40 engine oil and repeat steps 1–6 Engine MUST BE AT FULL OPERATING TEMPERATURE until the reading is within the safe operation range.5 US quarts. position. With the motorcycle in an upright. 11. install 4. 7. centered position. 12. Stop engine and wait for 1–2 minutes. cold engine.10 section in this chapter for setting proper oil level. NOTE Recycle used oil and oil filter in accordance with local regulations. Shut engine OFF and add approximately 1. If oil level is low. 9927618 R03 . do not increase RPM above idle until indicator lamp goes out or engine may be damaged. 6. run the engine for several minutes until operating temperature is reached. Remove and clean the oil off of the dipstick q. I D L E S P E E D / FA S T I D L E S P E E D NOTE Idle speed is continuously monitored and adjusted by the ECM. Screw the dipstick in until seated. Oil level will NOT be accurate if checked on a cold 3. CAUTION 2.5 US quarts is an acceptable amount of oil to run the engine for the initial check. then 4. Be careful not to overfill! Approximate volume from 1. page 2. Refer to the Checking Engine Oil. Remove dipstick / filler cap and wipe clean. Oil level should be between ADD e and FULL w lines on dipstick. Remove dipstick and view oil level. CAUTION If the low oil pressure indicator remains illuminated longer than usual after an oil change.5 US quarts of Indian Motorcycle 20W40 engine oil. Check for leaks around drain plug and oil filter. 5. DO NOT OVERFILL! IMPORTANT Total fill with oil filter change will be approximately 5. start engine and run at varied speeds to 2500 RPM for approximately 3 minutes.

180/60R16 41 PSI (282 kPa) ROADMASTER FRONT: Dunlop Elite 3 (130/90 36 PSI (248 kPa) B16) REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa) 9927618 R03 . When a FRONT: Dunlop Elite 3 (130/90 tire reaches the minimum tread depth listed 36 PSI (248 kPa) B16) below. cuts.063 in (1. Inspect tires for weather checking.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2. (180/65 B16) WARNING CHIEF DARK HORSE It is dangerous to ride with a worn tire. Measure in 3-4 places equally spaced around the REAR: Dunlop American Elite 40 PSI (276 kPa) tire and record the smallest measurement.6 mm) Tread Depth FRONT: Dunlop Elite 3 (130/90 46 PSI (317 kPa) Rear Tire Minimum Tread B16) . 36 PSI (248 kPa) 130/60B19 REAR: Dunlop Elite 3 . REAR: Dunlop American Elite 40 PSI (276 kPa) (180/65 B16) 1. replace the tire immediately. etc. REAR: Dunlop American Elite 40 PSI (276 kPa) Minimum Tread Depth (ALL MODELS) (180/65 B16) Front Tire Minimum SPRINGFIELD . Inspect front and rear wheels for damage. designated tires listed below as original equipment. The use of tires other than original CHIEF CLASSIC 2 equipment may cause instability. (130/90 B16) 4. MAINTENANCE 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 Tire Pressure Table (Cold) WARNING NOTE Indian motorcycles are produced using the Also refer to Manufacturing Information label. Measure tread depth at center of tread. This includes field testing to ensure stability and superior handling.063 in (1. CHIEF VINTAGE 2. See Steering / FRONT: Dunlop American Elite 36 PSI(248 kPa) Suspension chapter for a review of all tire related (130/90 B16) Warnings.6 mm) Depth REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa) CHIEFTAIN DARK HORSE FRONT: Dunlop Elite 3 (130/90 36 PSI (248 kPa) B16) REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa) CHIEFTAIN FRONT: Dunlop Elite 3 (130/90 36 PSI (248 kPa) B16) REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa) CHIEFTAIN LIMITED / ELITE FRONT: Dunlop American Elite .11 . imbedded foreign objects. FRONT: Dunlop American Elite 36 PSI (248 kPa) 3.

rotate the clutch 36 PSI (248 kPa) shaft arm r to release the cable housing from the B16) mounting boss. Using an adjustable wrench. smooth cable ends. Reverse steps 3–4 to reinstall clutch cable. Periodic lubrication of cables is not required and could be detrimental to cable performance. 2. 9927618 R03 .. Remove lower cable guide fastener w and E-clip FRONT: Dunlop Elite 3 (130/90 e. page 2. See Periodic Maintenance Interval Table. REAR: Dunlop Elite 3 (180/60 R16) 41 PSI (283 kPa) C L U T C H C A B L E I N S P E C T I O N / L U B R I C AT I O N NOTE Control cable casings are lined with a low friction sleeve and are factory lubricated for reliable operation. Apply a thin coating of all purpose grease to both 1. 6. Inspect the clutch cable for proper routing. movement.12 © Copyright . Do not kink. 4. installation. Adjust cable free play. CAUTION IMPORTANT Inspect inner cable for fraying. 5. Tighten the lower cable guide fastener to specification. TORQUE Cable Guide Fastener: 84 in-lbs (10 Nm) 7. bend or Protect finish of clutch shaft arm with a shop towel or twist inner cable or cable casing during removal or tape.6. Only cable ends must be periodically inspected and lubricated in accordance with the Periodic Maintenance Schedule.MAINTENANCE ROADMASTER CLASSIC 3. and damage to the external casing.2017 Indian Motorcycle (Full-Size) Service Manual 2. Push the rubber boot q up to expose the lower cable end and inspect for damage or frayed wires.

Assemble lever. Rotate cable back through slot in perch. 6. Inspect both ends of inner cable for frayed adjustment is required.12. measure Clutch Cable Inspection / Lubrication. Clean parts and apply moly paste to pivot fastener and both cable ends. 6.019–. 2 MEASUREMENT Clutch Lever Free Play: . proceed to Step 3.5–1. 5.059” (0. page 2. Compare measurement to specification. Tighten adjuster jam nut to specification. 3. Disconnect clutch cable at primary cover.13. Pull cable housing out of lever perch and remove barrel from clutch lever. Lubricate and attach lower end of cable to clutch arm on primary cover. the clutch lever free play at point shown q. 4. Remove snap ring q and push pivot pin w upward to remove. Hold cable and loosen the adjuster jam nut. Adjust clutch lever free play. Locate the clutch cable adjuster boot w and pull it back to expose the jam nut and barrel adjuster. Do not kink cable. With handlebars pointing straight ahead. 5. and push outer casing back into perch recess. MAINTENANCE C L U T C H L E V E R L U B R I C AT I O N C L U T C H L E V E R F R E E P L AY 1. See Clutch Lever Free Play. TORQUE Clutch Cable Adjuster Jam Nut: 48 in-lbs (5 Nm) 7. 8. If 4. 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2. strands.5 mm) 2. Install cable to lever. page 2.13 . Slide adjuster boot back over adjuster assembly. See 1. 3. 2. 7. Turn cable adjuster in or out until clutch free play is correct.

9927618 R03 . 2.1–25. See Brake Fluid Replacement & Bleeding Precautions. and contact surface of pushrod as shown.4 mm) 3. Verify wheel rotates freely without drag or binding when lever is released. Pull and release the front brake lever. MEASUREMENT Brake Lever Free Play: . Measure brake lever free play q. It should 1. 3. Clean pivot pin. inspect for brake fluid leaks and bleed air from the system. If brake lever travels too far before beginning to apply the brake. Safely elevate the front wheel. You should feel a firm resistance in the lever within the specified length of lever travel. 4. Lubricate brake lever if binding.MAINTENANCE FRONT BRAKE LEVER INSPECTION F R O N T B R A K E L E V E R L U B R I C AT I O N 1. or if it does not return quickly and completely when released. Remove snap ring q and pivot pin w. page 9.14. lever bushing.14 © Copyright . Remove brake lever and apply grease to pivot pin w.75–1. move freely and smoothly and return to its rest position quickly when released. Assemble brake lever.2017 Indian Motorcycle (Full-Size) Service Manual 2. 2. lever and lever perch. page 2.0” (19. See Front Brake Lever Lubrication.22.

BRAKE PEDAL INSPECTION 1. maintenance table. remove 2 floorboard support fasteners q and move floorboard / master cylinder assembly so the brake pedal pivot pin can be accessed. The adjustment pin will seat at different depths in the dial at each setting.15 . Press brake pedal and check for firm resistance. Once the reach is set. NOTE It is not necessary to disconnect the brake line from the master cylinder to perform this procedure. pull the brake lever 2–3 times to verify proper operation. 2. MAINTENANCE FRONT BRAKE LEVER REACH B R A K E P E D A L L U B R I C AT I O N 1. Press and release brake pedal. Remove cotter pin and flat washer w and pushrod Precautions. page 2. Lever reach (distance to hand grip) is adjustable: Lubricate brake pedal at intervals listed on periodic • Pull lever forward (away from hand grip) and hold. Release the pushrod from the brake pedal. page 9. pedal feels spongy or travels too far without resistance. See Periodic Maintenance Interval Table. inspect system for leaks and bleed brakes. IMPORTANT Make sure the adjustment pin is not resting between pockets on the dial. 9927618 R03 . Stop once the proper brake lever reach is achieved. Place the motorcycle in an upright position with the front wheel clamped in a wheel vise. 1. 2. If enter the brake system.6. Working on the RH side of the motorcycle.22. It should move IMPORTANT freely and smoothly and return to the rest position Keep the floorboard / master cylinder assembly in an quickly when released. • TO ADJUST reach distance. turn dial q on the lever. pivot pin e. upright position at all times to ensure air does not 2.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2. See Brake Fluid Replacement & Bleeding 3.

Bleed brakes if necessary. 1. Clean off old lubricant and dirt from all parts. 8. flat washer t and snap ring r. Torque mounting fasteners q to specification.2017 Indian Motorcycle (Full-Size) Service Manual 2. 6. Install pushrod pivot pin e and flat washer and cotter pin w. Lubricate shift pedal pivot bushing and all pivots q with all-purpose lubricant. Check all shift pedal and linkage fasteners to be sure they are tight. page 7. page 2.19. See Brake Fluid Replacement & Bleeding Precautions. Depress brake pedal to verify proper operation and pedal feel.22. 7. 5.17. Installation. See Floorboard (Driver). 9. Remove snap ring r and washer t. 10. Torque fasteners to specification. 2. Remove pedal 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 and inner wave washer from post. pedal. 9927618 R03 . Install wave washer. Apply all-purpose grease to post and pedal bushing as shown. Assemble floorboard support to frame. Be sure snap ring is fully seated in the groove. See Shift Pedal Adjustment.16 © Copyright . page 9.MAINTENANCE 4.

Tighten jam nuts q to specification. TORQUE 2. 1. Dots on shift shaft and shift arm must be aligned for gears to shift correctly. Loosen jam nuts q.17 . MAINTENANCE SHIFT PEDAL ADJUSTMENT 3. Shift Rod Jam Nuts: 84 in-lbs (10 Nm) CAUTION 2 Do not remove and reposition the shift arm on the shift shaft to adjust gear shift pedal height.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2. Rotate linkage rod w until pedal angle is correct. 9927618 R03 .

to the neutral position. cylinder reservoir. 4. View front brake fluid level through sight glass. 11. Wipe area around reservoir cover with a clean cloth.18 © Copyright . reservoir cover u. UPPER and LOWER level marks. Reinstall reservoir diaphragm and cover and torque fasteners to specification. Wipe brake fluid container with a clean cloth. Remove fasteners y. View fluid level through reservoir sight glass t. 6. and diaphragm r. return it to the neutral position. If you notice a constant or sudden Front Master Cylinder Cover Fasteners: 14 in-lbs (2 lowering of the brake fluid level.MAINTENANCE BRAKE FLUID LEVEL INSPECTION 7. cloth. 9927618 R03 . The fluid should be clear and at or above the LOW The fluid should be clear and at a level between level mark q. Fluid level is checked at the rear brake master of reservoir is level. 5. level to the upper edge of the sight glass. If diaphragm is extended. IMPORTANT The brake fluid level in the reservoir will go down as TORQUE brake pads wear.2017 Indian Motorcycle (Full-Size) Service Manual 2. Wipe brake fluid container with a clean cloth. Front Brake Fluid Inspection Rear Brake Fluid Inspection 1. Carefully add enough DOT 4 brake fluid to bring 13. Carefully add enough DOT 4 brake fluid to bring level to the upper edge of the sight glass. reservoir cover e and 12. If diaphragm is extended. 3. Wipe area around reservoir cover with a clean 10. inspect brake pads Nm) for wear and brake system for leaks. Turn handlebars or adjust the motorcycle until top 8. 2. 9. return it diaphragm i. Remove fasteners w.

Inspect pads by viewing from rear of 18 in-lbs (2 Nm) caliper. Torque to specification. 2. Install diaphragm and cover.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2. Install caliper cover. See Front Brake Pad Replacement. Remove two acorn nuts q and fastener w from each side of the motorcycle and remove the caliper covers e.19 . MAINTENANCE 14. F R O N T B R A K E PA D I N S P E C T I O N 4. Wear indicator grooves should be visible on both inboard and outboard brake pads of both calipers. 3. NOTE Wear indicator grooves are provided on each front TORQUE brake pad to allow for a visual inspection without pad Caliper Cover Acorn Nuts: removal. Rear Master Cylinder Cover Fasteners: 7 in-lbs (1 both front calipers should receive new pad sets. 9927618 R03 .26 1. resulting in a vehicle crash. locate the wear indicator grooves q. Tighten cover CAUTION fasteners to specification. Nm) Failure to replace both sets of front brake pads together may cause reduced braking performance or 2 brake failure. Replace pads if worn to bottom of grooves. If it is determined that an individual brake pad has worn past the wear indicator groove. page 9. Viewing the front brake pads from the rear of the calipers. Front brake pads should always be replaced as a TORQUE complete set.

Be sure hoses are not restricted. 9927618 R03 . Viewing the rear brake pads from behind the motorcycle and below the lip of the rear fender. Inspect pads by viewing from the rear of the motorcycle.2017 Indian Motorcycle (Full-Size) Service Manual 2. directly behind the LH tailpipe. 3. Replace hose if worn or damaged. locate the wear indicator grooves q.20 © Copyright . Inspect condition of ventilation hose q along its NOTE length and at both ends. Wear indicator grooves are provided on each rear brake pad to allow for a visual inspection without pad removal. kinked. 2. or cracked. 4. 2. 3.MAINTENANCE R E A R B R A K E PA D I N S P E C T I O N C R A N K C A S E V E N T I L AT I O N S Y S T E M 1. Inspect condition of ventilation hose w along its length and at both ends. See Rear Brake Pad Replacement.27. Replace pads if worn to bottom of grooves. Place the motorcycle in an upright position with the front wheel clamped in a wheel vise. Wear indicator grooves should be visible on both inboard and outboard brake pads. 1. page 9.

Check that all connections for both vent and canister purge systems are securely attached.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2. Inspect all EVAP lines for abrasion or wear. through the purge valve and into the throttle body for combustion. NUMBER PART DESCRIPTION q Fuel Tank Vent Hose w Evaporative Emissions Vapor Canister e Purge Hose (Canister to Purge Valve) r Canister Purge Valve t Purge Hose (Purge Valve to Throttle Body) 9927618 R03 .21 . MAINTENANCE F U E L TA N K V E N T I N S P E C T I O N ( 4 9 S TAT E ) E VA P O R AT I V E E M I S S I O N C O N T R O L S Y S T E M 1. Be sure the NOTE hose is clear and not pinched or kinked. Fuel vapor is then routed out of the vapor canister. 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 M O D E L S ) periodic maintenance schedule and any time fuel tank has been removed and installed. and that The fuel tank vent line is routed to a vapor canister all connections are tight. where the fuel vapor is stored until specific operating parameters are met and the ECM opens the purge 2 valve.

2. leakage. Replace with genuine Indian Motorcycle replacement parts to reduce the possibility of fuel line failure. or kinked areas. damage. Inspect fuel supply line-to-fuel rail connection e for signs of leakage. 9927618 R03 . Replace any components that fail inspection with genuine Indian Motorcycle replacement parts.2017 Indian Motorcycle (Full-Size) Service Manual 2.MAINTENANCE F U E L S U P P LY H O S E ( F U E L R A I L ) I N S P E C T I O N 1. Be sure fuel lines are routed properly and do not come in contact with sharp or hot objects. Inspect fuel supply line q and fuel rail w for deterioration. or anything that may cause wear or damage.22 © Copyright . The fuel supply hose (fuel rail) can be found behind the horn cover on the RH side of the motorcycle. 3. WARNING The fuel lines exiting fuel pump are subjected to high pressure.

See Spark Plug Removal. slightly to release from the spark plug. With the engine at room temperature.9 mm) 3. 1. 2 1. NOTE page 2. remove spark plugs.23. Remove spark plugs. 9927618 R03 . 4. 2. grasp the 3. The front spark plug can be removed without having to remove the fuel tank by using a 3” extension and 2. Measure electrode gap with a wire gauge q. DO NOT pull on the wire or spark plug wire may be CAUTION damaged. Spark Plug Type: DCPR8E Spark Plug Gap: . 4. A wire brush or coated abrasive (sandpaper) should not be used to clean electrodes. MAINTENANCE S PA R K P L U G R E M O VA L S PA R K P L U G I N S P E C T I O N / G A P CAUTION CAUTION HOT COMPONENTS A hot engine can cause serious burns. pull straight out of spark plug well. Inspect electrodes for wear and carbon buildup. spark plugs.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2. Look for a sharp outer edge with no rounding or erosion of the electrodes. Adjust gap if necessary by carefully bending the grounding electrode until the specified gap is achieved.034 in (0. standard 5/8” spark plug socket. Using a 3” extension and a 5/8” spark plug socket. 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. Clean with electrical contact cleaner or a glass spark plug boot q and rotate back and forth bead spark plug cleaner only.23 . Grabbing only the base of the spark plug boot. Clean out spark plug wells with compressed air to remove any loose dirt or debris.

2. Spark Plug Type: DCPR8E Spark Plug Gap: . Remove the Fuel Pump Relay w to disable fuel 1. Shift transmission into neutral and stop engine. page 7. If gap pump. ENGINE COMPRESSION TEST 1. Removal / Installation. bend ground electrode carefully using a spark plug gap tool. Install compression tester in the spark plug hole following manufacturers instructions. 8. See Spark Plug Removal.3 threads.MAINTENANCE S PA R K P L U G I N S TA L L AT I O N 4. Do not over tighten spark plugs. Torque spark plugs to specification. Install spark plug wire boots securely over the plugs.24 © Copyright . Warm engine to operating temperature. 6. 4. avoiding the bottom 2 . Damage to the cylinder head or spark plug may result. Open throttle and crank engine until needle on compression gauge stops rising (about 5 seconds).23.17. Specification . See Side Cover (Upper). Repeat procedure for other cylinder. Disconnect ignition cables from both spark plugs. 3. Apply anti-seize compound sparingly to spark plug threads.Thunder Stroke 111: All Models STD: 90-110 psi (620-758 kPa) SERVICE LIMIT: Below 80 psi (552 kPa) High engine compression may indicate: • Carbon deposits in combustion chamber • Engine modification • Faulty Gauge Low engine compression may indicate: • Slow starter motor cranking speed • Carbon or foreign material on valve seat 9927618 R03 .9 mm) 2. 10. 9. 7. Remove the LH upper side cover to access the fuse box q. TORQUE Spark Plug: 13 ft-lbs (17 Nm) 5. Disconnect the ignition coil e to disable ignition CAUTION system. Remove spark plug from cylinder to be tested. 3. adjustment is necessary. Inspect spark plug gap with a wire gauge. page 2.034 in (0.2017 Indian Motorcycle (Full-Size) Service Manual 2.

Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP CHILDREN AWAY FROM BATTERY. DO NOT remove cell caps or add distilled water to the battery. Call physician immediately. away. MAINTENANCE • Worn or damaged piston and/or piston rings ENGINE COMPRESSION TEST (WET) • Leaking exhaust or intake valves If a cylinder leakage tester is not available. If cylinder compression is below specification. It contains sulfuric acid. refer to Electrical chapter for diagnostic information. Keep sparks. piston. When reinstalling the battery. cigarettes. and rings. disconnect the negative (black) cable first. Do not remove the battery cables while the engine is running. • Valve timing incorrect • Non-OEM camshafts or faulty gauge 1. Follow with milk of magnesia. eyes or clothing. CAUTION Whenever removing the battery. Antidote: External: Flush with water. 2 the leak is occurring. Internal: Drink large quantities of water or milk. 3. Serious burns can result from contact with skin. etc. inspect with the leakdown tester.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2. If the battery discharges. Eyes: Flush with water for 15 minutes and get prompt medical attention. Pour 3-5 cc of clean engine oil into each cylinder through spark plug hole. 9927618 R03 . If compression increases substantially. B AT T E R Y This motorcycle is equipped with a maintenance free battery which is located under the seat. Repeat cylinder compression test. inspect valves and valve seats. Take great care NOT to reverse the battery leads when installing the battery. beaten egg. If compression does not increase. connect the negative (black) cable last. perform a cylinder leakage test to determine where page 2. or vegetable oil. perform a • Leaking head gasket wet cylinder compression test. WARNING Battery electrolyte is poisonous. Doing so may damage the Electronic Control Module (ECM). flame.24. Batteries produce explosive gases. See Engine Compression Test. Follow the instructions provided 2.25 . cylinder.

Do not disconnect VCM. Batteries contain acid that is caustic.2017 Indian Motorcycle (Full-Size) Service Manual 2. remove battery from motorcycle and wash terminals with water and B AT T E R Y R E M O VA L baking soda solution. deformed. Clean terminals. corrosion with a stiff wire brush. 5. cable first q . or if electrolyte is leaking. page 7. B AT T E R Y S T O R A G E When the motorcycle is not used for periods of one month or longer the battery should be fully charged prior to operation. See Battery Charging .17. KEEP Replace battery if housing is damaged. Store battery in a cool. See Seat Removal / Installation - All (except Roadmaster).5V DC. case is OUT OF REACH OF CHILDREN. 2.8 amp-hr. fasteners.16. Removal / Installation.48. 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. 4. Rinse could ignite the gasses away. B AT T E R Y C H A R G I N G See Battery Charging . cable last w . flames.New Battery. See Vehicle Control Module Specification: 12. Replace battery if it will not accept a charge. Coat ventilation when charging in an enclosed space. page 10. Measure battery voltage.5V DC minimum (VCM).16. Remove the seat. It is not necessary to disconnect the VCM from 3.15 or Battery Charging . terminals with dielectric grease.26 © Copyright . page 10. Remove negative (-) battery terminal fastener and thoroughly. Visually inspect the exterior of the battery. cigarettes or anything that of one tablespoon baking soda to one cup water. See Side Cover (Upper). page 7. charge it 4.In Service. Wear protective clothing and a face shield or protective 1. and cable ends with a brass wire brush and apply IMPORTANT a thin film of dielectric grease. Provide adequate well with tap water and dry off with clean rags. eyewear when working with the battery. page 10. Wash with a solution keep sparks. Removal / Installation. Battery should be charged monthly using a 12 volt battery charger with a maximum charge rate of 1. 2.21. 1. To remove corrosion. page 10. dry place. 9927618 R03 . 3.In Service. Remove positive (+) battery terminal fastener and 5. remove the Battery charging can create explosive gasses. the negative battery cable must be disconnected first. If battery voltage is below 12. If cleaning is necessary.MAINTENANCE B AT T E R Y I N S P E C T I O N WARNING Battery terminals and connections should be kept free of corrosion. the electrical harness during battery removal. If the VCM must be disconnected for any reason. Remove the upper side covers.

27 . but Cracks monitor NOTE condition It may be necessary to push the VCM harness away from the battery. missing teeth. MAINTENANCE 6. If the drive belt or sprocket is being replaced due to damage.13. 2 DRIVE BELT CONDITION SERVICE WEAR RECOMMEN- EXAMPLES DATION External Tooth Replace Belt Cracks Internal Tooth OK to run. See Periodic Maintenance Interval Table. D R I V E B E LT I N S P E C T I O N NOTE Inspect drive belt in accordance with Periodic Maintenance Interval Chart and replace at specified intervals regardless of belt condition. See Battery Installation.6. Missing Teeth Replace Belt Bevel Wear OK to run. into the RH side of the frame in Fuzzy Edge OK to run. Lift battery straight up and out of the battery box. 3. NOTE Adjust drive belt tension at intervals in accordance with the Periodic Maintenance Interval Chart. but Serious) monitor condition Stone Damage Belt should be replaced if damage is on the edge of the belt 1. If any damage is found. or any other damage. replace belt and both sprockets as a set if drive system has more than 5000 miles (8000 Km) of use.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2. Periodically inspect drive belt for cuts. belt should be replaced. foreign substance (oil. 2. but order to remove the battery.6. page 2. excessive wear. page 2. See Periodic Maintenance Interval Table. 9927618 R03 . page 10. grit). but (Outer Edge monitor Only) condition Chipping (Not OK to run. Cord monitor condition Hook Wear Replace Belt B AT T E R Y I N S TA L L AT I O N 1.

tain Road- master Road- master 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 NOTE Due to the low frequency levels produced by Indian Motorcycle drive belts. Chief Dark Horse Spring- field Chief- tain Dark Horse 1.3“ (34 mm) or 11 notches up on belt Chief.29.28 © Copyright . See Drive Belt Tension. page 2. page 2.MAINTENANCE D R I V E B E LT S P E C I F I C AT I O N S D R I V E B E LT D E F L E C T I O N D ATA MODEL DEFLECTION AT 10 LBS FORCE Chief Classic Chief 1.1” (28 mm) or 8 notches up on belt Vintage guard. it is recommended to use a commercially available CLAVIS optical sensor or equivalent to achieve the most accurate tension measurement. See Drive Belt Tension.29.2017 Indian Motorcycle (Full-Size) Service Manual 2. 9927618 R03 . guard.

or immediately after rotation as viewed from belt side of motorcycle. Push up on gauge until O-ring just touches tool body. • Adjust belt deflection with wheel in this position. checking deflection or adjusting the belt. WARNING Care should be taken to be sure the motorcycle will not tip or fall while elevated. use the graduations on lower belt guard for 2. Slide O-ring on belt tension gauge to the 10 lb. Rotate wheel in a CLOCKWISE Do not adjust the belt when wet. Shift transmission into NEUTRAL. reference.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2. • Continue to rotate the wheel in normal drive direction (CLOCKWISE) 1-2 revolutions until your reference mark (the tightest point) is lined up with IMPORTANT the tension setting window in the lower belt guard Perform this procedure to achieve proper belt q. Find Tight Spot In Belt • Place belt tension gauge squarely against belt at center and keep it at a 90° angle to the belt surface. • 7. ELEVATE rear wheel off the ground when 6.29 . 2 important for accuracy. See Drive Belt Specifications. tension and alignment. MAINTENANCE D R I V E B E LT T E N S I O N M E A S U R E M E N T 4. This is extremely (least deflection) to use as a reference. causing possible belt failure and loss of control of the motorcycle. WARNING A drive belt that is not properly tensioned can cause drive line noise and damage the drive belt. Severe personal injury or death may occur if the motorcycle tips or falls. riding. Belt must be dry and the drive system must be • Place a mark on rear wheel at the tightest point at ambient temperature (60-80° F).28 for drive belt deflection specifications. page 2. Belt tension should be set before performing the alignment procedure. Secure motorcycle in an upright position with the 5. Place tape measure or ruler next to drive belt or front wheel clamped in a wheel vise. mark. 9927618 R03 . 3. Use the tire valve stem as a reference and perform Special Tool: Belt Tension Gauge PV-43532 the following Steps: • Check / record belt deflection at 4 different points. IMPORTANT 90 degrees apart. 1.

1” (28 mm) Darkhorse / Vintage Springfield / Chieftain / Chieftain 1.MAINTENANCE 8. D R I V E B E LT T E N S I O N . If deflection is less than specified loosen the belt. If belt deflects more than the specified distance with 10 lbs. NOTE New drive systems (new vehicle or when belt and sprockets are replaced) should be set to the tight side of the specification and inspected after the first 500 miles (800 km). See Drive Belt Adjustment. of force.30 © Copyright . Required Data For Specification Sonic Tension Meter Span 719. tighten the belt. page 2.31.10mm Belt Width 24mm Belt Mass Constant 8. Follow Steps 1-4 and the instructions included with your sonic tension meter.3“ (34 mm) Darkhorse / Roadmaster SONIC TENSION DATA The following data is provided for use with the Gates 507C Sonic Tension Meter or an equivalent.4 g/mm Tension Chief / Chief 23 Hz (± 1 Hz) Darkhorse / Vintage Tension Springfield / Chieftain / Chieftain 18 Hz (± 1 Hz) Darkhorse / Roadmaster 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual 2.S P E C I F I C AT I O N S Specifications: Drive Belt BELT DEFLECTION Model Deflection @ 10 lbs force Chief / Chief 1.

6. causing possible belt failure and loss of control of the motorcycle. 2. TORQUE Axle Nut Torque (ADJUSTMENT SPECIFICATION): Step 1: 15 ft-lbs (20 Nm) Step 2: 65 ft-lbs (88 Nm) 5. MAINTENANCE D R I V E B E LT A D J U S T M E N T 4. When belt tension is correct.31 . Belt tension should be set before performing the alignment procedure. Marks should be in roughly the same position on both left and right sides of wheel. check and adjust final wheel alignment as follows: Belt Alignment 9927618 R03 . Loosen axle nut e and retighten to the ADJUSTMENT SPECIFICATION during the IMPORTANT adjustment procedure. 1. 2 Belt Tension WARNING A drive belt that is not properly tensioned can cause drive line noise and damage the drive belt. Make note of adjuster locations q and w. See Drive Belt Tension Measurement. Turn the RIGHT SIDE adjuster nut r to achieve proper belt tension.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2. page 2. Raise the rear of the motorcycle so the rear tire can be freely rotated. Place the motorcycle in an upright position with the front wheel clamped in a wheel vise. Perform this procedure to achieve proper belt tension and alignment. NOTE Marks q and w are used as a reference for initial wheel alignment. 3.29.

drive line noise and damage the drive belt.2017 Indian Motorcycle (Full-Size) Service Manual 2. 8. Sprocket teeth should be visible from both causing possible belt failure and loss of control of sides of the drive belt. FUSE REPLACEMENT Fuses and relays are located in the fuse box under 9. Rotate the wheel BACKWARD. adjuster only to make final adjustments to belt alignment. Closely inspect drive belt condition. Tighten LEFT SIDE Step 1: 15 ft-lbs (20 Nm) adjuster until belt comes off inside sprocket flange during backward wheel rotation. Rotate the wheel in the FORWARD direction and SPROCKET INSPECTION verify that sprocket teeth are still visible on both NOTE sides of the drive belt t. To minimize change in belt tension. Inspection 1. Clean the drive belt and front and rear sprockets with a mild mixture of dish soap and warm water. use LEFT SIDE 12. or high debris environments. Removal / Installation.17. 11. Cleaning interval is approximately every tire change. See Side Cover and begins to track down the center of the driven (Upper). loosen the axle nut and LEFT SIDE the LH upper side cover. dusty. Rinse and dry thoroughly.MAINTENANCE 10. belt.32 © Copyright . Tighten rear axle nut to FINAL specification. Step 2: 65 ft-lbs (88 Nm) IMPORTANT 13. 9927618 R03 . If necessary.29. Pump rear brake pedal several times to reset The belt should track to the center of the sprocket brake pad distance. adjuster until belt just moves off the right flange 1. Sprocket 14. 2. the motorcycle. Verify wheel rotates smoothly and freely without teeth should be visible on both sides of the drive drag when brake pedal is released. NOTE It may be necessary to loosen the axle nut and tap the left end of the axle to ensure it moves forward when the adjuster is loosened. page 7. Inspect front and rear sprocket teeth for wear or damage from foreign material. Rear wheel alignment is satisfactory when the WARNING drive belt remains centered on driven sprocket A drive belt that is not properly aligned can cause during forward and backward wheel rotation. Remove LH upper side cover. 3. or more often if operated in dirty. TORQUE Axle Nut Torque (FINAL TIGHTENING): 7. The axle nut must be retightened to the ADJUSTMENT SPECIFICATION before proceeding. Drive belt and sprocket service life are maximized and drive line noise minimized by proper cleaning. See Drive Belt Tension NOTE Measurement. tooth surface when properly aligned t. sprocket flange during forward wheel rotation. page 2. Verify that drive belt tension is still within specification.

33 . Substituting a higher amperage fuse can lead to extensive electrical system and vehicle damage. If the correctly rated fuse continues to blow. If any fuse is blown. 2 3. CAUTION Do not use fuses of a higher amperage rating than what is specified. 9927618 R03 . turn off main switch. MAINTENANCE 2. Turn on switches and see if system operates correctly. something is wrong and needs to be corrected.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2. Install new fuse of specified amperage. Squeeze fuse box tabs together as shown and lift cover off of fuse box. Repeat fuse failure indicates an electrical problem.

See Tire Adjust headlight aim when there is a change in load Pressure / Specifications.6 m) from beam. straddle the motorcycle in an upright position and sit in the seat (s). Verify suspension ride height is set correctly. models listed below. accessories.37. Check and adjust the tire pressure. and place it so the top front SPRINGFIELD: With the headlight switched to HIGH edge of the headlight housing is 25 ft. page 2. (7. Compare the position of headlight beam on the inspection. cargo. Set headlight to HIGH beam and LOW beam for bulb when centered straight ahead at 25 feet (7. CHIEF CLASSIC / CHIEF VINTAGE / CHIEF DARK 3. Follow all steps below to ensure accurate aim 7. be 3. wall to the illustration below and adjust if necessary. See adjustment.2017 Indian Motorcycle (Full-Size) Service Manual 2. Rear Shock Preload Inspection. Have the rider (and passenger if normally present) ahead at 25 feet (7.0 in (7.5 in (19 cm) below the height of the headlight bulb when centered straight 4. Move the motorcycle to a clear area with a level HORSE / CHIEFTAIN DARK HORSE / CHIEFTAIN / floor and dim lighting. etc.62 m).34 © Copyright . the top of the highest intensity (appears as a diamond shape) should 5.) or after suspension 2. headlight switched to LOW beam. Center the handlebars in a ROADMASTER / ROADMASTER CLASSIC: With the straight ahead position. the center of highest intensity (appears as a the wall. diamond shape) should be 7. Turn ignition switch ON.62 m).MAINTENANCE HEADLIGHT AIM INSPECTION 1.11. page 2. (rider.6 cm) below the height of the headlight 6. CHIEF CLASSIC / CHIEF VINTAGE / CHIEF DARK HORSE / CHIEFTAIN DARK HORSE / CHIEFTAIN / SPRINGFIELD HIGH BEAM 9927618 R03 .

1.All Models. Turn fasteners out (counter-clockwise) to raise the beam. 9927618 R03 . turn the left adjustment fastener out (counter-clockwise) to NOTE adjust the beam to the left. To adjust the headlight horizontally. It is not necessary to remove the nacelle for adjustment. page 10. To adjust the headlight vertically. Turn the right Chieftain / Roadmaster models:Access headlight adjustment fastener out (counter-clockwise) to adjustment fasteners by removing the headlight adjust the beam to the right.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2. Classic / Vintage / Dark Horse / Springfield models: Headlight adjustment fasteners can be accessed directly through the headlight nacelle. MAINTENANCE ROADMASTER 2 LOW BEAM HEADLIGHT AIM ADJUSTMENT 2. both adjustment fasteners q must be turned in or out equally. bezel.52.35 . See Headlight Bulb Replacement . Turn fasteners in (clockwise) to lower the beam.

Turn handlebars from full left to full right and inspect for smooth. Sidestand will be moved between the UP not tip or fall while elevated. Installation: Attach spring to sidestand. See 3. and returns to the fully retracted position. The nut is a crushed lock and therefor it can not be reused. pull Sidestand Pivot Fastener: 37 ft-lbs (50 Nm) stand rearward against spring tension until the mounting flange on the sidestand drops onto the mounting boss on the frame. 10. 12. adjust or replace steering head bearings as necessary. mounting boss on the frame. removal and installation. S I D E S TA N D R E M O VA L / I N S TA L L AT I O N 11. Torque to specification and wipe off any excess grease. Do not attempt to straighten sidestand. Swing sidestand to the extended position to align fastener hole and install NEW fastener and nut. Secure motorcycle with front wheel off the floor. TORQUE 9. Replace sidestand if it is bent. Relax tension and remove spring. 7. or if movement is detected at steering stem. 2. If steering binds. NOTE 2. 4. 6.36 © Copyright . Be sure stand returns to fully retracted position. Inspect side stand for smooth movement. 1. Support the motorcycle in an upright position with until mounting flange on sidestand is clear of the the front wheel clamped in a wheel vise. Inspect sidestand spring for damage or loss of 5. feels rough or uneven. 5.2017 Indian Motorcycle (Full-Size) Service Manual 2. See Steering / Suspension chapter. Pull sidestand rearward against spring tension 1. Inspect sidestand pivot fastener nut for proper torque. Grasp sidestand firmly and move it to the UP position. Remove sidestand pivot fastener q using a 6mm hex wrench while holding the nut with a 15 mm Be sure control cables. Point front wheel straight ahead. Be sure the vehicle is properly secured before you begin. IMPORTANT STEERING HEAD / FRONT WHEEL INSPECTION Sidestand fasteners must be replaced any time the sidestand is removed. replace front wheel bearings. Cycle the sidestand to be sure it moves freely. 8. Be sure vehicle is properly secured.MAINTENANCE S I D E S TA N D I N S P E C T I O N 4. tension. 3. If roughness or unusual sounds are present. 2. Lightly grease sidestand mounting boss on frame and the shouldered portion of the pivot fastener. free movement. With sidestand in the retracted position (up). WARNING Care should be taken to be sure the motorcycle will 1. Place loose end of spring through hole in frame rail. 9927618 R03 . grasp fork tubes and pull/ push fork tubes back and forth. Severe personal injury (retracted) and DOWN (extended) position during or death may occur if the motorcycle tips or falls. Rotate front wheel and inspect for smooth rotation of front wheel bearings. interfering with handle bar rotation. 3. Wear eye and face protection when removing and installing the Sidestand Pivot Fastener: 37 ft-lbs (50 Nm) spring and sidestand. hoses and wiring are not wrench. WARNING TORQUE The sidestand spring is under tension.

adjust the rear wheel and attempting to move wheel side- preload if ride height is out of specification. For the most 3. Attempt to move front wheel side-to. suspension several times and check for smooth 9. Secure motorcycle with rear wheel elevated. Verify axle nut is tight. 3. CAUTION For CALIFORNIA and INTERNATIONAL motorcycles. If a joint has Care should be taken to be sure the motorcycle will radial movement. 5. determine if movement is at axle area e or swingarm pivot area r. REAR SHOCK PRELOAD INSPECTION Periodically inspect rear shock preload. Turn handle bars full right or left and hold against 5. Remove saddlebags. remove rear shock absorber and not tip or fall while elevated. Severe personal injury inspect suspension pivot linkage. the Evaporative Canister must be removed prior to raising the motorcycle. inspect rear wheel bearings. inspect front axle. See Steering / or death may occur if the motorcycle tips or falls. of rear wheel bearings. Inspect for worn swing arm bearings by grasping comfortable ride and proper ground clearance. Compress the rear 8. 2 WARNING 7. and quiet operation w. Rotate rear wheel and inspect for smooth rotation the fork stop. 1. 9927618 R03 . If the canister is not removed and the motorcycle is raised. Inspect suspension pivots and shock mounts for radial movement in all pivot joints. Using a scissor jack or similar tool. 1. If movement is observed. page 2. Verify that tire pressure is at specification. Replace any worn or damaged parts. Sit astride the motorcycle. if equipped. to-side q. See Tire Pressure / Specifications. Apply a strip of removable tape q to the rear fender directly over the center of the rear axle. 4.37 . raise the motorcycle until the rear shock is completely extended. 2. the fittings will contact the swingarm and become damaged.11. and bearings. Inspect rear shock for leakage and all rear suspension components for damage or loose SWINGARM INSPECTION fasteners. sounds are detected. See Steering / Suspension belt tension and alignment. and brake pads. 6. Refer to Steering / Suspension chapter for wheel bearing and swingarm bearing replacement. 2. MAINTENANCE 4. If roughness or unusual side. If movement is detected.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2. Place the motorcycle in an upright position with the front wheel clamped in a wheel vise. Suspension chapter. 4. chapter. wheel.

39 for adjustment procedure. Remove the seat as outlined in Frame / Body chapter. 2. SeeRear Shock Preload Adjustment . RECOMMENDED SUSPENSION SAG Chief Classic / Chief 35 mm Vintage / Chief Dark Horse Springfield / Chieftain 45 mm Dark Horse / Chieftain / Roadmaster 9927618 R03 . (M1–M2=Sag) 11. 9. Install the seat as outlined in Frame / Body chapter. page 2. Record the results as measurement M2. Load the motorcycle with all intended cargo. 10. Have an assistant measure the same location. Place the motorcycle in an upright position with the front wheel clamped in a wheel vise. 8. Wearing riding gear. IMPORTANT Have an assistant stabilize the motorcycle in a vertical position so rider can sit in a normal riding position with feet on floorboards. 1. Lower the motorcycle and remove the scissor jack. Subtract measurement M2 from M1. nut. 7. 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).CHIEF center of the rear axle w to the bottom of the tape MODELS e. 8. page 2.MAINTENANCE 6. Spray a light lubricant on the adjuster nut where it contacts the spring. 3.38 © Copyright .2017 Indian Motorcycle (Full-Size) Service Manual 2. Using shock spanner wrench (PV-46993) loosen the lock nut by turning it counter-clockwise (as viewed from the top of the shock).38 or Rear Shock Preload Adjustment . sit on the motorcycle in the normal riding position. Measure the distance (in millimeters) from the REAR SHOCK PRELOAD ADJUSTMENT . 6. Adjust preload as needed to achieve suspension sag indicated in the table below. Recheck the preload measurement after adjusting. 5. Record the results as measurement M1. Tighten the lock nut securely against the adjuster 7. The result is the measured rider sag.Chief Models.Springfield / Chieftain / Roadmaster. 4.

S P R I N G F I E L D / C H I E F TA I N / R O A D M A S T E R Refer to the label located on the inside of the left side adjust shock preload (ride height) based on your cover. 300 38 48 60 REMOVE ALL PASSENGERS AND 325 48 60 71 CARGO BEFORE SETTING / CHECKING SHOCK PRESSURE. To reduce air pressure. level surface. • Use shock air pump (PV-48909) to complete adjustment procedure. Remove the LH upper side cover. MAINTENANCE R E A R S H O C K P R E L O A D A D J U S T M E N T . Remove the cap from the air fitting q. SET 350 60 71 85 PRESSURE WITH BIKE ON SIDE STAND.17. Removal / Installation. 5.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 2. Release air until the desired pressure reading is obtained. Follow these guidelines when adjusting: • Park motorcycle with the sidestand down on a firm. 1. based on potential load weights. page 7. • Remove all riders and cargo. 9927618 R03 . 4. 375 71 85 100 400 85 100 122 425 100 122 134 450 122 134 145 475 134 145 NA 500 145 NA NA IMPORTANT 2. push the bleed button on the gauge. See Side Cover (Upper).39 . • DO NOT exceed 150 psi (1034 kPa) in the shock. Always inspect and AIR SUSPENSION ADJUSTMENT AIR PRESSURE (PSI) 2 TOTAL CARGO & LEATHER PAINTED OCCUPANT WEIGHT (LB) NO TRUNK TRUNK TRUNK MAX PRESSURE: 150 PSI 0 0 0 0 150 0 0 0 175 0 0 10 200 0 10 23 225 10 23 30 250 23 30 38 SELECT PRESSURE 275 30 38 48 CORRESPONDING TO TOTAL CARGO AND OCCUPANT WEIGHT. Install the hose fitting the shock air pump onto the fitting and read the gauge. 3. Refer to the label on the inside of the LH side cover to determine the recommended shock air pressure. The label shows recommended pressures actual load weight.

See Rear Shock Preload Inspection.000 miles. Inspect spokes after first 500 miles. 2. spokes.40 © Copyright .37. pump the handle until MAINTENANCE .MAINTENANCE 6. 9927618 R03 . 7. grasp each spoke and try to move it side to side or up and down. To identify loose spokes.2017 Indian Motorcycle (Full-Size) Service Manual 2. broken or missing the cap. Tighten loose spokes or replace bent. bent. Remove the hose from the air fitting and reinstall inspect both wheels for loose.CHECK WHEEL SPOKES pressure increases to the desired level. page amount of flex. If your motorcycle is equipped with spoked wheels. broken or missing spokes. All 8. Repeat the preload inspection to verify proper spokes should be equally tight and have the same preload. To increase pressure. then again every 5.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . .21 SPECIAL TOOLS. . .7 SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . .17 LUBRICATION / COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 PREPARATION FOR ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . .7 TORQUE SPECIFICATIONS . . . . . . 3. . . . . . . . . . . . . . . . . . . . . . . .27 OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. . . . . . . . . . . . . . . . . . . . . . . 3. . . . . . . . . . . . . . . . . . . .8 ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 AIR BOX REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 CYLINDER HEAD / VALVES . . . . . .22 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 3 SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .23 OIL COOLER . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 OIL COOLER INSPECTION . . . . . . . . . . . . . . . . .9 LEFT SIDE BRACKETS / FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . .3. . . .28 OIL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE / COOLING / EXHAUST CHAPTER 3 ENGINE / COOLING / EXHAUST AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 ASSEMBLY VIEWS . . . . . . . . . . . . .3. . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 FILTER ADAPTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . .32 SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 GENERAL INFORMATION . . .27 OIL PUMP SERVICE . . . . . .30 OIL COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 ENGINE BRACKETS / FASTENERS . . .21 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 OIL COOLER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . .5 ENGINE REMOVAL / INSTALL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 OIL FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 9927618 R03 . . . . . . . . . . 3. . . . . . . . . . . . . . . . . . . .3. . . . 3. . . . . . . . . . . . . . . . . . . .7 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 ENGINE REMOVAL . .11 REMOVING ENGINE FROM FRAME . . . . 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . .9 RIGHT SIDE BRACKETS / FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . .32 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 OIL COOLER REMOVAL . . . . . . . . . . . . . .7 GENERAL INFORMATION . . . . . . . . . . . . . . . .26 OIL PRESSURE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 AIR BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 SERVICE NOTES . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . .36 CAM CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 CAM CHAIN TENSIONER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 VALVE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 CAMSHAFT INSTALLATION . . . . .47 CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 CAM CHAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . .62 CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .43 CAM CHAIN INSTALLATION . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 VALVE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . .40 CAM CHAIN SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 LIFTER INSTALLATION . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 LOCKING THE CRANKSHAFT FOR SERVICE . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 CAM CHAIN GUIDE INSTALLATION . . . . . .3. . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . .53 CAMSHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . .58 CYLINDER HEAD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . .3. . . . . .3. . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . .46 CAMSHAFT CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . .63 VALVE SPRING FREE LENGTH INSPECTION. . . . . . . . . . . . .ENGINE / COOLING / EXHAUST TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . .ENGINE OUT . . . . . . .3. . . . . . . . . . . . . . .3. . . . . . . . .59 VALVE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2017 Indian Motorcycle (Full-Size) Service Manual 3. . . . . . . . . .3. . . . . . . . . . . . . . .3. . . . . .65 VALVE GUIDE REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . .50 CAMSHAFT CARRIER INSTALLATION . . . . . . . . . . . . . .2 © Copyright . . . . . . . . . . . . . . . .69 CYLINDER / PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . .66 VALVE SEAT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 CAMSHAFT / LIFTER SERVICE . . . . . . .3. . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 CAMSHAFT CARRIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .39 CAMSHAFT TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 CAMSHAFT CARRIER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 CAM CHAIN GUIDE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD AND VALVE TRAIN . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . .33 ASSEMBLY VIEWS . . . . . . . . . . . . . .45 LIFTER REMOVAL . . . . . . . . . . . . . .36 CAMSHAFTS . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 CYLINDER HEAD INSPECTION .3. . .41 CAM CHAIN COVER REMOVAL / INSTALLATION .61 ROCKER ARM INSPECTION . . . . . . . . . . . . . . . . . . . . . . .66 VALVE SEAT RECONDITIONING .42 CAM CHAIN TENSIONER INSTALLATION . . . .3. .42 CAM CHAIN TENSIONER INSPECTION . . . . . . . . .72 9927618 R03 . . . . . . .67 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . .61 ROCKER ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 SERVICE SPECIFICATIONS .63 VALVE INSPECTION. . . .37 LIFTERS / PUSHRODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IN BIKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 9927618 R03 . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . .74 CYLINDER / PISTON . . . . . . . . .3. . . . . . . . . . . . . . . . . . . .76 3 CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . .3. . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . .3. . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. .3. . . . . . . . . . . . .86 ASSEMBLY VIEWS . . . . . . . . . . . . . .75 CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 PISTON & PISTON RING REMOVAL . . . . . . . . . . . . . .73 ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 HEAD PIPE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 HEAD PIPE INSTALLATION . . . . . . . . . . . . . . . . . . . . ENGINE / COOLING / EXHAUST GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 CYLINDER BORE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 MUFFLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 PISTON RING PROFILE AND ORIENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 PISTON TO CYLINDER CLEARANCE WORKSHEET . . . . . . . . . .72 SERVICE SPECIFICATIONS . . . . . . . . . . . . .3.83 EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 CYLINDER WARPAGE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 PISTON & PISTON RING INSPECTION . . . . .86 EXHAUST SERVICE . . .86 EXHAUST SYSTEM . . . . . . . . . .87 CROSS OVER PIPE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.87 MUFFLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER / PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 CYLINDER / PISTON SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . .80 PISTON INSTALLATION . . . . . . . . . . . .3. . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 CYLINDER STUD REPLACEMENT . . . . . . . . . . . . . . .91 CROSS OVER PIPE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 SERVICE NOTES . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 PISTON PIN / PIN BORE INSPECTION . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. remove the three fasteners e securing the air filter adapter plate to fasteners q securing the air cleaner cover to the the air box assembly and remove adapter plate. Disconnect the multi-plug from the throttle body. remove the three 1.2017 Indian Motorcycle (Full-Size) Service Manual 3. remove the three fasteners When removing the adapter plate. outward to release the valve cover vent hose from the back side of the adapter plate. start by applying w securing the air filter element to the adapter more pressure to the forward (LH) edge and pull plate and remove element. Using a T30 Torx wrench. Using a 4mm hex wrench. Remove the two fasteners r securing the baffle plate to the intake air boot. 9927618 R03 . air box. NOTE 2.4 © Copyright .ENGINE / COOLING / EXHAUST AIR CLEANER SERVICE A I R B O X R E M O VA L 3. 4. Using an 8mm socket.

3. Install the four fasteners q securing the air box mounting plate and remove throttle body assembly. Feed the throttle body electrical connector through the hole in the air box and install the rubber harness seal in the rectangular cutout. Using a 5 mm hex wrench. 8. ENGINE / COOLING / EXHAUST 6. Air Box Bracket Fasteners: 88 in-lbs (10 Nm) 2. Fit the air box to the mounting bracket and press breather hose w through the rubber grommet until the air box sits flat against the bracket. Using an 8 mm socket. Install air box retainer fastener r and torque to specification.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. Install the intake air boot and baffle plate. remove the lower fastener TORQUE y securing the air box to the mounting plate.5 . 4. Push the rubber harness seal through to the back side of the air box and remove the air box from the motorcycle. 9927618 R03 . Torque baffle plate fasteners e to specification. NOTE Make sure that the harness seal is fully seated in the air box cutout. remove the four A I R B O X I N S TA L L AT I O N fasteners t securing the throttle body to the 1. 5. mounting bracket to the engine and torque to specification. 3 7.

Install the three air filter adapter plate fasteners y and torque to specification. Throttle Body Fasteners: 89 in-lbs (10 Nm) 7.6 © Copyright . Torque throttle body fasteners t to specification. 8.2017 Indian Motorcycle (Full-Size) Service Manual 3. TORQUE Air Box Cover Fasteners: 84 in-lbs (10 Nm) TORQUE Air Filter Adapter Plate Fasteners: 31 in-lbs (4 Nm) 9927618 R03 .ENGINE / COOLING / EXHAUST TORQUE 10. Press the hose fitting on the adapter plate into the breather hose until the plate is fully seated. TORQUE Air Filter Fasteners: 62 in-lbs (7 Nm) 11. Install the air filter element and torque fasteners u to specification. Baffle Plate Fasteners: 31 in-lbs (4 Nm) Air Box Retainer Fastener: 86 in-lbs (10 Nm) 6. Install throttle body o-ring and throttle body. Install air box gasket and cover. 9. Torque fasteners TORQUE i to specification. Connect throttle body electrical connector. Install the air filter adapter plate and seal into the airbox.

4) Stator.0 x 12 (QTY. Approximately 6.2) Limit Clutch Starter Solenoid — M6 x 84 in-lbs (10 Nm) Crankshaft Position 1. ENGINE / COOLING / EXHAUST 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 S E R V I C E S P E C I F I C AT I O N S SERVICE NOTES ITEM SPECIFICATIONS A floor jack or commercially available motorcycle engine lift or hoist is required for engine removal.1) Starter.2) Piston/Cylinder Oil Pump Drive Engine Mounts.4) Cylinder Heads Fuel Injectors / Throttle Down Tube.7 Liters) stand is recommended for engine disassembly and assembly.5 x 60 Cylinders Voltage Regulator.4) Transmission/All Torque Compensator Ground Wire — M6 x 1.2) Balance Shaft Ignition System Engine Mounts.5 x 100 (QTY.1) Parts Side Stand Bumper — 84 in-lbs (10 Nm) Valve Covers M6 x 1.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. Upper LH — 45 ft-lbs (60 Nm) (External) M10 x 1.0 x 12 (QTY.0 x 12 (QTY.0 x 12 (QTY.0 84 in-lbs (10 Nm) Internal Transmission Assembly x 12 (QTY. an engine Oil Capacity (Dry Fill) Quarts (5.2) Sensor Timing Wheel 9927618 R03 . Front — 18 ft-lbs (24 Nm) M8 x 1.0 Once the engine is removed from frame.1) Oil Pump Gearshift Linkage Down Tube. (QTY. but T O R Q U E S P E C I F I C AT I O N S always be sure the engine and chassis are securely PART DESCRIPTION TORQUE supported at all times.25 x 20 (QTY. Rear — 75 ft-lbs (102 Nm) Pushrods Output Shaft Seal M12 x 1.5 x 25 (QTY. Engine removal and installation methods may differ 3 slightly depending on available equipment. Lower LH — 45 ft-lbs (60 Nm) Lifters Clutch M10 x 1.8 x 16 (QTY.4) SERVICE FRAME Battery Box — M6 x 1. Approximately 293 lbs Engine Dry Weight Arrange for assistance when removing and installing (133 kg) the engine.7 .2) Crankshaft & Crankshaft Camshaft Chain / Guide Brake Line Routing Tabs 84 in-lbs (10 Nm) Component Service / Tensioner Assembly — M6 x 1. Starter One-Way Side Stand Switch — M5 43 in-lbs (5 Nm) Clutch.0 x 84 in-lbs (10 Nm) Camshaft(s) / Bearings Airbox Removal 12 (QTY. Rotor (Flywheel) Down Tube. Starter Torque x 0.75 x 50 (QTY. Lower (Both 45 ft-lbs (60 Nm) Body / Fuel Rail Sides) — M10 x 1. SPECIFICATION REQUIRES ENGINE CAN BE SERVICED ABS Module Bracket — 84 in-lbs (10 Nm) REMOVAL FOR WITH ENGINE IN M6 x 1.

ENGINE / COOLING / EXHAUST 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.2017 Indian Motorcycle (Full-Size) Service Manual 3.8 © Copyright .com/ 9927618 R03 .

2) 18 ft-lbs (25 Nm) 9927618 R03 .2) 75 ft-lbs (102 Nm) w Fastener.2) 45 ft-lbs (60 Nm) t Fastener.9 . ENGINE / COOLING / EXHAUST 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 L E F T S I D E B R A C K E T S / FA S T E N E R S 3 NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Fastener. Frame Down Tube — M10 x 1.1) 45 ft-lbs (60 Nm) e Fastener.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. Engine Mount — M10 x 1.5 x 60 (QTY.5 x 25 (QTY.5 x 100 (QTY. Engine Mount — M10 x 1.75 x 50 (QTY.2) 45 ft-lbs (60 Nm) r Fastener. Front Engine Mount — M8 x 1. Engine Mount — M12 x 1.25 x 20 (QTY.

2) 45 ft-lbs (60 Nm) 9927618 R03 .5 x 60 (QTY.1) 75 ft-lbs (102 Nm) w Fastener. Engine Mount — M12 x 1.2017 Indian Motorcycle (Full-Size) Service Manual 3.ENGINE / COOLING / EXHAUST R I G H T S I D E B R A C K E T S / FA S T E N E R S NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Fastener. Engine Mount — M12 x 1.10 © Copyright . Engine Mount — M10 x 1.75 x 50 (QTY.1) 75 ft-lbs (102 Nm) e Fastener.75 x 120 (QTY.

page 7. prior to placing the front tire in a wheel vise. Loosen axle nut q and loosen belt tension P R E PA R AT I O N F O R E N G I N E R E M O VA L adjustment nuts w and remove belt from drive Remove the front fender with the motorcycle rest.17. See Drive Sprocket Cover. 11. 2. page 7. page 7.40. Removal / Installation. page 8. See Highway valve covers. Remove air box. 16.15. 3 1. Remove the battery. Removal / Installation. Classic / Vintage / Chieftain.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. 7. Remove the RH and LH floorboard assemblies. if equipped. See Fuel Tank Removal.24. Remove both ends of the breather hose y from the 12. 4. Disconnect the CHT sensor t. 6. 10. page 7. See EXHAUST SERVICE. Clamp front tire securely in a wheel vise. Removal / Installation. page 3. See Ignition Coil Removal / Installation. See Air Box Removal. page 10. 9.11 . 3. See Side Cover (Upper). Removal / Installation . 17. Remove highway bars.4. See Front Fender Removal. See Battery Removal. Remove the seat. With the motorcycle resting on it’s side stand.18. ing on it’s side stand.26. sprocket. 8. 9927618 R03 . page 7. (Lower). page 7. 14. Removal. ENGINE / COOLING / EXHAUST E N G I N E R E M O VA L 13. Bar Removal. Remove lower side covers. Remove the knock sensor e. All methods require the front wheel to be held securely in an upright position. page 2. 18. Support motorcycle securely in an upright position. Remove the fuel tank. 5. See Side Cover 15. Remove the sprocket cover.17. remove the front fender.26.48.21. Remove the complete exhaust system. See Seat. See Floorboard (Driver). NOTE Different methods can be used to remove the engine depending on the equipment available to the technician. Disconnect the TMAP sensor r. Remove upper side covers. page 4. Remove the ignition coil assembly.

securing the clutch cable clip to the bottom of the LH engine case. Engine Removal.12 © Copyright .12. See Sensors — Powertrain Management. Using a 5 mm hex wrench. See Sensors — 3.12. 9927618 R03 . 20. Disconnect the gear position switch.11. See Sensors — Powertrain Management. Using a 10 mm socket. remove the two front motor mount fasteners w from the engine case. 5. remove the 4 fasteners e r t securing the LH front down tube to the frame top tube and lower engine boss.ENGINE / COOLING / EXHAUST 19. Using a 6 mm hex wrench.2017 Indian Motorcycle (Full-Size) Service Manual 3. 21. 22. 4. remove the two fasteners securing the sidestand switch and move switch out of the way. page 4. page 4. touching the crankcase). page 4. Remove the E-clip from the end of the clutch cable. Perform the preliminary engine removal steps plugs up through the fuel rail (distribution line) outlined in this chapter. Using a 4 mm hex wrench. 23. remove the fastener q Powertrain Management. Disconnect the oil pressure switch. Disconnect electrical connectors from both fuel REMOVING ENGINE FROM FRAME injectors and feed the electrical harness and all 1.12. Place a platform jack beneath the engine and raise fastener u and release the oil cooler from the enough to support crankcase (Jack should just be lower mounting tabs i. remove the top oil cooler 2. rotate the clutch arm by hand and release the clutch cable end from the arm. See Preparation For and move out of the way. page 3. Using an 8 mm hex wrench. 6.

Remove CPS. See Starter Motor. page 10. remove the four fasteners i securing the hard hydraulic lines to the RH frame down tube and engine case. Using a 5 mm hex wrench. 9. stator / regulator harness to the mounting bracket as they can be moved out of the way as an assembly. See Sensors — Powertrain It is not necessary to clip the cable ties securing the Management. Using a 5 mm hex wrench. Removal / Installation. remove the two fasteners y securing the voltage regulator to the mounting bracket and move the regulator enough to access the mounting bracket fasteners. 9927618 R03 . 11. Remove the starter motor. NOTE 12. 3 8. Remove the LH frame down tube and side stand as 10. 13. Disconnect the stator from the regulator.25.12. Remove the three regulator mounting bracket an assembly. ENGINE / COOLING / EXHAUST 7. page 4. fasteners u securing the regulator bracket to the engine case and move bracket out of the way.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3.13 .

18. Remove canister. disconnect hoses a from the charcoal canister.ENGINE / COOLING / EXHAUST 14.14 © Copyright . remove the remaining 16. Noting position. Disconnect the main ABS electrical connector and two brake switch connectors from the ABS Module.2017 Indian Motorcycle (Full-Size) Service Manual 3. Remove the two fasteners d securing the charcoal canister mounting bracket to the ABS bracket. Using an 8 mm hex wrench. NOTE STEPS 15–17 APPLICABLE TO CA AND INTERNATIONAL MODELS ONLY. Using a 5 mm hex wrench. 15. remove the two two fasteners o from the RH frame down tube and fasteners s securing the charcoal canister to the remove. 9927618 R03 . bracket. 17.

9927618 R03 . It is not necessary to remove the hydraulic lines from the ABS module during engine removal. Remove the two fasteners g securing the starter and engine mounts. solenoid to the ABS bracket. Remove the four fasteners f from the ABS bracket. using a 16 mm socket.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. remove the two spacers l from the RH side of the engine between the frame panel 20. 21. 3 23. Remove the two fasteners h securing the battery tray to the engine and the grounding fastener j NOTE from the engine case. 22. remove the two fasteners k securing the rear of the motor to the frame side panel. Working from the RH side. 24.15 . 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. Using a pick tool. ENGINE / COOLING / EXHAUST 19.

9927618 R03 . remove the two fasteners 1 ( securing the rear of the engine to the LH frame panel. lower the engine from the frame and remove from vehicle. Working from the LH side of the motorcycle. Push engine slightly to the RH side to free up from alignment dowels. With an assistant.16 © Copyright .ENGINE / COOLING / EXHAUST 25.2017 Indian Motorcycle (Full-Size) Service Manual 3. 26.

Refer toEngine Brackets / Fasteners. ready for installation. Be sure all wiring and hoses are properly routed before installing rear spacers and mounting fasteners. stand. DO NOT force engine alignment using the mounting fasteners. Be sure engine is properly supported before proceeding. 9927618 R03 . 4. Install the two engine mounting fasteners into the LH frame panel and tighten until the engine is fully drawn into the frame panel. Install alignment dowels q. or hoses.17 . The engine must be held securely to prevent damage to engine. or the dowel pins may be damaged! Adjust engine height and angle continuously as required while drawing up the fasteners. CAUTION Arrange for assistance when installing engine. ENGINE / COOLING / EXHAUST E N G I N E I N S TA L L AT I O N 3. Slide the engine towards the LH frame panel until the dowel pins are fully seated. the motorcycle and slide into position so the gine has been assembled and is resting on an engine engine is orientated correctly front to back. 7. Slide the engine back until the rear mounting ears are aligned with the mounting holes in the frame 1. page 3. align rear mounts and dowel pins. 6. Position the engine on a platform jack to the left of The following procedure is written assuming the en. wiring. Place motorcycle in an upright position with the front wheel clamped in a wheel vise. The engine is very heavy and could cause severe personal injury if not 3 handled properly.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. Adjust height of engine as needed to crankcase.9 in this chapter for torque values and assembly views. frame. Clean mating surfaces of frame and engine side panels. IMPORTANT Be sure alignment dowels are in place in the LH rear engine mounts prior to installation. CAUTION Be sure engine is aligned at the proper height and angle with the dowel pins. 5. Do not torque fasteners at this time. 2.

Reconnect the main connector and brake switch fasteners to specification. TORQUE Starter Solenoid Mounting Fasteners: 84 in-lbs (10 Nm) TORQUE 15. Install the two engine mounting fasteners e into the RH frame panel. 9. If applicable. Install the four fasteners y securing the ABS spacers w into position between the RH frame module bracket to the rear of the engine and panel and the engine crankcase. page 3.9. Install the two fasteners r securing the battery box to the engine and the grounding wire fastener t and torque to specification. slide the 12. Working on the RH side of the engine. Install the two fasteners u securing the starter TORQUE solenoid to the ABS bracket and torque to Rear Engine Mounting Fasteners: 75 ft-lbs (102 Nm) specification.2017 Indian Motorcycle (Full-Size) Service Manual 3. Torque the left hand rear engine mounting 13. TORQUE ABS Module Bracket Fasteners: 84 in-lbs (10 Nm) 10. Grounding Wire Fastener: 84 in-lbs (10 Nm) 9927618 R03 . 14. connectors to the ABS module. 11. install the mounting bracket and Battery Box Fasteners: 84 in-lbs (10 Nm) charcoal canister to the back of the ABS module bracket and reconnect vapor hoses.18 © Copyright .ENGINE / COOLING / EXHAUST 8. through the spacers and torque to specification. See Engine Brackets / Fasteners. torque to specification.

9927618 R03 . See Rectifier / NOTE Regulator Replacement.33 Pay attention to brake line routing while installing the 20.9. TORQUE Brake Line Mounting Fasteners: 84 in-lbs (10 Nm) 18. 19. while the brake line running up toward the head tube runs to the rear of the down tube. page 3. Removal / Installation. page 10. Place the RH frame down tube in position and install the lower two fasteners i to the engine 3 case and torque to specification. page 10.9. See Engine Brackets / Fasteners. 21. page 3. The brake line with a 90° bend above motorcycle with the clutch cable a properly the oil cooler should run forward of the down tube routed. 17. Place the LH frame down tube in position on the RH down tube.25. Using a 5 mm hex wrench. ENGINE / COOLING / EXHAUST 16. Install the two fasteners s. install the four fasteners o securing the hard hydraulic brake lines to the engine case and RH down tube and torque to specification. See Engine Brackets / Fasteners. Install the starter motor.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. See Starter Motor. Install the regulator / rectifier mounting bracket and the regulator / rectifier.19 . two fasteners d and two fasteners f securing the LH down tube to the motorcycle and torque to specification.

See Oil Cooler 45. See Front Fender Installation.24. Side Stand Switch Fasteners: 43 in-lbs (5 Nm) 44. Fit the drive belt over the drive sprocket and set belt tension / wheel alignment. 38. Inspect oil level and adjust if necessary.48.12. page 7. Install the lower side covers. Install the LH and RH floorboard assemblies.19. Install side stand bumper fastener g and side 34. check entire vehicle the fuel injector harness down through the fuel and engine for fluid leaks and be sure all fasteners distribution line (fuel rail) and reconnect the fuel have been properly torqued. 31. page 10.31. Install the seat. See Battery Installation. Install the oil cooler to the frame. 30. See EXHAUST stand switch fasteners h and torque to SERVICE. 26. Test brakes to be sure switch and oil pressure switch. page 3. page 4. page 7. side stand seat pads against disc. Install new oil filter and fill engine to proper level with Indian Motorcycle engine oil. Install the air cleaner assembly and throttle body.40. Side Stand Bumper Fastener: 84 in-lbs (10 Nm) 43. See Fuel Tank Installation.21. Install front fender. sensor. Install the complete exhaust system. page 7. See Drive Belt Adjustment.5. When test ride is completed. If equipped. Installation. Working on the RH side of the motorcycle. Add fuel to fuel tank and prime fuel system. TMAP sensor. 35. page 3. 29. page 7. proper operation. Removal / Installation.17. 33. route 46. See Ignition Coil Removal / Installation. 37. 25. page 4. Install ignition coil and cover.17. Start engine and set oil to proper level. Bleed Powertrain Management. See Sensors — operation and pedal pressure are normal. See Air Box Installation.12.20 © Copyright . Check operation of all cables and controls and adjust as necessary.ENGINE / COOLING / EXHAUST 22. 28. injectors. page 2. 36. Removal / Installation. 32. See Drive Sprocket Cover.19. Removal / Installation - Classic / Vintage / Chieftain.13. page 7. Removal / Installation. 27. page 8. Install the fuel tank. See Floorboard (Driver). 39. 41.27. Install the battery. See Highway Bar Installation. 24.31. page 4. page 10. install the highway bar. page 7. Install the sprocket cover. 40. See Side Cover (Upper). TORQUE 42. Pump front brake lever and rear brake pedal to 23. Test ride motorcycle and check all systems for Installation. See Seat. CHT sensor and knock 47. 9927618 R03 . brake system if necessary. See Side Cover (Lower). Connect the gear position switch. specification.2017 Indian Motorcycle (Full-Size) Service Manual 3. Remove motorcycle from wheel vise and place on side stand for remainder of engine installation procedure. Install the upper side covers. See Sensors — Powertrain Management.

oil filter screen or passages SPECIAL TOOLS TOOL DESCRIPTION PART NUMBER The oil pump has two sets of internal gerotors. review the troubleshooting charts located in this chapter.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3.com/ To access the oil pump. and recheck the oil pressure after a repair. The oiling system pressure Bosch Automotive Service Solutions: 1-800-328- relief valve is also located inside the oil pump.21 . check the lubrication side oil pressure. The engine oil is housed in a Incorrect oil being used Incorrect oil being used separate chamber within the engine cases q as shown or low oil level in the image below. Restricted oil filter.service-solutions. If the engine is making irregular noises that appear to be coming from rotating parts. One set Oil Pressure Gauge PV-43531 provides lubrication pressure and the second set provides the scavenge. Before disassembly. ENGINE / COOLING / EXHAUST 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 TROUBLESHOOTING SERVICE NOTES LOW OIL PRESSURE HIGH OIL PRESSURE The Thunderstroke 111 uses a semi-dry sump lubrication system. the engine must be removed from the frame and disassembled. 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 3 Pressure relief valve Incorrect oil filter stuck open Damaged engine Pressure relief valve stuck bearings/excessive closed engine wear. 6657 or https://polaris. 9927618 R03 . Check the oil pressure before engine disassembly.

003"-. qts (5.005" (.4 U. use motorcycle oil with 20W/40 same specifications.0014"-.015" (.081 mm) .006"-. qts (5.203 mm) Gerotor Tip Clearance .S.010" (.2017 Indian Motorcycle (Full-Size) Service Manual 3.8 kPa) OIL PUMP CLEARANCES Scavenge Gerotor OD to Oil Pump Body .7 kPa) Readings should MINIMUM operating temperature and specified Indian be within 20% of the specification.006"-.381 mm) Feed Gerotor OD to Oil Pump Body .076 mm-.8 U.22 © Copyright .381 mm) Oil Pump End Clearance .008" (. Recommended Engine Oil if Indian Motorcycle Indian Motorcycle Semi-Synthetic Not Applicable 20W/40 is not available. PRESSURE: 30 psi Motorcycle Engine Oil (206.15 mm-.1 Liters) Not Applicable Follow the oil change procedure outlined in the Maintenance chapter. Oil Pressure @ 3000 rpm (supply side) Engine at 60 psi (513. Engine Oil Capacity (At Change without Filter) 5.0032" (. qts (5.S.2 Liters) Not Applicable the oil change procedure outlined in the Maintenance chapter.036 mm-.010" (.007" (.ENGINE / COOLING / EXHAUST T O R Q U E S P E C I F I C AT I O N S PART DESCRIPTION TORQUE SPECIFICATION Cylinder Head Temperature Sensor (CHT) . Oil Filter Fitting to Oil Filter Adapter 22 ft-lbs (30 Nm) Oil Filter Adapter to Crankcase 88 in-lbs (10 Nm) Oil Pickup Screen to Oil Pump 88 in-lbs (10 Nm) Oil Pressure Sensor 88 in-lbs (10 Nm) Oil Pressure Sensor Adapter 15 ft-lbs (20 Nm) Oil Pump to Crankcase 88 in-lbs (10 Nm) Oil Scavenge Inlet Screen 88 in-lbs (10 Nm) Oil Scavenge Tube to Oil Pump and Engine Case 88 in-lbs (10 Nm) S E R V I C E S P E C I F I C AT I O N S ITEM STANDARD LIMIT Engine Oil Capacity (After Disassembly) 5.Supply and Return 84 in-lbs (10 Nm) Oil Drain Plugs .(Install 71 in-lbs (8 Nm) new if removed) Oil Cooler Line Flange Fittings .5 U.S.127 mm) .25 mm) .25 mm) .15 mm-.015" (.178 mm) 9927618 R03 .5 Liters) Not Applicable Engine Oil Capacity (At Change with Filter) Follow 5.Scavenge and Oil Tank 15 ft-lbs (20 Nm) Oil Filter (Apply oil to filter seal) Approximately 3/4 turn after sealing ring has contacted the filter adapter.

0 x 12 84 in-lbs (10 Nm) (QTY. page 3.M6 x 1. O-ring – t O-ring. ENGINE / COOLING / EXHAUST A S S E M B LY V I E W S OIL COOLER 3 NOTE This system only applies to certain 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. Oil Cooler – y Fitting.25 for list of affected models.23 . See Oil Flow Diagram.0 x 40 88 in-lbs (10 Nm) (QTY.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. w Fastener. Oil Filter 22 ft-lbs (30 Nm) u Fastener.M6 x 1.3) i Oil Filter Adapter Assembly – 9927618 R03 . Oil Filter Adapter . Oil Cooler Pipes .2) e Oil Cooler Assembly – r Backing Ring.

24 © Copyright .2017 Indian Motorcycle (Full-Size) Service Manual 3. Oil Filter Adapter . Oil Cooler – 9927618 R03 .0 x 40 88 in-lbs (10 Nm) (QTY.M6 x 1.3) w Oil Filter Adapter Assembly – e O-ring.ENGINE / COOLING / EXHAUST F I LT E R A D A P T E R NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Fastener.

25 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. ENGINE / COOLING / EXHAUST OIL FLOW DIAGRAM 3 OIL COOLER FILTER ADAPTER INTERNAL BYPASS • Chieftain Dark Horse • Chief Classic • Chieftain • Chief Vintage • Roadmaster • Chief Dark Horse • Springfield 9927618 R03 .

3) 88 in-lbs (10 Nm) u Fastener. Oil Pump .ENGINE / COOLING / EXHAUST L U B R I C AT I O N S Y S T E M NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Fastener.2) 62 in-lbs (7 Nm) y Fastener .M6 x 1.0 x 12 (QTY.2) a Oil Pressure Sensor 88 in-lbs (10 Nm) s Adapter. Oil Pump – o Oil Drain Plugs.3) 88 in-lbs (10 Nm) i Pickup Screen.M5 x 0.M6 x 1.M12 x 1.2017 Indian Motorcycle (Full-Size) Service Manual 3. Oil Jet . Oil – 9927618 R03 .26 © Copyright . Scavenge and Oil Tank .0 x 15 (QTY.5 15 ft-lbs (20 Nm) (QTY.0 x 115 (QTY. Piston Cooling – t Fastener.M6 x 1. Oil Pressure Sensor 15 ft-lbs (20 Nm) d Dipstick.3) 84 in-lbs (10 Nm) w Oil Feed Pipe – e Engine Case (RH) – r Oil Jet. Oil Feed Pipe .8 x 10 (QTY.

27 . page 3. refer to the troubleshooting section. 4. 5. 1. TORQUE Oil Pressure Switch: 88 in-lbs (10 Nm) 9927618 R03 . ENGINE / COOLING / EXHAUST OIL PRESSURE INSPECTION OIL PRESSURE CAUTION Use caution when working around hot engine oil. Start the engine and temperature is reached. run until operating 3 2. clean threads with Loctite® Primer N. 9. NOTE Oil pressure switch activates at 3 psi ± 1 psi. Start engine and check oil pressure at 3000 rpm. 8. 7. Turn the engine OFF. if necessary. Remove oil pressure sensor q. Compare reading to oil system specifications. If oil pressure is outside of specification. 3. 6. Once testing is completed. and apply thread sealant to the oil pressure switch threads and torque to specification.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3.21. Use the dipstick to check the engine oil level and add recommended oil. Install oil pressure gauge.

ENGINE / COOLING / EXHAUST OIL PUMP SERVICE 5. page 6. 3. Remove the oil pump snorkel tube fasteners t. oil pump drive gear e. Remove external snap-ring q. Remove the three fasteners y from the oil pump O I L P U M P R E M O VA L assembly. See Removing Engine From Frame.12. page 3. See Crankcase Separation. 4. 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual 3. flat washer w. 1. Separate engine cases. and drive pin r from oil pump input shaft. 2. Remove engine from frame. 6.23. Remove the oil pump / snorkel tube assembly from the LH crankcase.28 © Copyright .

Loosely install the snorkel tube and fastener q to the pump body.29 . Install engine in frame. See Oil Pressure. 8. 10. See Engine Installation. sprocket t. 9927618 R03 . e and torque to specification. Assemble engine crankcase. ENGINE / COOLING / EXHAUST O I L P U M P I N S TA L L AT I O N TORQUE 1. If it is difficult to rotate. loosen then re-torque oil pump fasteners and check again. Install the oil pump / snorkel tube assembly into the crankcase and loosely install fastener w securing the snorkel tube to the LH crankcase. TORQUE Snorkel Tube Fasteners: 88 in-lbs (10 Nm) 6. Install oil pump drive pin r. 3 NOTE Pump should rotate by hand with little resistance.17. See Crankcase Assembly. 3. page 6. 4.27. Rotate the oil pump drive shaft by hand a few revolutions to verify smooth operation. Align fastener holes and install oil pump fasteners page 3.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3.39. page 3. washer y and external snap-ring u. Clean oil pipe and dry with compressed air. Verify engine oil pressure after assembly. 7. 5. Torque snorkel tube fasteners to specification. Oil Pump Fasteners: 88 in-lbs (10 Nm) 2. 9.

9927618 R03 . Remove the oil cooler assembly from the vehicle. 5. Inspect cooler mounting fastener for proper torque. 7. Replace if there is catch any oil that drains out of the cooler assembly any sign of abrasion or damage. Place an oil pan beneath the oil filter adapter to 2. 3. NOTE 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. Inspect oil cooler fins for deformation. 2. 4. Replace any damaged components. 8. 3.ENGINE / COOLING / EXHAUST OIL COOLER SERVICE OIL COOLER INSPECTION O I L C O O L E R R E M O VA L 1. Inspect cooler surface for obstructions or debris. Remove the upper oil cooler fastener w and lift the lower cooler mounts off of the rubber isolators.30 © Copyright . Inspect mounting bracket and rubber grommets for cracks or damage. 5. upon removal. Remove the two fasteners q securing the oil cooler lines to the oil filter adapter. Rinse from back side to front with low pressure water. 4. 1. Inspect cooler. Inspect lines for proper routing. Pull the oil cooler lines out of the filter adapter. lines and all connection for leaks.2017 Indian Motorcycle (Full-Size) Service Manual 3. 6. Fins can be straightened if not severely deformed and no oil leaks are present.

Top off if necessary.31 . Fit the lower oil cooler mounts into the rubber isolators located on the frame down tubes. Run the engine to cycle oil through the oil cooler and check oil level. 1. ENGINE / COOLING / EXHAUST 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. TORQUE Oil Cooler Line Fasteners: 84 in-lbs (10 Nm) 4. 3 TORQUE Oil Cooler Mounting Fastener: 84 in-lbs (10 Nm) 3. 9927618 R03 . Install the upper oil cooler mounting fastener q and torque to specification. 2.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. Install the oil cooler lines into the oil filter adapter and torque flange fasteners w to specification.

• Refer to Engine / Cooling / Exhaust chapter for Bosch Automotive Service Solutions: 1-800-328- engine removal and installation. If you are not sure of your capabilities in these areas. • Handle and store all parts in such a way that they will not be damaged or contaminated.32 © Copyright . cam chain and tensioner. have a competent machinist perform these operations. • Mark and store all mating parts for correct engine assembly. camshafts. • Some fasteners have a pre-applied locking agent. Crankshaft Locking Tool PF-51235 adjusting hydraulic lifters and pushrods. • Use Moly Assembly Paste . Dry parts with compressed air and lubricate before engine inspection and engine assembly. Crankshaft Rotation Tool PF-51239 SERVICE NOTES Seal and Bearing Driver Set PV-43558 • This chapter covers service of the cylinder heads. • Cleanliness of parts is critical to engine life and accurate parts inspection.2017 Indian Motorcycle (Full-Size) Service Manual 3. • Valve guide and seat reconditioning should be performed by a technician proficient in cylinder head reconditioning techniques using high quality equipment with grinding stones. 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. • The intake and exhaust valves cannot be re-faced. Each cylinder is equipped with two valves that are opened and closed via self. TOOL DESCRIPTION PART NUMBER The central camshaft uses a gear drive to turn two Valve Spring Compressor PV-1253 outer camshafts (exhaust). 9927618 R03 .P/N: 2871460 or Indian Motorcycle Synthetic 20W/40 Engine Oil to lubricate parts where indicated. Use clean solvent to clean all disassembled parts.service-solutions. • There are some precision machining steps to be performed in this section. cam chain Camshaft Service Tool PF-51455 guide and roller / rocker arms.ENGINE / COOLING / EXHAUST 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 SPECIAL TOOLS The Thunder Stroke 111 uses a single cam chain system to drive a centrally located camshaft (intake). 6657 or https://polaris. Do not attempt cylinder head repair without the proper equipment or experience in cylinder head reconditioning techniques.com/ • If cylinder heads are removed the cylinder base gasket must be replaced also.

0° BTDC Intake Valve Closes At 1 mm Lift 43.2) 71 in-lbs (8 Nm) Cam Chain Tensioner Fastener — M8 x 1.18) 89 in-lbs (10 Nm) Valve Cover Fasteners. Intake (Timing Gear) — 52 ft-lbs (70 Nm) M10 x 1.25 x 40 15 ft-lbs (20 Nm) (QTY. Inner — M6 x 1.33 .0° ABDC CAMSHAFT DATA Exhaust Valve Opens At 1 mm Lift 44° BBDC Exhaust Valve Closes At 1 mm Lift 4° ATDC Max Lobe Lift INTAKE (7.25 x 30 (QTY.1) Cylinder Head Nut — M8 x 1.4) / 15 ft-lbs (20 Nm) M6 x 1.1) Crankshaft Sprocket Fastener (Timing Gear) — M10 x 52 ft-lbs (70 Nm) 1.5 (QTY.6) 89 in-lbs (10 Nm) S E R V I C E S P E C I F I C AT I O N S Camshaft Data DESCRIPTION SPECIFICATION Over Head Valve / 2 valves per cyl Valve Train 1 Intake Valve / 1 Exhaust Valve Intake Valve Opens At 1 mm Lift 2.1) Camshaft Sprocket Fastener.5 x 40 (QTY.5 x 40 (QTY.3) 15 ft-lbs (20 Nm) Camshaft to Carrier Bearing Fasteners.20 mm) 9927618 R03 . Exhaust — M10 x 1.0 x 20 (QTY. ENGINE / COOLING / EXHAUST T O R Q U E S P E C I F I C AT I O N S PART DESCRIPTION TORQUE SPECIFICATION Cam Chain Cover Fasteners — M6 x 1.8 x 12 (QTY.0 x 40 (QTY.0 x 25 (QTY.6) Camshaft Carrier Bearing Retainer Plate Fasteners — 62 in-lbs (7 Nm) M5 x 0. Step 3: 40 ft-lbs (54 Nm) Lifter Block Fasteners — M6 x 1.8) Step 1: 22 ft-lbs (30 Nm) Step 2: Back nuts off completely.5 x 40 (QTY.6) 89 in-lbs (10 Nm) Lifter Retaining Plate Fastener — M5 x 0.8 x 12 (QTY.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3.0 x 65 (QTY.0 x 40 (QTY.6) Camshaft Carrier Fasteners — M8 x 1.2) 62 in-lbs (7 Nm) Rocker Arm Fastener 22 ft-lbs (30 Nm) Spark Plug 13 ft-lbs (17 Nm) Valve Cover Fasteners.20 mm) EXHAUST (7. Outer — M6 x 12 x 14 (QTY.2) 52 ft-lbs (70 Nm) 3 Cam Chain Guide Fasteners — M6 x 1.

053" (1.3128” (7.69 — 0.973 mm) .9835 . . .013 mm) Valve Head Radial Runout ..ENGINE / COOLING / EXHAUST DESCRIPTION SPECIFICATION Max Valve Lift INTAKE (12. - 56.005” (.8 mm) - Exhaust Valve Maximum Lift . (Exhaust) .953 INTAKE – 7.004” (.9832” (24.35 mm) - Valve Stem Runout . Replace as an Rocker Arm: IN/EX Replace as an Shaft.05 mm) Valve Installed Height 2.49 - INTAKE 56.047" (1.00 mm) 2.945 mm) – 7. .979 Journal O. . & Lifter assembly.8 mm) Cylinder Head & Valve Train Data ITEM STANDARD SERVICE LIMIT Cam Chain Ratchet / Spring .3131 — .993 mm) . Valve & EXHAUST) Seat Valve Seat Width INTAKE ..224" (55.7 — Valve Guide Installed Height - 18.8 mm) - 9927618 R03 .973 mm) Valve.13 mm) Guide. assembly.102 mm) Cam Shaft .993 mm) Cylinder Head Warpage (Distortion) .5788” (40.9832” (24. - Tensioner Lobe Height INTAKE 1.504" (12.D.D.2 mm) - EXHAUST .6260” (41.3128” (7.973 mm) .9835 .20" (56.3138” (7.953 .401 mm) 1. .0005” (.9840" (24.2017 Indian Motorcycle (Full-Size) Service Manual 3.49mm) Free Length (INTAKE & 2.169” (55.49 . (Intake) .24.301 mm) EXHAUST 1.24.72” (17.10 mm) EXHAUST) Valve Spring Intake Valve Maximum Lift .224" (55.10 mm) Non-Serviceable.002” (.3138” (7.9840" (24.184 . Valve Valve Stem Deflection (INTAKE .8 mm) EXHAUST (12.3 mm) Valve Stem O.D. Hydraulic/Self Valve Clearance - Adjusting 0.34 © Copyright .202 mm) 1.2.49mm) - EXHAUST 2.979 Journal O.6299" (41.2.973 mm) .184 .3131 — . Non-Serviceable.5827" (40. Rocker Arm.504" (12.945 mm) EXHAUST .

007" (49.2. ENGINE / COOLING / EXHAUST ITEM STANDARD SERVICE LIMIT 1.35 .929 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3.00 - Spring Installed Height - 51.00 mm) 3 9927618 R03 .

36 © Copyright . Crankshaft - g Timing Gear. Tensioner Arm - u Tensioner Arm. Timing Chain - y Snap Ring.6) / Fastener . Timing Gear .ENGINE / COOLING / EXHAUST A S S E M B LY V I E W S CAM CHAIN NUMBER PART DESCRIPTION TORQUE SPECIFICATIONS (IF APPLICABLE) q Fastener .5 x 40 (QTY.2017 Indian Motorcycle (Full-Size) Service Manual 3.4) w Cam Cover - e Cam Cover Gasket - r Fastener.2) 71 in-lbs (8 Nm) o Pivot.0 x 65 (QTY.M10 x 1. Timing Gear - f Timing Gear.25 x 40 (QTY.M8 x 1. Timing Chain Guide . Tensioner Arm 15 ft-lbs (20 Nm) a Guide. Camshaft (Intake) - h Timing Chain - 9927618 R03 .0 x 40 15 ft-lbs (20 Nm) (QTY. Timing Chain Tensioner .0 x 40 (QTY.M6 x 1.M6 x 1.1) 15 ft-lbs (20 Nm) t Tensioner.2) 52 ft-lbs (70 Nm) d Washer. Timing Chain - s Fastener.M6 x 1. Timing Chain - i Fastener.

M5 x 0. Exhaust (Front) - k Camshaft.6) - o External Snapring - a Washer.25 x 40 (QTY. Split (Exhaust) NOT SERVICEABLE - h Camshaft Gear (Intake) SERVICEABLE AS ASSEMBLY ONLY - j Camshaft.1) 15 ft-lbs (20 Nm) i Bearing Carrier.3) / M8 x 1. Camshaft Gear (Split) - g Camshaft Gear. Bearing Retainer Plate . ENGINE / COOLING / EXHAUST CAMSHAFTS 3 NUMBER PART DESCRIPTION TORQUE SPECIFICATIONS (IF APPLICABLE) q Fastener.5 x 40 (QTY. Split (Exhaust) - f Spring. Cam Bearings - e Fastener.6) 62 in-lbs (7 Nm) w Retaining Plate.M8 x 1. Timing Gear . Intake (Center) - l Camshaft.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. Camshaft Gear (Split) - d Camshaft Gear.M10 x 1. Camshaft (QTY.2) (Exhaust Camshafts) 52 ft-lbs (70 Nm) r Washer. Camshaft (Intake) - y Bearings. Timing Gear (QTY. Camshaft (Outer) - u Fastener . Exhaust (Rear) - 9927618 R03 .8 x 12 (QTY.25 x 30 (QTY. Belleville - s Retainer.37 .3) - t Timing Gear.

1 per cylinder) 62 in-lbs (7 Nm) i Dowel.8 x 12 (QTY. Retaining Plate .2017 Indian Motorcycle (Full-Size) Service Manual 3.M6 x 1. Lifter Block . Lifter Block - u Fastener. Lifter Guide - o Lifter - 9927618 R03 .38 © Copyright .M5 x 0.ENGINE / COOLING / EXHAUST LIFTERS / PUSHRODS NUMBER PART DESCRIPTION TORQUE SPECIFICATIONS (IF APPLICABLE) q O-ring.3 per cylinder) 89 in-lbs (10 Nm) t Lifter Block - y Gasket. Pushrod Tube - w Pushrod Tube - e Pushrod - r Fastener.0 x 25 (QTY.

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.0 x 20 (QTY.4 per cylinder) Refer to procedure f Gasket. Exhaust - w Valve. Valve Spring - s Rocker Arm Assembly / Rocker Arm Nut 22 ft-lbs (30 Nm) d Nut.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. Valve Cover - g Inner Valve Cover - h Fastener. Inner Valve Cover .39 . Cylinder Head .9) 89 in-lbs (10 Nm) j Outer Valve Cover - k Fastener. Outer Valve Cover .3) 89 in-lbs (10 Nm) l Cylinder Head Temperature Sensor (CHT) 71 in-lbs (8 Nm) 9927618 R03 . ENGINE / COOLING / EXHAUST CYLINDER HEAD 3 NUMBER PART DESCRIPTION TORQUE SPECIFICATIONS (IF APPLICABLE) q Valve.M10 x 1. Valve Spring - a Keepers. Intake - e Gasket.50 (QTY.M6 x 12 x 15 (QTY.M6 x 1.

40 © Copyright .ENGINE / COOLING / EXHAUST CAMSHAFT TIMING 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual 3.

5. INSTALLATION is performed by reversing the removal procedure. rotate the 2. Torque cam chain cover fasteners following the forward or back to properly align holes. Remove the RH floorboard / master cylinder assembly and move out of the way. See Cylinder Head. while performing this procedure. Remove the cam chain cover and gasket. Lock the crankshaft by inserting a 5/16” pin punch (or equivalent) into the locking hole q. Remove the ten fasteners q securing the cam 3 crankshaft counterclockwise (primary side) until chain cover to the inner timing cover. Removal. 4. 4. 3. NOTE 1. page disconnect the brake line from the master cylinder 10.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. page 3. can be removed as an assembly. page 7.23. It is not necessary to 2.30. It may be necessary to rotate the crankshaft slight 6. See Stator Removal. the front piston is at TDC. Remove the stator. Clean gasket mating surfaces and install cam NOTE chain cover using a new gasket.39. Using special service tool PF– 51239. See Floorboard This procedure describes how to lock the crankshaft in (Driver). Remove the spark plugs.18 the Top Dead Center (TDC) position using commercially available hand tools. ENGINE / COOLING / EXHAUST CAM CHAIN SERVICE 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 LOCKING THE CRANKSHAFT FOR SERVICE 1. specified torque sequence. The RH floorboard and rear brake master cylinder page 2.41 . See Spark Plug Removal. 3. TORQUE Cam Chain Cover Fasteners: 15 ft-lbs (20 Nm) 9927618 R03 .

Replace tensioner assembly if plunger doesn’t fully extend when released from a compressed state. page 3. 2. Inspect the tensioner arm spring for cracks or fatigue. Verify that the engine is at TDC and the timing marks are properly aligned.39. 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. Slide the tensioner arm and spring over the pivot pin and. Inspect the ratchet pawl mechanism e and verify remove the cam chain tensioner. With a new gasket and both mating surfaces clean. 3.2017 Indian Motorcycle (Full-Size) Service Manual 3. 9927618 R03 . Compress the tensioner assembly and slide into position over the alignment dowel. proper spring operation. or burrs. See Cam Chain housing w to check for smooth movement without Cover. Remove the external snap ring w from the tensioner arm and remove arm and spring as an assembly. 6. 5. binding. 4. TORQUE Tensioner Fastener: 15 ft-lbs (20 Nm) 6. See Cam Chain Cover. Removal / Installation. page 3. CAUTION scoring. 4. loop the tensioner arm spring over the retainer pin and slide down until fully seated. using a needle nose pliers or similar tool. Install tensioner fastener and torque to specification. install the cam chain cover. 5. Removal / Installation. cracks or fatigue. Visually inspect ratchet plunger q for damage. 2.41. 2. Depress the release pawl and move plunger in and out of 1.ENGINE / COOLING / EXHAUST C A M C H A I N T E N S I O N E R R E M O VA L CAM CHAIN TENSIONER INSPECTION 1. 3. Lubricate ratchet plunger with engine oil. Remove cam chain tensioner fastener q and 3. Inspect tensioner arm for excessive wear marks from timing chain. See Cylinder Head. Remove the cam chain cover.41. Do not rotate engine with tensioner(s) removed.42 © Copyright . page 3. Install the tensioner arm snap ring.

Removal / Installation.44. install the cam chain. 3. page 3. Install the cam cover. 4. page 2.41 front wheel clamped in a wheel vise.41. If removed. page 3.43 9.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. Perform the crankshaft locking procedure.42. ENGINE / COOLING / EXHAUST C A M C H A I N G U I D E R E M O VA L C A M C H A I N R E M O VA L 1. See Cam Chain Cover. 9927618 R03 . See Cam Chain 1. Remove the cam chain cover. crankshaft sprocket and cam chain off as an assembly. and spacers. Place motorcycle in an upright position with the Cover. 6. See Locking the Crankshaft for Service. See Cam Chain Cover. Pull the camshaft sprocket. page 3.23. Torque to specification. Removal / Installation. Place an oil drain pan beneath the engine to catch any residual oil when primary and cam chain covers are removed. 8. Remove the two fasteners q securing the cam 2. Collect the woodruff key from the crankshaft. Remove the cam chain guide. page 2. See Cam Chain Guide Removal. Drain the engine oil.41.41. Removal / Installation.43 . See Cam Chain Installation. See Cam Chain Tensioner Removal. page 3. 2. Install cam chain guide q and fasteners w . 2. 1. 3 5. Remove the cam chain cover. page 3. Remove spark plugs. 11. page 3. Remove the cam chain tensioner and tensioner arm assemblies. 10. TORQUE Cam Chain Guide: 71 in-lbs (8 Nm) 3. Remove the camshaft and crankshaft sprocket C A M C H A I N G U I D E I N S TA L L AT I O N fasteners q . 7. See Spark Plug Removal. SeeEngine Oil / Filter chain guide to the engine and remove the guide Change.9. page 3.

page 3. The Thunder Stroke 111 is an INTERFERENCE 1. ENGINE. the pistons to contact the valves resulting in engine damage. See Locking the Camshaft / Crankshaft Sprocket Fasteners: 52 ft-lbs Crankshaft for Service. Working on a flat surface. 2. 1. 9. page 3. Camshaft timing marks q & w should be aligned as shown. See Cam Chain Cover.Stator Installation. If the camshafts and crankshaft must be turned independently of each other to set valve 2. 11.31. 13. 8. Align timing marks r . Install crankshaft and camshaft sprocket fasteners and washers and torque to specification. See Torque Compensator Installation. 12. See Clutch Installation. Position the chain on the sprockets so that the timing.ENGINE / COOLING / EXHAUST C A M C H A I N I N S TA L L AT I O N 4. 7. 14. page 5. Removal / Installation. 10.19. Remove the crankshaft locking pin installed during the crankshaft locking procedure in step 2. page 10. Install primary cover. See Flywheel Installation. page 5. 5. See Cam Chain Tensioner Installation.2017 Indian Motorcycle (Full-Size) Service Manual 3. Place the woodruff key in the end of the crankshaft. Install the cam chain guide.41. Verify that the camshafts are set to TDC. Failure to do this may cause hashmarks. Verify that the crankshaft woodruff key is still in place and that the timing marks are still aligned. page 5. This will ensure the crankshaft is TORQUE locked in the TDC position.42.41.43. 9927618 R03 . Install torque compensator. 16. Slide the chain and sprockets onto the crankshaft and center camshaft as an assembly. Install flywheel. 6. Install stator. page 5. See Cam Chain Guide Installation. 15.44 © Copyright .21.22. the camshafts must be set to TDC prior to dark chain links line up with sprocket rotating the crankshaft. The camshaft sprocket alignment dowel e should be at 12 o’clock. Perform METHOD 1 of the crankshaft locking procedure. Install the cam chain cover. page 3. (70 Nm) 3. Install clutch assembly and clutch rack.12. See Primary Cover Installation. assemble the timing chain onto the crankshaft and camshaft sprockets CAUTION as shown. Install the cam chain tensioner and tensioner arm assemblies. page 3.

45 . Repeat steps 3–5 to remove the rear lifters.61. 2. Using a T25 Torx.ENGINE OUT 4. 3. page 3. Remove cylinder heads and push rods from engine. Starting with the front lifter block. It is important to put lifters and lifter blocks back in the same location. IMPORTANT When removing the lifter guides. See Cylinder Head Removal. Remove lifter guides r and pull lifters out of bore. 6.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. 5. 9927618 R03 . Remove push rod tubes q by pulling out of the 3 lifter blocks to release the o-rings. be careful not to drop them into the inner cam chain cover. ENGINE / COOLING / EXHAUST CAMSHAFT / LIFTER SERVICE . IMPORTANT Keep mated parts together for assembly. remove the three fasteners w and the lifter block. 1. remove the fastener e securing L I F T E R R E M O VA L the lifter retaining plate to the inner cam chain cover and remove plate.

Install lifter retaining plate e with bevelled fastener relief facing up. 1. TORQUE Lifter Block Fasteners: 89 in-lbs (10 Nm) 9927618 R03 . Install inner and outer valve cover gaskets. 11. Install new gaskets into lifter blocks and install lifter blocks and fasteners finger tight. 7. Install retaining plate fastener r and torque to specification. Apply a light coat of engine oil to each lifter and slide into bore in the same position from which it was removed. page 3. 10. 3. 2. 8. Install cylinder heads. Starting at the front cylinder.60. 5.46 © Copyright . page 3. See Cylinder Head Installation. 4. Repeat steps 3–5 for the rear cylinder lifters. TORQUE Lifter Retaining Plate Fastener: 62 in-lbs (7 Nm) 6. Install push rod tubes t with new o-rings y.2017 Indian Motorcycle (Full-Size) Service Manual 3. install lifter guides w . Rotate each lifter so that the flat surface q is parallel with the lifter guide slot. Torque lifter block fasteners to specification.67.ENGINE / COOLING / EXHAUST L I F T E R I N S TA L L AT I O N 9. See Valve Cover Installation.

5.45. head and base gasket is recommended to prevent oil the intake (center) camshaft will be held in place by leaks.47 . Use caution while working on the carrier assembly so that camshafts do not fall from 1. Once the removing camshaft carrier. guide. See Removing Engine From Frame. Keep mated parts together. to remove the three camshafts. See Cam Chain Removal. Remove lifters.12. Remove the camshaft carrier assembly from the vise and remove camshaft fasteners.47. 2. Grasp the camshaft carrier w and pull straight out locking the camshafts. See Camshaft Carrier Removal. 1. cam chain tensioner and plate q from the carrier assembly.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. page 3. Care should be taken so camshafts don’t fall out of the carrier during this process. Remove the three remaining camshaft carrier fasteners q . page 3. NOTE The camshaft ends are slip-fit to the inner bearings and should come out by hand. do not remove. Remove the camshaft carrier assembly.43. page 3. 4. 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. an engine stand. fasteners e . gear preload only. Remove the engine from the frame and place on carrier and become damaged. 3 2. page 3. Replacement of both carrier assembly has been removed from the engine. thus 5. 3. 9927618 R03 . See Lifter Removal. Loosen. Remove the six fasteners and the bearing retainer 3. ENGINE / COOLING / EXHAUST C A M S H A F T C A R R I E R R E M O VA L C A M S H A F T C A R R I E R D I S A S S E M B LY NOTE IMPORTANT Base and head gasket seal is released when Camshafts are slip-fit to carrier bearings. the exhaust camshaft carrier as an assembly. outer bearings and 4. Remove cam chain.

remove the camshafts and sprockets r from the carrier bearings.48 © Copyright . 9. Camshaft carrier bearings can be removed using a suitable press or bearing driver. Separate components of gear as shown. Noting position in the carrier for reassembly. NOTE The following procedure is to INSPECT split gear springs only.2017 Indian Motorcycle (Full-Size) Service Manual 3.ENGINE / COOLING / EXHAUST 6. wrap a shop rag around the teeth of the gear so springs are contained and remove external snap-ring t . To separate split gears. 8. If the split gears are damaged they MUST be replaced as an assembly as parts are not individually serviceable. 7. 9927618 R03 . Pressure must be applied from the backside of the carrier plate and bearings pressed through the front.

D. 9927618 R03 . of each camshaft journal. Visually inspect camshaft journal surfaces for scoring or signs of insufficient lubrication. Measure O.33. Replace camshaft if heavy scoring or damage is noted.49 . 2. refer to the camshaft service specifications sec- tion. Exhaust cam lobes q and intake cam lobes w. 3 1. See Service Specifications. ENGINE / COOLING / EXHAUST CAMSHAFT INSPECTION For the following camshaft inspection procedure. page 3. 3. Exhaust journals e and Intake journals r .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. Inspect height of each cam lobe.

gears. Belleville washer r. 2. Install fasteners and torque to specification. Install the bearing retainer plate y with the countersunk fastener holes facing out. Install the spring retainer e. Install the outer cam gear onto the inner cam gear making sure the alignment holes w are positioned as shown. 5.ENGINE / COOLING / EXHAUST C A M S H A F T C A R R I E R A S S E M B LY CAUTION 3. and the snap-ring t to complete split gear Wear eye protection while assembling split camshaft assembly. If the split gears are damaged they MUST be replaced as an assembly as parts are not individually serviceable. 6.2017 Indian Motorcycle (Full-Size) Service Manual 3. IMPORTANT The following procedure details split gear assembly following inspection. TORQUE Bearing Retainer Plate Fasteners: 62 in-lbs (7 Nm) 9927618 R03 . 4. Load springs q into the inner cam gear spring pockets. press or drive new bearings into the carrier from the front side until seated against shoulder.50 © Copyright . 1. If replacing camshaft carrier bearings.

ENGINE / COOLING / EXHAUST

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.

3

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.
NOTE
It may be necessary to use a flat fastenerdriver 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 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 Installation, page 3.44.
NOTE
5. Install lifters. See Lifter Installation, page 3.46.
Base and head gasket seal is released when
removing camshaft carrier. Replacement of both 6. Install engine in frame. See Engine Installation,
head and base gasket is recommended to prevent oil page 3.17.
leaks.

1. Lift the camshaft carrier assembly q into position
so that each of the camshaft ends fits into the inner
bearings.
3

2.
NOTE
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 Nm)

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CAMSHAFT SERVICE - IN BIKE 4. Leaving the camshafts in position in the crankcase
C A M S H A F T R E M O VA L bearing bores, remove the camshaft bearing
carrier e.
IMPORTANT
Camshaft removal with the engine installed in the
frame requires Special Tool #: PF-51455.

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

1. Remove the cam chain, guide and tensioner
assemblies. See Cam Chain Cover Removal /
Installation, page 3.41.
2. Remove the exhaust camshaft fasteners q.

5. Remove the intake r and exhaust t camshaft
drive gears.

3. Remove the remaining camshaft carrier fasteners
w.

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6. Loosely assemble the lower camshaft retainer plate 9. Install camshaft gear washers and fasteners until
y to the main plate using two fasteners u. they are hand-tight.

3

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.
NOTE
NOTE
The lower camshaft retainer plate should be tight
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.

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12. Use the second etched line (marked “B”) to 15. Rotate the camshaft using a suitable wrench while
determine when the shaft is fully seated in the hole pressing on the retaining pin until it seats at the
marked “B”. The lifter is now held in place by the line marked “A”.
retaining pin.

NOTE
The crankcase has been removed in this picture to
show the correct retaining pin position.

16. Slide the fourth retaining pin into the rear cylinder
intake camshaft position (hole marked “B”) until it
stops.

NOTE
It will be necessary to rotate the camshaft
13. Repeat steps 10-12 for the forward exhaust (clockwise) with a wrench to seat the pin.
camshaft.
NOTE 17. Rotate the camshaft using a suitable wrench while
pressing on the retaining pin until it seats at the
For the forward exhaust camshaft you will use the line marked “B”.
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.

NOTE
It will be necessary to rotate the camshaft
(clockwise) with a wrench to seat the pin.

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18. Remove fasteners f and lower camshaft retaining
plate g.

3

19. Carefully pull each of the camshafts out from its
respective bore.

NOTE
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.
NOTE
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 Frame,
page 3.12.
2. Using a T40 Torx, remove the three fasteners q
from each of the outer valve covers and remove
covers.

3

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

1. Using new gaskets, install the inner valve covers
and thread fasteners q in finger tight.

2. Reference the torque sequence at the beginning of
this section and torque inner valve cover fasteners
to specification.

TORQUE
Inner Valve Cover Fasteners: 89 in-lbs (10 Nm)

3. Install the outer valve covers and torque fasteners
to specification.

TORQUE
Outer Valve Cover Fasteners: 89 in-lbs (10 Nm)

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

1. Remove engine from frame and place on an
engine stand. See Removing Engine From Frame,
page 3.12.
3
2. Remove inner and outer valve covers. See Valve
Cover Removal, page 3.59.
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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ROCKER ARM INSPECTION C Y L I N D E R H E A D D I S A S S E M B LY
NOTE CAUTION
Rocker arms are non-serviceable and must be Wear eye protection while removing valve springs.
replaced as an assembly.

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

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

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ENGINE / COOLING / EXHAUST 4. page 3.63 . 1.33. Check in different directions and locations on the cylinder head. see Service Specifications. Inspect cylinder head for distortion with a straight edge and feeler gauge. Clean gasket surfaces. Replace springs that do not meet specification. 6. 2. Visually inspect cylinder head for cracks or damage. page 3. Clean carbon deposits from combustion chamber. NOTE Intake and exhaust springs are identical. Remove and discard the spring seat / valve stem CYLINDER HEAD INSPECTION seal assemblies t . See Service Specifications. VA LV E S P R I N G F R E E L E N G T H I N S P E C T I O N 1. 9927618 R03 .33. Measure free length of valve springs. Pay close attention to the areas around spark plug q and valve seats w .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. 3 5. For cylinder head service limits.

Place valves on V-block as shown and inspect C.400") off of seat. Position dial indicator as shown. page 3. measures outside standard range. This work should be performed by an experienced technician properly equipped to perform cylinder head reconditioning. If valve stem deflection exceeds service limits with a new valve installed. Measure valve stem deflection for each valve to determine if valve or valve guide requires 1. measure valve stem diameter.ENGINE / COOLING / EXHAUST VA LV E I N S P E C T I O N 4.. 8. If valve deflection exceeds service limit valve head radial runout w . 3. See Service Specifications. 2.2017 Indian Motorcycle (Full-Size) Service Manual 3. Replace valve and repeat step 6 if valve stem O. Installation of new valve guides and/or new valves requires valve seat reconditioning. Place valves on V-blocks as shown and measure replacement. 6. Inspect the valve face for damage from burning. Raise valve 10mm (0. Insert valves into their original locations in cylinder head. deflection in two directions perpendicular to each other (X & Y axis). B. Inspect that each valve moves up and down Valve service specifications can be found at the smoothly without binding in guide. valve stem runout q using a runout gauge or similar tool. beginning of this chapter. A.33. Measure pitting or uneven contact.D. 9927618 R03 . NOTE 5. valve guide must be replaced.64 © Copyright . 7.

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.65 . proper width. centered in seat. settling of valve seat Lower with 30o stone Contact area too low Wear. foreign Replace valve and reface material damage seat 3 Contact area too high Wear. settling of valve seat Raise with 60o stone Contact area too wide Wear. 9927618 R03 . ENGINE / COOLING / EXHAUST 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.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. pitted.

If valve seat is incorrect. Apply 90 weight oil to outside of new valve guides. 9927618 R03 . CAUTION 6. 4. Follow recommendations of the manufacturer of the valve seat reconditioning equipment being used. See Service Specifications. 2. competent machinist. Drive or press old valve guides out of cylinder 5. correctly.7–18. on the valve face. Ream new valve guides to size to obtain specified stem-to-guide clearance. 3. procedure is done carelessly. If you are unsure of your ability to do the repair professionally it is best to sublet the labor to a 1. Clean cylinder head thoroughly with clean solvent. The use of carbide cutters is not recommended. Ream from combustion chamber side of head. pitting or uneven contact. 7. Support cylinder head and place valve guide 3. VA LV E S E AT R E C O N D I T I O N I N G NOTE Valve seat reconditioning should be performed by a technician proficient in cylinder head reconditioning techniques using grinding stones.ENGINE / COOLING / EXHAUST VA LV E G U I D E R E M O VA L / I N S TA L L AT I O N VA LV E S E AT I N S P E C T I O N CAUTION NOTE Replacement of valve guides requires an oven. Remove valve and measure contact area (valve The cylinder head can be easily damaged if the seat width).33. chamber side. 5. Remove carbon deposits from valves and seats. Drive or press new guides from rocker arm side of head. Install valve into valve guide. Valves cannot be ground. 7. 8.2017 Indian Motorcycle (Full-Size) Service Manual 3. page 3. Tap valve several times to make a clear impression head. 2. Measure valve guide height from spring seat: MEASUREMENT Valve Guide Installed Height: 17.66 © Copyright . Inspect and recondition valve seats. replace the valve. Valve seat reconditioning is required when valve guides are replaced. Apply a light coating of machinist’s layout fluid or remover into valve guide from the combustion paste to valve face. If valve face is burned or special equipment and experience to do the job badly worn. 4. Do not rotate valve.3 mm 6. Do not grind seats more than necessary to provide proper seat width and contact point on valve face. recondition as needed. 1. Inspect valve face for burning.

Installation. careful not to dislodge spring from seal. Support cylinder head so valves will not be damaged. rotating the seal as them into the lifter blocks until fully seated. Remove spring compressor. mating surfaces. Set cylinder head in place on cylinder and press down over the push rod tubes until fully seated. Hold prior to installation. Rocker arms must be removed from cylinder head 2. same location from which they were removed. NOTE All push rods and rocker arms are identical. If previously removed. 2. 1. Be cylinder deck. Slide push rods through push rod tubes until seated in lifters. 9.82.67 . Verify that locating dowels q are in position on the 4. Apply a small amount of grease to both sides of a an effort should be made to put parts back into the valve keeper. Repeat previous steps for remaining valves. See Cylinder 1. 10. Press seal firmly in place on top of guide. 3. although 7. Insert both valve keepers in place on valve. oil and grease during assembly. The base gasket seal is broken when the cylinder head is removed and must be replaced. page 3. 8. Be sure all keepers are fully seated in groove. NOTE Use care not to damage. Apply Indian Motorcycle engine oil to valve guide rings with a small amount of engine oil and press seal and install seal on valve. valve against seat wipe off the portion that extends above the guide. CAUTION NOTE Do not compress valve springs more than necessary Gaskets and gasket sealing surfaces must be free of to install keepers. 5. 3 you install it. Install a new head gasket w . tear or displace push rod tube o-rings when fitting the cylinder head to the cylinder. ENGINE / COOLING / EXHAUST C Y L I N D E R H E A D A S S E M B LY C Y L I N D E R H E A D I N S TA L L AT I O N CAUTION NOTE Wear eye protection during assembly. Lubricate valve stems with assembly lube. Install valve in head before installing seal. 6. 11. Install valve spring and upper retainer. 4. Compress valve springs using a valve spring compressor and adapter. 9927618 R03 . Thoroughly clean cylinder and cylinder head 5. lubricate push rod tube o- 3.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. 6.

Install washers and nuts on cylinder studs. Tighten finger tight. 9. 8.2017 Indian Motorcycle (Full-Size) Service Manual 3. Fully torque cylinder head following the procedure below to ensure accurate final torque: 9927618 R03 .ENGINE / COOLING / EXHAUST 7. Apply assembly lube to the tops of the valve Torque stems.68 © Copyright .

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 Repair / Retest Leak Hard Starting / Won’t Start Low Compression Slow Starter Motor Refer to Electrical chapter Worn Rings. Piston. Always thoroughly investigate before disassembling an engine. or Refer to Engine / Cooling Combustion Chamber Cylinder / Exhaust chapter Engine Oil Overfilled Correct Engine Oil Level Collapsed Hydraulic Bleed Air from Lifter(s) / Engine Noise Valve Train Area Lifter(s) Run at high idle for 10 minutes 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3.69 . excessive oil consumption or abnormal noises. Piston. De-carbon Combustion up 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 Bleed Air from Lifter(s) / Lifter(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. The troubleshooting tables that follow list possible causes of engine mechanical problems. or Refer to Engine / Cooling Cylinder / Exhaust chapter Collapsed Hydraulic Bleed Air from Lifter(s) / Lifter(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. C Y L I N D E R H E A D A N D VA LV E T R A I N NOTE Cylinder head. ENGINE / COOLING / EXHAUST T R O U B L E S H O O T I N G . 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.

ENGINE / COOLING / EXHAUST PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Broken or Weak Valve Replace Spring(s) 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.2017 Indian Motorcycle (Full-Size) Service Manual 3. Repair / Replace Cylinder. Refer to Fuel Delivery / EFI chapter Ignition Problem .70 © Copyright . Refer to Electrical Poor High-Speed Running chapter 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. Poor Valve Seating Valve Timing Incorrect Cam Chain and Sprockets Correct 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 9927618 R03 . Rings. 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 .

ENGINE / COOLING / EXHAUST PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Oiling Problem Oil Overfilled Correct Engine Oil Level 3 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3.71 .

If you are not sure of your capabilities in these areas. • Cleanliness of parts is critical to engine life and proper parts inspection. Handle Connecting Rod 22 ft-lbs (30 Nm) and store all parts in such a way that the mating Bearing Cap surfaces will not be damaged. Follow the assembly lubrication procedures carefully. Cylinder Studs 25 ft-lbs (34 Nm) • Many parts require assembly lubrication.72 © Copyright . 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 9927618 R03 . Coat parts with fresh lubricant to prevent oxidation after cleaning.ENGINE / COOLING / EXHAUST CYLINDER / PISTON G E N E R A L I N F O R M AT I O N TOOL DESCRIPTION PART NUMBER SERVICE NOTES Straightedge. Use clean solvent and hot. Pistons / Studs Available Bosch Automotive Service Solutions: 1-800-328- • This section covers service of the cylinder.2017 Indian Motorcycle (Full-Size) Service Manual 3. Feeler Commercially NOTE Gauge Available Clean the machine thoroughly before removing Protective Sleeves For Commercially engine from frame. • Mark and store all mated parts for assembly. DESCRIPTION TORQUE Assemble engine by putting used parts that pass SPECIFICATION inspection back in the same location. • Machined mating surfaces are very delicate. • There are many precision measuring steps in this section.service-solutions. have a competent machinist perform the precision part inspection operations.com/ and rings. The engine must be removed from the frame to perform the procedures in this section. piston 6657 or https://polaris. Refer to Engine / Cooling / Exhaust chapter for T O R Q U E S P E C I F I C AT I O N S engine removal and installation. soapy water to clean parts. Dry with compressed air before inspection and engine assembly.

. (.000 mm 21.0067") 9927618 R03 .006 .02 .0007") (.0039") Piston Mark Direction Piston orientation is determined by arrow on piston 3 crown.96 mm (. “CTOP” mark must face UP on all rings. ..0043") Land (1.8666") (.010") (.004mm Replace if piston-to- (Measured 12 mm up (3.023 .002") base gasket surface Taper 0.0024") Piston Ring to Ring 2nd Ring . ENGINE / COOLING / EXHAUST S E R V I C E S P E C I F I C AT I O N S ITEM STANDARD SERVICE LIMIT I.006 .05 mm (.D.0014") Ring End Gap .101...8659 .101.. Top Ring .35 mm .3.0009 .9759" ..047 mm Piston (.016") (. Position BOTH pistons so arrows point to front of engine.001 .060 mm .0008 .9769”) out-of-round Cylinder Out of Round Measure 66mm up from 0.0043") (1.22.8680") Piston Pin O.53 mm 1.80 mm (Installed) (.975 ...987 .80 mm (Installed) (.966 .22.D.976") cylinder clearance is from bottom of skirt.014") (.15 .995 .006 .3..26 mm (. (Nominal) 100.031") Piston Ring Marks .1mm max.035 mm (.40 mm .006") Piston to Piston Pin ..05 mm (.012 mm 22.8661") (..017 mm .2mm ring thickness) (.Top . 100..D. (...33 .D.03 ..043") Piston Ring Clearances 3rd (Oil Control Rails) .864") Piston to Cylinder . Piston O.006 .11 mm (Installed)Ring End Gap ..0008 .11 mm (.0024") .060 mm .002") Gasket Surface Warpage .73 .0002 . 90 excessive with good degrees to pin) cylinder Piston Pin Hole I.031") Ring End Gap .067 mm .021") (.013 Check taper and (3.17 mm Oil Control Ring .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3.013 ..2nd .11 mm (.2mm ring thickness) (.15 mm (.15 .0026") (.8664 .02 . 21. 22..

Wristpin - t Wristpin - y Piston (101 mm) - u Ring. Compression (top 2 rings) - o Gasket.2017 Indian Motorcycle (Full-Size) Service Manual 3. Connecting Rod Bearing Cap 22 ft-lbs (30 Nm) w Bearing Cap. Connecting Rod - e Bearing. Cylinder Head - 9927618 R03 .74 © Copyright . Connecting Rod (52 mm) - r Circlip.ENGINE / COOLING / EXHAUST A S S E M B LY V I E W S CYLINDER / PISTON NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Fastener. Oil Control - i Ring. Cylinder Base - a Cylinder - s Gasket.

Both arrows point toward the front of the engine. 2 u Compression Ring No. 1 9927618 R03 .75 . r Wrist pin circlip. e Front piston is installed closest to the camshaft side of the engine. w Rear piston is installed closest to the primary drive side of the engine. t Oil Control Ring y Compression Ring No.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. Install the circlip with the gap positioned at 12 o’clock. ENGINE / COOLING / EXHAUST 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 3 NUMBER DESCRIPTION q Arrows on piston crown indicating installation direction.

• Cylinder Bore Inside Diameter • Cylinder Taper • Out of Round 2.61. Support pistons to prevent damage. CYLINDER INSPECTION 1. Place a section of hose over the cylinder studs to prevent damage to the piston rings. 3. Measure each cylinder bore in 6 places to Removal. pistons or rings may cause irreparable damage.ENGINE / COOLING / EXHAUST C Y L I N D E R R E M O VA L CYLINDER BORE MEASUREMENT 1. Remove cylinder base gasket q .2017 Indian Motorcycle (Full-Size) Service Manual 3. 3. NOTE Bottom measurement should be taken 2. Use the worksheet provided to record measurements and calculate the clearance. Remove cylinder head (s). Clean gasket surfaces of cylinders thoroughly. determine: 2. Remove cylinder (s).76 © Copyright . 2. Use maximum measurement to determine wear. Do not damage gasket surfaces during cleaning. See Cylinder Head 1. CAUTION Careless handling of cylinder. Visually inspect cylinder bores for scratches and wear. 9927618 R03 . 4.6 in (66 mm) up from base gasket surface. Inspect gasket surfaces for scratches or other damage that may cause an oil leak. page 3.

2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. If the piston-to-cylinder clearance exceeds the service limits with a new piston.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 (. the cylinder must be replaced. taper or out-of-round exists.77 . the cylinder must be replaced. 9927618 R03 .05mm (.15 measurement and piston measurement mm (.002") Piston Skirt Measurement Difference between largest “X” axis Piston-to-Cylinder Clearance* Piston-to-Cylinder Clearance Service Limit: . NOTE • The cylinders are Ni-SiC plated and cannot be reconditioned by boring or honing. If measured value exceeds service limit replace the appropriate part.05mm (. If excessive surface damage.006") Compare recorded measurement to specifications.15 measurement and piston measurement mm (.002") Piston Skirt Measurement Difference between largest “X” axis Piston-to-Cylinder Clearance* Piston-to-Cylinder Clearance Service Limit: . measure a new piston and re-calculate the clearance. ENGINE / COOLING / EXHAUST PISTON TO CYLINDER CLEARANCE WORKSHEET Front Cylinder Recorded Measurement Specification Top “X” Middle “X” Bottom “X” Top “Y” Middle “Y” Taper Service Limit: .006") Rear Cylinder Recorded Measurement Specification Top “X” Middle “X” Bottom “X” Top “Y” Middle “Y” Taper Service Limit: .05mm (. • If the piston-to-cylinder clearance exceeds the service limit.002") Bottom “Y” 3 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 .

3. 9927618 R03 . Inspect cylinder for warpage at cylinder head 1. prevent piston circlip from falling into the crankcase. 3. Spread rings only wide enough to remove them from piston. Clean carbon deposits from piston. Use this piston ring to carefully clean piston ring grooves. File or grind one edge square and remove all burrs. 7. 4. Spreading rings too wide will damage them. Push piston pin w out to left side of engine and remove the piston e . slide a . Place a straight edge diagonally across cylinder mating surfaces in several positions.05mm (. Attempt to 2. Rings should rotate freely in grooves.002") feeler gauge under the straight edge in each position. Cover crankcase with a clean shop towel to surface and base gasket surface. 2. Remove the left piston pin circlip q . 6.ENGINE / COOLING / EXHAUST C Y L I N D E R W A R PA G E M E A S U R E M E N T P I S T O N & P I S T O N R I N G R E M O VA L 1. Rotate rings in piston grooves. Replace cylinder if warped beyond the service limit. NOTE A soft wire brush may be used to only clean the top of the piston. Clean piston ring grooves. 5. Break or cut a piston ring in half.2017 Indian Motorcycle (Full-Size) Service Manual 3.78 © Copyright . Do not use a wire brush to clean the sides of piston or the piston ring grooves.

D. Push rings in until 1. D. 6. Replace piston if worn beyond the service limit. scoring. they are flush with piston. Using a feeler gauge.79 . page 3. Replace parts that do not meet specification. measure side clearances for the 1st & 2nd rings. Calculate Piston to Cylinder Clearance. NOTE If piston-to-cylinder clearance exceeds service limit. Visually inspect piston for cracks. etc. (90° to pin and 12 mm from bottom of piston skirt).D. cylinder must be replaced. 9927618 R03 . Measure piston skirt O. Measure installed ring end gap with a feeler gauge and compare to specifications. from cylinder bore I. Subtract piston O. and compare to specifications. See Service Specifications. Use a piston to push each ring squarely into cylinder bore from bottom (push rings 25-50 mm into cylinder). excessive wear. Install rings onto a clean piston. 4.73.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. ENGINE / COOLING / EXHAUST PISTON & PISTON RING INSPECTION 7. page 3. Replace parts that exceed service limit. 5. 3.73.73. See Service Specifications. 2. 3 8. page 3. If piston-to-cylinder clearance exceeds service limits with a new piston. See Service Specifications. measure a new piston and re-calculate clearance.

Install top ring (marked “C”) and second ring (marked “CTOP”) with markings facing UP.D from rod hole I. D.75 largest measurement. Measure piston pin hole I.D. Carefully install oil control ring expander with end gap located as shown. 9927618 R03 . page 3. top to bottom (as by subtracting pin O. page 3. replace any worn parts. Compare measurements to specifications and smallest measurement. Calculate connecting rod-to-piston pin clearance 1. shown) and as close to the circlip groove as possible with a telescoping gauge. See Service Specifications. 1.D. page 3. Install top and bottom rails with end gap located as shown. 4. D. from pin hole I. at two locations. Lubricate all rings with engine oil.75. Calculate piston pin-to-piston clearance.D.2017 Indian Motorcycle (Full-Size) Service Manual 3.80 © Copyright .73. Measure connecting rod small end I. 2. See Piston Ring Profile And Orientation.ENGINE / COOLING / EXHAUST PISTON PIN / PIN BORE INSPECTION 5. Record the 6. at three locations. 2. 3. Compress each ring by hand and rotate to be sure they rotate freely in grooves. 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. Subtract pin O. See Piston Ring Profile And Orientation. 3. Record page 3. 6. Measure piston pin O. See Piston Ring Profile And Orientation.D.75. Locate ring end gaps as shown below in relation to arrow on piston crown. 5. 4.

Install a new circlip on one side of the piston with TORQUE end gap facing UP (12:00 position).81 . 6. Install pistons on connecting rods with arrow q facing the FRONT of the engine. 9927618 R03 . ENGINE / COOLING / EXHAUST P I S T O N I N S TA L L AT I O N CYLINDER STUD REPLACEMENT The pistons are marked with an arrow on the crown. 1. 4. Place a clean shop towel over crankcase to prevent foreign material from entering crankcase. 3. 2. Cylinder Studs: 25 ft-lbs (34 Nm) IMPORTANT Never reuse piston pin circlips. Push piston pin w through rod and piston pin hole until it is stopped by circlip. Make sure both piston circlips are seated properly in the groove. Install piston over connecting rod with arrow on piston crown facing FRONT of engine. Apply engine oil to stud threads.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. Use a stud extractor to remove 10 mm studs q . Install studs and torque them to specification. 4. Install remaining circlip e with end gap facing up (12:00 position. 3. 1. 5. Lubricate piston pin and I. 3 2. of connecting rod small end with engine oil or moly lube.) 7. D. Clean threads in cases thoroughly.

Remove piston ring compressor when rings are fully captive in cylinder. DO NOT allow oil or grease to contact Installation.ENGINE / COOLING / EXHAUST C Y L I N D E R I N S TA L L AT I O N 8.82 © Copyright . torqued. 7. Cylinder 2. Rinse the cylinders with clear water and with Knock Sensor is the front cylinder. immediately dry with compressed air. Monitor rings carefully. Install cylinders in their original locations. inspect ring carefully for damage. remove and gasket surfaces are clean and oil-free. 12. Inspect all sealing surfaces carefully for scratches or 14. 5. Apply a light coat of engine oil to piston and rings. Remove protective covering from crankcase. cylinder. If a piston ring becomes 4. 1. Cylinder bore should be wiped with a clean white shop 9. 6. Ensure cylinder alignment dowel pins are in place dislodged from the ring compressor. Repeat for other cylinder. IMPORTANT 13. Apply a small amount of engine oil to inside surfaces of a piston ring compressor band. assembly. 11.67. 9927618 R03 . page 3.2017 Indian Motorcycle (Full-Size) Service Manual 3. Slide cylinder down over piston until seated to base gasket and crankcase surface. 10. Carefully install cylinder (s) over piston/ring 3. towel and engine oil. Apply a small amount of crankcase sealant to the crankcase parting lines on base gasket surface as shown. gaskets or sealing surfaces during the assembly process. CAUTION Sealant on crankcase parting line must not be Be sure compressor band end gap does not align allowed to dry before top end is assembled and with any ring end gap when compressing the rings. then with NOTE hot soapy water. Install new cylinder base gaskets onto crankcase. Do not force cylinder over piston. NOTE Be sure all top end parts are ready for assembly. See Cylinder Head imperfections. First wash cylinders with clean solvent. Install cylinder head (s). Install piston ring compressor over rings and compress rings into ring grooves.

Piston. ENGINE / COOLING / EXHAUST 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. 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 Bleed Air from Lifter(s) / Lifter(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.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3.83 . or Refer to Clutch / Primary Cylinder / Shift chapter Collapsed Hydraulic Bleed Air from Lifter(s) / Lifter(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. or Refer to Engine / Cooling Combustion Chamber Cylinder / Exhaust chapter Engine Oil Overfilled Correct Engine Oil Level Collapsed Hydraulic Bleed Air from Lifter(s) / Lifter(s) Run at high idle for 10 minutes Engine Noise Valve Train Area Broken or Weak Valve Replace Spring(s) Worn Camshaft or Rocker Replace Arm 9927618 R03 .

Repair / Replace Cylinder. Poor Valve Seating Lack of Power in all RPM Ranges Cam Chain and Sprockets Correct Valve Timing Incorrect Damaged Cam Gears Replace Valve Float Weak Valve Springs Replace 9927618 R03 . Refer to Fuel Delivery / EFI chapter Ignition Problem .2017 Indian Motorcycle (Full-Size) Service Manual 3. Rings.ENGINE / COOLING / EXHAUST PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED 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 Replace Piston Ring Lands General Exhaust Leak Reseal Exhaust Chain / Sprocket Worn Replace Timing Chain Area Replace Chain Tensioner and / or 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 Electrical Poor High-Speed Running chapter 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. Refer to Fuel Delivery / EFI chapter Fuel Injection Problem .84 © Copyright .

85 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. ENGINE / COOLING / EXHAUST PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED 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 3 9927618 R03 .

Muffler Hanger — M8 x 1.86 © Copyright .25 x 16 (QTY. Head Pipe Trim Cover — M6 x 1.2) 14 ft-lbs (19 Nm) u Fastener.4) 15 ft-lbs (20 Nm) 9927618 R03 . Rear Head Pipe Hanger — M8 x 1.4) i Nut.ENGINE / COOLING / EXHAUST EXHAUST A S S E M B LY V I E W S EXHAUST SYSTEM NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Fastener. Worm Drive 31 in-lbs (4 Nm) t Clamp.4) 18 ft-lbs (24 Nm) w Clamp. Exhaust (QTY.4) 31 ft-lbs (42 Nm) e Fastener.25 x 20 18 ft-lbs (24 Nm) (QTY.25 (QTY. Worm Drive 31 in-lbs (4 Nm) y Oxygen Sensor (QTY.2017 Indian Motorcycle (Full-Size) Service Manual 3.0 x 20 84 in-lbs (10 Nm) (QTY.4) r Clamp. Head Pipe — M8 x 1.

WARNING Engine and exhaust components get hot and remain hot for a period of time after the engine is stopped. 2. Wear insulated protective clothing or wait for components to cool sufficiently before working on the machine. ENGINE / COOLING / EXHAUST EXHAUST SERVICE 3. Loosen the forward muffler clamps w between the head pipe / cross over pipe and muffler. Using a flat head screwdriver.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. Remove the four fasteners e securing each M U F F L E R R E M O VA L muffler to the rear hanger. 9927618 R03 . loosen (do not remove) the rear heat shield clamps q.87 . 1. 3 4. Slide the muffler assemblies rearward to remove from the head pipe and cross over pipe.

7.2017 Indian Motorcycle (Full-Size) Service Manual 3. page 3. 3. Disconnect the rear oxygen sensor connector e. 6. Using a flat head screwdriver. WARNING Engine and exhaust components get hot and remain hot for a period of time after the engine is stopped.ENGINE / COOLING / EXHAUST C R O S S O V E R P I P E R E M O VA L 5. Remove left and right muffler assemblies. 4. Remove saddlebags. 1. Wear insulated protective clothing or wait for components to cool sufficiently before working on the machine. if equipped.87. Remove cross over pipe support fastener w from left hand side of the motorcycle. Loosen rear head pipe and cross over pipe exhaust clamps r and remove rear head pipe support fasteners t. loosen the heat shield clamps on both sides of the motorcycle until the ends can be opened up. Connector is tucked into the RH side frame panel. 2.88 © Copyright . Remove the heat shields q. 9927618 R03 .

Remove the cross over pipe from the rear head pipe.89 . Remove flange nuts. Wear gloves while removing from the cylinder head assembly. ENGINE / COOLING / EXHAUST WARNING Heat sink edges are extremely sharp and could cause personal injury. 9927618 R03 . Slide the rear head pipe and cross over pipe assembly back to remove from the front head pipe.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. 9. Remove the two fasteners y and the heat sink trim cover u to access the head pipe flange nuts i. 3 8.

assembly. at the front motor mount.2017 Indian Motorcycle (Full-Size) Service Manual 3.. Remove cross over pipe / rear head pipe trim cover to the cylinder head and remove cover.90 © Copyright . 3. and disconnect. page 3. NOTE It is not necessary to remove the hydraulic line from the master cylinder during this operation. 9927618 R03 . Remove the flange nuts r from the head pipe and 2. 4. move the floorboard and master cylinder out of the way. Remove the two fasteners q securing the RH remove head pipe from motorcycle.. floorboard to the frame.88 5. cause personal injury. Wear gloves while removing Wear insulated protective clothing or wait for from the cylinder head assembly. components to cool sufficiently before working on the machine.ENGINE / COOLING / EXHAUST H E A D P I P E R E M O VA L WARNING WARNING Engine and exhaust components get hot and remain Heat sink edges are extremely sharp and could hot for a period of time after the engine is stopped. Locate the front oxygen sensor connector w. Remove the fasteners e securing the heat sink 1. Keeping the master cylinder reservoir in an upright position.

page 3. Tighten front and rear head pipe flange nuts to specification.92 assembly.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3.91 . slide the front TORQUE head pipe into position over the flange studs w Heat Sink Trim Cover Fasteners: 84 in-lbs (10 Nm) and tighten nuts finger tight. Install the cross over pipe / rear head pipe. TORQUE TORQUE Head Pipe Flange Nuts: 15 ft-lbs (20 Nm) Floorboard Support Fasteners: 35 ft-lbs (48 Nm) 9927618 R03 . 4. 6. 3. Verify that the old head pipe gasket has been 5. and install a new gasket q. Move RH floorboard into position and torque the two support fasteners r to specification. ENGINE / COOLING / EXHAUST H E A D P I P E I N S TA L L AT I O N 1. 3 2. Install front and rear heat sink trim covers and removed from the front cylinder head exhaust port torque fasteners e to specification. With the new gasket in position. 7. Reconnect front and rear oxygen sensors and secure wires with cable ties.

2017 Indian Motorcycle (Full-Size) Service Manual 3. Install left and right heat shields r and torque front clamps to specification. page 3.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. TORQUE Head Pipe Flange Nuts: 15 ft-lbs (20 Nm) 5. Reconnect rear oxygen sensor. specification. TORQUE Heat Shield Clamps: 31 in-lbs (4 Nm) 10. Install left and right muffler assemblies. Do not TORQUE tighten clamp q at this time. TORQUE Exhaust Clamps: 31 ft-lbs (42 Nm) 8. 1. NOTE TORQUE Rear heat shield clamps should not be tightened until Heat Sink Trim Cover Fasteners: 84 in-lbs (10 Nm) the mufflers have been installed. Install heat sink trim covers and torque fasteners to specification.93.92 © Copyright . 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. Tighten head pipe and cross over pipe exhaust clamps e to specification. Slide the cross over pipe / rear head pipe assembly into position on motorcycle and install head pipe flange nuts finger tight. Slide cross over pipe onto rear head pipe. Cross Over / Head Pipe Support Fasteners: 18 ft-lbs (24 Nm) 7. 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. 9927618 R03 . 4. Tighten head pipe flange nuts to specification. 2. 9.

ENGINE / COOLING / EXHAUST M U F F L E R I N S TA L L AT I O N 1. Start engine and listen for exhaust leaks.93 . 3 2. TORQUE Heat Shield Clamps: 31 in-lbs (4 Nm) 6. 3. Tighten left and right muffler clamps w to specification. specification. Torque rear heat shield clamps e to specification.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 3. TORQUE Muffler Clamps: 31 ft-lbs (42 Nm) 9927618 R03 . Install rear muffler support fasteners q into left and right muffler assemblies finger tight. Torque rear muffler support fasteners q to rear support fasteners can be installed. Slide the left and right mufflers into position so the 4. TORQUE Muffler Support Fasteners: 18 ft-lbs (24 Nm) 5.

2017 Indian Motorcycle (Full-Size) Service Manual 3.94 © Copyright .ENGINE / COOLING / EXHAUST NOTES 9927618 R03 .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TEST / REPLACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL DELIVERY / EFI CHAPTER 4 FUEL DELIVERY / EFI GENERAL INFORMATION . . . . . . . . . . . . . . . REMOVAL / INSTALLATION . . . . . .1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 ASSEMBLY VIEWS. . .12 FUEL DELIVERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 FUEL INJECTOR. . . .4. . . . . . . . . . . . . . . . . . . . . . . .3 SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . .4. . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . .13 FUEL PUMP PRESSURE INSPECTION . . . . . . .26 SENSOR DIAGNOSTICS . . . .4. . . .14 FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 ECM CONNECTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 CYLINDER HEAD TEMPERATURE SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. .4. . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . .13 INTAKE MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 4 FUEL LINE ROUTING (49 STATE MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.OVERVIEW OF OPERATION . .35 TEMPERATURE & MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) REPLACEMENT .35 ECM REMOVAL / INSTALLATION . . . TEST / REPLACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 FUEL TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . .4 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . .5 EFI SYSTEM PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . .37 FUEL RAIL REMOVAL. . . . . . . .4. . . . . . . . . . . . . . . . . . . . .33 ECM PINOUT TESTING . . . . . . . . . 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 SERVICE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 FUEL INJECTOR RESISTANCE TEST . . . . . . .4. . . . . . . . . . . . . . . . . . . .22 EFI SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. . . . . . . .4. . . . . . . . . . . . . . . . . . . . .23 ECM CONNECTOR MAP .21 PRIMING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 FUEL PUMP SUPPLY VOLTAGE TEST . 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 AIR BOX . . . . . . . . . . . . . . . . . . . . .4 TORQUE SPECIFICATIONS . . . . .4. . . . . . . . . . . . . . . . . . . . . .19 FUEL LEVEL SENSOR RESISTANCE TEST . .20 FUEL PUMP CURRENT DRAW TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 FUEL INJECTION SYSTEM . . .4. . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . .16 FUEL TANK VENT INSPECTION .43 CRANKSHAFT POSITION SENSOR. . . . . .42 FUEL RAIL INSTALLATION. . . .7 FUEL LINE ROUTING (CA & INTL) . . . . . . . . . . . . . . .13 FUEL SYSTEM DEPRESSURIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. . . . . . . . . . . . . . . . . . . . . . . . . .17 FUEL PUMP INSTALLATION . . . . . . .4. . . . . . . . . . . . . . . . . . . . . .3 SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 9927618 R03 . . . . . . . . . . . . . . . . . . .4. . . . .9 FUEL TANK . . .4. . . .4. . 4. . . . . . . . . . . . . . . . . . . . .15 FUEL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 SENSORS — POWERTRAIN MANAGEMENT .

. .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 ENGINE CONTROLLER REPROGRAMMING (REFLASH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . .56 DIGITAL WRENCH SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . .56 DIGITAL WRENCH VERSION AND UPDATE ID .4. . .61 FUEL SYSTEM TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 FUEL SYSTEM TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . PART 2. . . . . . . . . . . . . PART 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 DIGITAL WRENCH DIAGNOSTIC CONNECTOR . . .4. . . . . . . . . . . . . . . . .4. .62 FUEL SYSTEM TROUBLESHOOTING. . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 DIGITAL WRENCH DIAGNOSTIC SOFTWARE OVERVIEW. . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2017 Indian Motorcycle (Full-Size) Service Manual 4. . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 THROTTLE BODY (ETC) REMOVAL . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 DIGITAL WRENCH COMMUNICATION ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . .2 © Copyright . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . .64 9927618 R03 . . . . . . . . . . .61 FUEL SYSTEM TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. .56 DIGITAL WRENCH UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 ECM REPLACEMENT . . .55 DIAGNOSTIC SOFTWARE VERSION. . . . . . .55 GUIDED DIAGNOSTIC AVAILABLE . . .57 DIGITAL WRENCH FEATURE MAP. . . . . . . . . . . . . . . . . . . . . . . . . . . .4. .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PART 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. .52 CYLINDER MISFIRE DETECTION . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 DIGITAL WRENCH . . . . . . . . . . . . . . .FUEL DELIVERY / EFI DETONATION SENSOR TEST / REPLACE . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 CAN DIAGNOSTICS. . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . PART 4. . .54 CAN (CONTROLLER AREA NETWORK) DIAGNOSTIC OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . .59 TROUBLESHOOTING . . . . . .

function and durability. WARNING Always stop the engine and refuel outdoors or in a well ventilated area. This can cause the absorbent towel to minimize spillage while cables to stick or bind. 9927618 R03 . always use genuine Indian WARNING Motorcycle replacement parts. The engine and exhaust system become very hot • Fuel tank vent line pinched or obstructed. The engine exhaust from this product contains • A battery in a low state of charge can cause chemicals known to cause cancer. sparks and cigarettes must be caution when disconnecting lines for service. or incorrectly connected for hands and arms or wait until the engine and wiring. Always depressurize the fuel system prior to WARNING service. after the engine is shut off. • Air leaks in intake tract / air box . 4 twisting or bending of the cables. When replacing fuel lines. exhaust system have cooled before performing • Poor ground connections . 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. Work in a well ventilated Fuel lines remain under pressure at all times. clean and tight. • Restricted fuel flow / filters (low fuel pressure). control. Engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time. kept away from gasoline. Be sure battery is in good condition and other reproductive harm.check for air leaks and repair to avoid misdiagnosing the EFI system.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. Open flames. WARNING • Contaminated or improper fuel. Careless handing of the control cables can result in Cover the fuel hose connections with a clean. resulting in loss of vehicle disconnecting. Wear insulated protection • Corroded. during operation and remains hot for a period of time • Faulty spark plug(s). This will ensure top Gasoline is extremely flammable and is explosive performance. under certain conditions. 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. Disconnect the fuel pump electrical connector to disable fuel pump and crank engine to release pressure. WARNING Never start the engine or let it run in an enclosed area. birth defects or problems. WARNING If you get gasoline in your eyes or if you swallow gasoline. Never try to syphon gasoline using mouth suction. • Exhaust system restriction or improper exhaust. Use area. • Engine mechanical condition.be sure all grounds are service work. views of connectors are from WARNING WIRE side of the connector. see your doctor immediately. fully charged. disconnected. on any component in this section. Don’t overlook the basics while troubleshooting the fuel system: • Except where noted.3 .

com/ Fuel Pump Nut 24 in-lbs (3 Nm) Fuel Tank Fastener 18 ft-lbs (25 Nm) S E R V I C E S P E C I F I C AT I O N S Gear position Switch 43 in-lbs (5 Nm) ITEM SPECIFICATIONS Head Pipe Flange Nuts 15 ft-lbs (20 Nm) Fuel Pump Pressure 3.4 © Copyright .99 BAR (400 kPa) (58 psi) (Normal Operation) Head Pipe Trim Covers 84 in-lbs (10 Nm) Idle Speed 800 rpm ± 50 rpm Ignition Coil 84 in-lbs (10 Nm) Fuel Pump Amp Draw Knock Sensor 15 ft-lbs (20 Nm) 3–5 Amps (Normal Operation) Muffler Hanger 18 ft-lbs (24 Nm) Recommended Fasteners 91 Octane Minimum Octane Oil Pressure Switch 88 in-lbs (10 Nm) Injector Resistance 11.2017 Indian Motorcycle (Full-Size) Service Manual 4.service-solutions.4 .FUEL DELIVERY / EFI SPECIAL TOOLS T O R Q U E S P E C I F I C AT I O N S TOOL DESCRIPTION PART NUMBER DESCRIPTION TORQUE Electrical Tester Kit PV-43536 SPECIFICATION Fuel Line Plug Tool 2521832 Air Box Cover 84 in-lbs (10 Nm) Air Filter Element 62 in-lbs (7 Nm) Fuel Rail Fastener 2564374 Torquing Tool Air Filter Retainer Plate 31 in-lbs (4 Nm) Fuel Pressure Adapter PV-48656 CHT 71 in-lbs (8 Nm) Fuel Pressure Gauge PU-43506–A Console Panel Fasteners 84 in-lbs (10 Nm) Relay Bypass PU-49466 CPS 89 in-lbs (10 Nm) Smartlink Module Kit PU-47471 Evaporative Emissions 84 in-lbs (10 Nm) USB to Serial Adapter PU-50621 Canister Exhaust Clamp 31 ft-lbs (42 Nm) Bosch Automotive Service Solutions: 1-800-328- 6657 or https://polaris.12.6 Ohms Oxygen Sensor 14 ft-lbs (19 Nm) Rear Head Pipe Hanger 18 ft-lbs (24 Nm) Side Stand Switch 43 in-lbs (5 Nm) TMAP 62 in-lbs (7 Nm) TPMS Sensor Fastener 44 in-lbs (5 Nm) Wheel Speed Sensor 96 in-lbs (11 Nm) Worm Drive Exhaust 31 in-lbs (4 Nm) Clamps 9927618 R03 .

Most of the connectors are sealed and cannot be back probed. aluminum foil or any other means. Always investigate the cause of the problem and repair before replacing the fuse. Never replace the fuse with a larger value fuse or “jumper” the fuse with wire. Also take care connecting and disconnecting connections. Dropping or hitting them may Connector test adapter kit PV-43526 cause irreparable damage. Fuses and circuit breakers protect critical electrical components and circuits.13. Be extremely careful not damage the connectors by forcing meter probes into the connectors. the electrical component could be damaged.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. components of the Fuel Injection system. ground Make sure that the ignition is powered down before yourself to dissipate any static charge. VCM and sensors are sensitive pieces of electronic equipment. Poor connections are the most common cause of Electronic Fuel Injection malfunctions. Always use the proper adapter from the Connector Test Adapter Kit when probing the terminals. Do not touch or probe the exposed pins on the ECM. The ECM. It is not advisable to “jump start” the machine with another battery. When connecting and disconnecting the battery Static electricity can damage the electronic controllers beyond repair. The human body can easily store 4 cables refer to Electrical chapter for complete battery enough static electricity to damage sensitive connection and charging information.5 . the components can be damaged or problems may occur if the following precautions are not taken. practice is to disconnect the battery before connecting or disconnecting the electrical connections. Anti-static wrist strap PV-43541 NOTICE: Some tests require probing of the ECM wiring harness connector. page 10. FUEL DELIVERY / EFI SERVICE PRECAUTIONS EFI SYSTEM PRECAUTIONS NOTE While electronic fuel injection is durable and reliable. Although problems are unlikely to occur if everything is done carefully. Never disconnect the battery while the engine is running. Static electricity from your body or the meter can easily damage the ECM. See Battery electronic components. Best not to touch any of terminal pins on the ECM. Inspect 9927618 R03 . Before working with any Installation.

Carefully inspect the connections of the failed circuit before doing any other troubleshooting steps. 9927618 R03 .6 © Copyright .2017 Indian Motorcycle (Full-Size) Service Manual 4.FUEL DELIVERY / EFI connector and wiring connections carefully during troubleshooting. Wire terminals should be corrosion free and fully seated into the connectors. Connector should snap together and lock.

Lower (to atmosphere) 9927618 R03 .7 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. Upper (from tank) e Vapor Vent Line. FUEL DELIVERY / EFI 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 ) 4 NUMBER PART DESCRIPTION q Fuel Supply Line (Pump to Fuel Rail) w Vapor Vent Line.

FUEL DELIVERY / EFI FUEL LINE ROUTING (CA & INTL) NUMBER PART DESCRIPTION q Evaporative Emissions Canister w Vapor Supply Line. Lower (to canister) t Vapor Supply Line. Upper (to tank) y Vapor Vent Line. Upper (from tank) u Fuel Supply Line (Pump to Fuel Rail) 9927618 R03 .8 © Copyright . Lower (from canister) e Canister Purge Valve r Vapor Vent Line.2017 Indian Motorcycle (Full-Size) Service Manual 4.

9 .2) 18 ft-lbs (25 Nm) y Nut. FUEL DELIVERY / EFI FUEL SYSTEM 4 NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Fastener.2) w Evaporative Emissions 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 1.10) 24 in-lbs (3 Nm) u Fuel Pump — 9927618 R03 . Evaporative Emissions Canister — M6 x 1.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4.25 x 35 (QTY.0 x 12 84 in-lbs (10 Nm) (QTY.8 (QTY. Fuel Pump — M5 x 0.

2017 Indian Motorcycle (Full-Size) Service Manual 4.2) 84 in-lbs (10 Nm) w Plastic Dart – e Console Cover – r Nut.2) 18 ft-lbs (25 Nm) 9927618 R03 . Fuel Pump – u Fuel Pump – i Fastener.0 x 12 (QTY. Console Panel — M6 x 1.10) 24 in-lbs (3 Nm) t Fuel Pump Access Panel – y Gasket.10 © Copyright . Fuel Tank — M8 x 1.25 x 35 (QTY.8 (QTY.FUEL DELIVERY / EFI F U E L TA N K NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Fastener. Fuel Pump — M5 x 0.

11 . Air Box Cover — M6 x 1. Air Filter Element — M5 x 0.0 x 10 (QTY.3) u Retainer Plate. FUEL DELIVERY / EFI AIR BOX 4 NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Fastener. Air Box – e Fastener.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. Air Box Cover – t Air Filter Element – y Fastener.3) r Gasket.8 x 10 62 in-lbs (7 Nm) (QTY. Air Filter – 9927618 R03 . Air Filter Retainer Plate — 10 x 5/8 31 in-lbs (4 Nm) (QTY.3) 84 in-lbs (10 Nm) w 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 Canister 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 Nm) i Gear Position Switch — Located inside the drive sprocket cover.12 © Copyright . — behind the drive sprocket r Fuse Box — Located inside the LH upper side cover. Rear — Located at the rear caliper carrier 96 in-lbs (11 Nm) e ECM (Engine Control Module) — Located inside the lower RH side cover.FUEL DELIVERY / EFI SENSORS — POWERTRAIN MANAGEMENT TORQUE (IF NUMBER SENSOR / LOCATION APPLICABLE) q TPMS (Tire Pressure Monitoring System) — Sensor located 180° from valve 44 in-lbs (5 Nm) stem w Wheel Speed Sensor. Front — Located on the front head pipe 14 ft-lbs (19 Nm) f Detonation “Knock” Sensor — Located on the rear face of the front cylinder 15 ft-lbs (20 Nm) heat sink g CHT (Cylinder Head Temperature) Sensor — Located on the rear face of the 71 in-lbs (8 Nm) front cylinder head h Fuel Injectors — Located at the cylinder head intake ports — j Ignition coil — Located behind the horn assembly on the RH side of the engine 84 in-lbs (10 Nm) k TMAP — (Temperature / Manifold Absolute Pressure) Sensor — Located on the 62 in-lbs (7 Nm) back side of the intake manifold 9927618 R03 . below the 43 in-lbs (5 Nm) drive sprocket o Oxygen Sensor.2017 Indian Motorcycle (Full-Size) Service Manual 4. Rear — Located on the rear head pipe 14 ft-lbs (19 Nm) a Side Stand Switch — Located behind the side stand hinge 43 in-lbs (5 Nm) s CPS (Crank Position Sensor) — Located on the front of the engine by the oil 89 in-lbs (10 Nm) filter d Oxygen Sensor.

page 4. Torque the intake manifold clamps and boots to 1. Start engine and record fuel pressure (or press the 7. WARNING 4 Gasoline is extremely flammable. See Fuel Tank Removal. page 3.4. KEEP GASOLINE OUT OF THE REACH OF CHILDREN! CAUTION Wear safety glasses or a face shield when working around the fuel system to protect your eyes. Loosen the two clamps q securing the intake manifold to the rubber boots at the front and rear FUEL PUMP PRESSURE INSPECTION cylinders. SeeFuel System Depressurization. Remove the fuel tank. See Air Box Removal. Work in a well ventilated area. sparks and cigarettes must be kept away from gasoline. Install fuel pressure gauge PU-43506– A and fuel 6. Rotate the air box mounting flange up as shown power switch ON and cycle the Engine Stop switch and remove the intake manifold from the engine. Remove the fuel injectors. TORQUE 4. Remove the air box / throttle body assembly. 2. Minimum Fuel pressure 3.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4.14 . Intake Manifold Clamps: 20 in-lbs (2 Nm) 3. boots to the cylinder head. See Fuel Injector.13 . page 4. 1.51 BAR (351 kPa) (51 psi) 8. front wheel clamped in a wheel vise. 5. 9927618 R03 . page 4. TORQUE 2. Remove the four fasteners securing the intake pressure gauge adapter PV-48656. Intake Manifold Boots: 89 in-lbs (10 Nm) Removal / Installation.42. Depressurize fuel system and disconnect fuel line at fuel rail. FUEL DELIVERY / EFI FUEL DELIVERY SERVICE I N TA K E M A N I F O L D . to read pressure when pump cycles for 2-3 seconds). Open flames. R E M O VA L / I N S TA L L AT I O N 9. INSTALLATION is performed by reversing the removal procedure.15. 3. Place motorcycle in an upright position with the specification.

instant that the key switch and Engine Stop switch are turned ON. (Fuel pump or circuit * Pressure regulator malfunction) malfunction (located 3.2017 Indian Motorcycle (Full-Size) Service Manual 4. Squeeze both release buttons (one on each side of * Restricted fitting. fuel on pump). LOW: INSPECT HIGH: INSPECT * Low fuel level (add * Plugged fuel return 1. fitting) and hold.56. Cover fuel fittings to keep debris out. Wear eye FUEL PRESSURE TOO FUEL PRESSURE TOO protection. Gently slide fitting straight off supply line. WARNING Allow engine and exhaust to cool completely before FUEL PRESSURE TROUBLESHOOTING disconnecting fuel line or removing tank. Turn ignition switch off.14 © Copyright . See Horn Removal / Installation. adapter hose * Fuel line kinked or restricted (from tank fitting to rail) * Fuel line leaking (leaking air in or fuel out) * Vent restriction * Plugged fuel pickup filter (located in fuel tank) * Pressure regulator malfunction (located on pump) *Fuel pump malfunction (Pump should run for about 2 seconds the 4. Disconnect gauge adapter F U E L S Y S T E M D E P R E S S U R I Z AT I O N and re-connect fuel line (Fuel Tank Installation. Remove the horn. page 4. or gauge fuel rail. 9927618 R03 . Wrap a clean shop towel around fuel line fitting q.FUEL DELIVERY / EFI 4. * Pump not running regulator) 2.19). fuel) (in tank on pressure page 10.

Removal / Installation - Classic / Vintage / Chieftain. 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.15 . 5. Lift the rear of the tank and slide back approximately 2” to expose the front console cover fastener.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. remove the fuel line y from the fuel pump. Protect fuel tank finish when removing. central locking and system power buttons and remove console cover. washer and rubber isolator at the rear of the fuel tank. storing. and installing tank. Disconnect electrical connectors at the security light.21 2. 7. WARNING Allow engine and exhaust to cool completely before disconnecting fuel line or removing tank. and the evaporative vent line t. 9927618 R03 . With a shop rag wrapped around the fuel fitting. Disconnect the fuel pump electrical connector r. 6. Remove the two fasteners q. Remove seat. See Seat. page 7. 4 • Chieftain / Roadmaster For these models the front fastener does not have to be removed. Remove console cover fasteners w and the plastic dart e. 1. FUEL DELIVERY / EFI F U E L TA N K R E M O VA L 4. 3. Remove rear fastener and slide console forward to release it from the front mounting grommet.

See STEPS 1–5 of Fuel Tank Removal. Disconnect the fuel pump electrical connector and move out of the way.16 © Copyright . disconnect the fuel pump electrical connector and the supply line r. Do not kink or bend fuel pickup hose upon removal. Wrap a shop rag around the fuel supply line release from the front isolators. 3. Review gasoline warnings outlined in the beginning of this chapter. page 4. Remove the console cover from the fuel tank. Always inspect wires and hoses 6. connector w and disconnect from fitting.5. F U E L P U M P R E M O VA L WARNING Replace all mounting fasteners and pump seal O-ring any time pump is removed for service. 2. Raise the fuel pump access cover enough to closely for damage after removing the fuel pump. jet pipe. Lift the tank off of the motorcycle and store safely. See EFI System Precautions. Lift the rear of the fuel tank and slide rearward to 4. Disconnect the fuel tank vent line q by sliding the rubber elbow off of the fitting. fuel pump. page 4. 1.15. 9927618 R03 .FUEL DELIVERY / EFI 8. electrical wiring.2017 Indian Motorcycle (Full-Size) Service Manual 4. or hoses when removing the pump assembly. CAUTION Be careful when performing this procedure to avoid damaging the fuel level float arm. Remove fuel pump access cover nuts e in an alternating or “star” pattern. 5. 9.

9927618 R03 . Lower the fuel pump assembly into the access hole the RH side of the fuel tank. Lift the fuel pump assembly out of the retaining bracket and carefully lift out of the fuel tank. with the level arm facing forward and the jet pipe resting on the left side of the tunnel. Reach in through the fuel pump access cover and F U E L P U M P I N S TA L L AT I O N gently press the fuel pump retaining tab t toward 1. 4. 4 8.17 . Slide the pump into position until the retaining tab engages and the pump is locked in place. page 2. line up the guide rails and retaining tab with the bracket q. F U E L TA N K V E N T I N S P E C T I O N 1. 2. FUEL DELIVERY / EFI 7. See Fuel Tank Vent Inspection (49 State). 3.21. Refer to Maintenance chapter for tank vent inspection and hose routing information.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. Verify that the float arm moves freely through it’s full range of motion. Once the pump body is inside the tank.

vent line and fuel pump electrical connector to the top of the access cover. Press a new sealing gasket w into the bottom of the 7. 10. page 4. Install fuel pump access cover nuts r and tighten fuel pump access cover. Connect the fuel supply line. See Priming The Fuel System.FUEL DELIVERY / EFI 5.22 9927618 R03 . TORQUE Fuel Pump Access Cover: 43 in-lbs (5 Nm) 8. 9. Prime the fuel system and verify fuel pump operation. Lower the fuel pump access cover into position and connect the electrical connector and supply line e. 6.2017 Indian Motorcycle (Full-Size) Service Manual 4. Install the console cover. to specification following the torque sequence shown.18 © Copyright .

Install fuel cap assembly if removed. Lower the rear of the tank into position over the rear mounting bracket.19 . 8. 4. TORQUE 1. TORQUE Fuel Tank Mounting Fasteners: 84 in-lbs (10 Nm) 10.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. 7. Install the console cover and torque fasteners to Place a protective cloth on the front of the tank when specification. DO NOT slide forward into position at this time. Console Cover Fasteners: 84 in-lbs (10 Nm) 2. Verify that the fuel tank vent line is routed properly and torque the fuel tank mounting fasteners to specification. assembling tank to frame. 4 3. Verify that forward tank isolators w are in position on the frame mounts and lower tank into position. 9. 9927618 R03 . FUEL DELIVERY / EFI F U E L TA N K I N S TA L L AT I O N 5. Install the outer isolators and washers onto the rear tank mount and install mounting fasteners y. Install the inner isolator / spacer assemblies q to the rear fuel tank mounts as shown. Install seat and side covers. 6. vent line r and fuel supply line t. Slide tank forward until fully seated on forward isolators. Connect the fuel pump electrical connector e.

or if the fuel gauge isn’t indicating fuel level at all. Press the POWER ON button to power up the motorcycle electrical system. On the fuel pump side of the connector. 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. keeping the pump powered. 2. 6. When a CPS signal is received by the ECM (engine is cranking or running) the ECM maintains the ground on Pin 42 (Gray wire). Remove the fuel pump. Connect meter across terminals A & B on the wire harness side of connector. Remove the console cover and disconnect the fuel the fuel pump.16.16 steps 1–5. 1. 3. continuity to battery (-) post. page 4. 3. 8. check Gray wire from fuel pump relay to ECM pin #42 . pump / level sensor electrical connector. The fuel level sensor is located inside the fuel tank on 1. Set multimeter to measure resistance. Attach Voltage reading should be close to battery voltage suitable test probe adaptors to meter leads (from for 2-3 seconds after switching Engine Stop switch kit PV-43526). See Fuel Pump Removal. verify that battery is fully measured by a variable resistance fuel level sensor q. resistance across the sensor and compare to the verify ground wire (Pin B. 7. See Fuel Pump Removal. 4. 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. perform the following test and refer to resistance values located at the end of this procedure. If fuel level readings are inaccurate when the motorcycle is powered up. LEVEL SENSOR ARM APPROXIMATE POSITION RESISTANCE LIMITS Full (Top of Range) 97–103 Ω Empty (Bottom of Range) 445–455 Ω 9927618 R03 . to RUN.2017 Indian Motorcycle (Full-Size) Service Manual 4. page 4. measure 5. 2. Turn Engine Stop switch to RUN and read DC voltage on meter when switch is first turned on.FUEL DELIVERY / EFI 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 F U E L P U M P S U P P LY V O LTA G E T E S T OVERVIEW OF OPERATION: Fuel level readings are Before performing this test.20 © Copyright . If ground is OK. If low or no voltage is delivered to the fuel pump. Black) has good table. charged and in good operating condition.

even with key and stop switch off. Read fuel pump current draw on meter and compare to specification. Be sure red meter lead is in the 10A jack. 5. Remove fuel pump relay w by pulling straight upward. FUEL DELIVERY / EFI F U E L P U M P C U R R E N T D R AW T E S T 4. Inspect fuel pump circuit wiring or replace fuel pump if current draw exceeds specification. 1. and current draw will be displayed on the meter. SPECIFICATION: Fuel Pump Current Draw Maximum: 6 DC Amps 2. Perform draw test if fuel pump operation is suspect. NOTE When meter leads are inserted the pump will run. Insert one meter lead in pin socket (4) and other meter lead in pin socket (7) of relay block. 3. Fuel tank must be completely installed and have enough fuel in it to cover the fuel pickup screens for an accurate test. 9927618 R03 . Set meter to DC Amps. or if fuel pump fuse is found open (blown). NOTE Fuel pump current draw is an indicator of pump condition. and black meter lead is in common (-) jack. Remove the LH upper side cover and fuse box 4 cover q. 6.21 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4.

• Whenever battery disconnected. Allow switch to remain in RUN position until pump stops running (about 2-3 seconds). 5. Press the power button to power down motorcycle.22 © Copyright . 3. 7. Turn stop switch to RUN. 9. Fill the fuel tank. 6. 8. 4. NOTE Fuel level in tank must be high enough to submerge pickup screen on fuel pump. • Whenever fuel system is serviced (fuel line is disconnected). 9927618 R03 . 1. Turn stop switch OFF. Turn Engine Stop switch OFF.2017 Indian Motorcycle (Full-Size) Service Manual 4.FUEL DELIVERY / EFI PRIMING THE FUEL SYSTEM Prime procedure should be performed: • If a new fuel pump is installed or if tank is run completely dry. 2. Repeat Steps 4-8 about 4 times to complete the priming procedure. Press the power button to power up the motorcycle. WAIT approximately 10 seconds.

). the ECM also evaluates feedback from minor sensors in the system. An electric fuel pump. It is programmed to provide the correct fuel/air mixture and ignition timing based on several sensor input signals (engine load. The locations of sensors and other EFI system related components are outlined in this chapter. The ECM also provides grounds or voltage to other EFI related circuits of the electrical and fuel delivery systems. The duration of an injector pulse (length of time the injector circuit is grounded) is controlled by the ECM. cable-operated throttle body. the ECM will operate in “closed loop fuel control” mode. The fuel injectors inject fuel when they are grounded by drivers inside the ECM. mounted inside the fuel tank supplies fuel pressure to the injectors continuously when the engine is running or cranking. Although TMAP and engine RPM are the most influential inputs for selecting a map reference point. See Sensors — Powertrain Management.23 . A pressure regulator incorporated on the pump keeps fuel pressure steady at approximately 3.51 Bar (350 kPa / 51 PSI). 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.12. 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 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.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 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 MAP portion of the TMAP sensor is the primary air flow and load sensing device. page 4. FUEL DELIVERY / EFI EFI SERVICE FUEL INJECTION SYSTEM . temp. altitude. 9927618 R03 . Pulse duration determines the amount of fuel delivered to the engine (longer cycles = more fuel). is located beneath the battery box.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. The ECM calculates an injection time based on the measured airflow and desired AFR. The ETC also serves as a plausibility check for the TMAP sensor. The Engine Control Module or “ECM”. The ETC controls throttle blade angle and provides 4 rate-of-change feedback to the ECM. manifold pressure etc. An Electronic Throttle Control (ETC) system takes the place of a conventional.

FUEL DELIVERY / EFI ECM CONNECTOR MAP PIN COLOR FUNCTION PIN COLOR FUNCTION ECM 1 ECM 2 1 .2017 Indian Motorcycle (Full-Size) Service Manual 4.24 © Copyright . NOT USED 7 BG FRONT O2 SNR RETURN 8 . NOT USED 17 YE/VT REAR BRAKE SWT OUTPUT 18 . NOT USED 14 . NOT USED 1 BK CPS NEGATIVE SIGNAL 2 . NOT USED 18 OG/WH TIPOVER SENSOR 19 DB/OG CLUTCH SWT OUTPUT 19 OG/BN MAP SENSOR OUTPUT 20 . NOT USED 8 OG/BN CHT RETURN 9 . NOT USED 10 WH/RD PPS 1 – 5 VOLT REF 11 YE/GN PPS 2 OUTPUT 11 . NOT USED 9 . NOT USED 20 VT/RD TPS 2 SIGNAL 9927618 R03 . 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 15 GY/BK ENGINE RELAY CNTL 15 OG/DB CHT SENSOR OUTPUT 16 PK K15 16 BN RH WARMER THERMISTOR 17 . NOT USED 2 GY/DB REAR O2 SNR OUTPUT 3 YE/BK PPS 2 RETURN 3 OG/YE TPS 1 OUTPUT 4 BN/GN MAP SENSOR RETURN 4 BK THERMISTOR RETURN 5 BN/WH TPS RETURN 5 BG/WH REAR O2 SNR RETURN 6 WH/BK PPS 1 RETURN 6 BK/BU FUEL SENDER GROUND 7 . NOT USED 10 .

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 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 36 DB LEFT REAR TS OUTPUT 37 . NOT USED 54 BK/WH ECM GROUND 54 BK REAR COIL SIGNAL 55 VT/PK ENG RELAY PWR OUTPUT 55 . NOT USED 43 WH/GY REAR FUEL INJECTOR DRIVER 44 DG CAN LOW 44 WH/DB FRONT FUEL INJECTOR DRIVER 45 . NOT USED 42 GY FUEL PUMP RELAY CNTL 42 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. NOT USED 29 . NOT USED 56 VT-PK ENG RELAY PWR OUTPUT 56 WH FRONT COIL SIGNAL 9927618 R03 . NOT USED 46 GY/WH FRONT O2 SENSOR CONTROL 47 BG/BK SIDESTAND SWT SIGNAL 47 BK/WH ECM GROUND 48 . NOT USED 35 DB/BK CANISTER PURGE VALVE 36 . NOT USED 27 OG/DG IAT SENSOR OUTPUT 28 . NOT USED 4 32 YE CAN HIGH 32 . NOT USED 22 . NOT USED 33 . NOT USED 22 . NOT USED 26 RD/BU TIPOVER SNR – 5 VOLT REF 26 WH/DG LH WARMER THERMISTOR 27 . NOT USED 33 . NOT USED 41 OG/BN STARTER RELAY CNTL 41 . NOT USED 48 DB/RD RIGHT REAR TS OUTPUT 49 . NOT USED 29 . NOT USED 30 . NOT USED 35 . NOT USED 49 . NOT USED 37 RD KNOCK SENSOR A 38 BN/DB TPS – 5 VOLT REF 38 BK KNOCK SENSOR B 39 . NOT USED 45 .25 . FUEL DELIVERY / EFI PIN COLOR FUNCTION PIN COLOR FUNCTION ECM 1 ECM 2 21 WH/GN PPS 1 OUTPUT 21 . NOT USED 31 . NOT USED 30 GY/RD FRONT O2 SENSOR OUTPUT 31 . NOT USED 28 . NOT USED 43 . NOT USED 46 . NOT USED 39 GY/YE REAR O2 SENSOR CONTROL 40 VT/DB AUX RELAY CONTROL 40 . NOT USED 34 BN CRUISE SFTY SWT OUTPUT 34 .

FUEL DELIVERY / EFI 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 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual 4.26 © Copyright .

27 . FUEL DELIVERY / EFI 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 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4.

FUEL DELIVERY / EFI 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 9927618 R03 .28 © Copyright .2017 Indian Motorcycle (Full-Size) Service Manual 4.

2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4.29 . FUEL DELIVERY / EFI SPN FMI COMPONENT CONDITION MIL P-CODE 5 Driver Circuit Open/Grounded OFF P1710 Right Turn Indicator Driver 2369 3 Driver Circuit Short to B+ OFF P1711 Circuit 4 Driver Circuit Grounded OFF P1712 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 3597 0 ECU Output Supply Voltage 1 Voltage Above Critical Level ON P16A3 4 16 Voltage Above Warning Level ON P16A5 1 Voltage Below Critical Level ON P16A6 18 Voltage Below Warning Level ON P16A7 3 Voltage Too High ON P16A9 4 Voltage Too Low ON P16A8 0 Voltage Above Critical Level ON P16AA 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 Detected 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 Throttle Position Sensor 2 1 Voltage Below Critical Level ON P1222 2 Signal Out of Range (Not Plausible) ON P0221 10 Abnormal Rate of Change ON P0220 9927618 R03 .

30 © Copyright .FUEL DELIVERY / EFI SPN FMI COMPONENT CONDITION MIL P-CODE 13 Calibration / Adaption Failure ON P1220 Condition Exists (engine disabled due to extended 520267 31 Kickstand Switch kickstand) ON P181C 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 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual 4.

Return Condition Exists 520278 Spring Check Failed ON P151C 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 . FUEL DELIVERY / EFI SPN FMI COMPONENT CONDITION MIL P-CODE 520261 7 ABS Fail Safe Relay On/Off Stick ON C1034 4 Drop ON C1038 520262 ABS Source Voltage 3 Raise ON C1039 520263 31 ABS Tire Irregular Tire Size ON C1040 520264 12 ABS ECU ECU Error ON C1041 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. Condition Exists 520279 Adaption Aborted ON P151D 31 Throttle Body Control . one failed) ON P150C 3 Maximum ON P150D 4 4 Minimum ON P150E 2 Throttle Body Control .Power Not Plausible ON P151A 520277 Stage 8 Signal Error ON P151B 31 Deactivated power stages due to 5V sensor supply error ON P153F 31 Throttle Body Control .Position Condition Exists ON P152E 520284 Deviation Fault 2 Brake Switch (1 or 2 Brake Switch Correlation Fault ON P153E 520285 Indeterminable) 520226 31 ECU Monitoring Error Condition Exists ON P1540 520287 31 ECU Monitoring Error (Level 3) Condition Exists ON P1541 31 ECU Monitoring of Injection Cut Condition Exists ON P1542 520288 Off(Level 1) 31 ECU Monitoring of Injection Cut Condition Exists ON P1543 520289 Off(Level 2) 31 Controller Option Settings not Condition Exists ON P1544 520290 Programmed 5 Open Circuit / Short to B+ ON C1075 520291 Left Fog Lamp 6 Grounded Circuit ON C1076 520292 5 Right Fog Lamp Open Circuit / Short to B+ ON C1078 9927618 R03 .Limp Condition Exists 520280 ON P151E Home Position Check Failed 31 Throttle Body Control .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4.31 .

32 © Copyright .FUEL DELIVERY / EFI SPN FMI COMPONENT CONDITION MIL P-CODE 6 Grounded Circuit ON C1079 5 Open Circuit / Short to B+ ON C122A 520293 Horn 6 Grounded Circuit ON C122B 5 Open Circuit / Short to B+ ON C1222 520294 Windshield Motor Driver 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 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual 4.

Multiple sensor failure is extremely unlikely. ECM. the sensor connector. These may include illuminate to alert the rider of a possible problem. a performed at the ECM wire connector. Connect Digital Wrench® to see what codes are present in memory. 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. and any depending on which system fault has occurred. cause of system faults.33 . the sensor OR a default value set by the ECM in the event of a fault in the sensor or wiring. If multiple codes are set. such as a power supply or common ground. 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 wiring between the two. 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. refer to the wiring diagram and focus your efforts on wiring and connections common to each of the sensors. Sensor tests can be performed at the sensor if easily accessible. it is important Poor or corroded connections are the most common to verify the condition of the sensor. and focus your diagnostics on that sensor and the related wiring for that circuit. such as jumper harnesses first step following illumination of the MIL is to perform a visual inspection to see if a cause can be where applicable. Refer to wiring diagrams and system break-out diagrams to narrow a problem search. determined. FUEL DELIVERY / EFI SPN FMI COMPONENT CONDITION MIL P-CODE 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 3 Voltage Too High ON P1327 520331 Knock Sensor Positive Line 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 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 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.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. 9927618 R03 . the ECM connector.

Static electricity from your body can damage the ECM.34 © Copyright . this could expand a terminal socket or damage the connector. and complicate the diagnostic process. This usually originates at the ECM connectors. Once ECM connector has been removed from the ECM: • Do not touch pins on ECM. • Do not attempt to perform tests on the ECM unit. create a problem where none existed before. • 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. • 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. but may include other connections. • DO NOT attempt to use standard meter probes or other devices to probe connector pin sockets.2017 Indian Motorcycle (Full-Size) Service Manual 4. 9927618 R03 .FUEL DELIVERY / EFI ECM PINOUT TESTING NOTE Tests in this section may require reading resistance and voltages at ECM connector.

Remove the RH upper side cover. 9927618 R03 .35. Remove the battery box. page 7. ECM Connector Installation TORQUE ECM Fasteners: 36 in-lbs (4 Nm) 4. page 10. See Side Cover 2. Removal / Installation. page 7. 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. until connector is disengaged from the ECM. Install the upper and lower side covers. (Lower). Torque ECM fasteners to specification.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. 3. 6. Connector Removal.13. 4 • Slide the lock lever toward the front of the vehicle 4. page 4. Remove the four fasteners q securing the ECM to • Locate the ECM connectors q. See Battery Box Removal. the battery box. Disconnect the ECM connectors.35 . 5. See Side Cover 1. 5. Removal / Installation. Reverse the removal procedure to install. FUEL DELIVERY / EFI 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. See ECM (Upper). To disconnect the two 56–pin ECM connectors: 3. (Do not tip or rotate the connector into the ECM).17. Remove the RH lower side cover.17. • Lift the connector straight off of the ECM. Carefully align the ECM connector straight with the flange on the ECM. 2.

engine load data.40. 5. Remove the ignition coil assembly and associated performs two functions in one unit. The TMAP sensor provides the ECM with removal procedure. comprised of separate air temperature and manifold absolute pressure readings.36 © Copyright . 9927618 R03 . the TMAP sensor q 1. it must be replaced TMAP Sensor Fastener: 62 in-lbs (7 Nm) IMPORTANT This sensor should only be tested using Digital Wrench Diagnostic Software. page 10. bracket. TMAP Sensor Test The TMAP sensor is a non-serviceable item. Air passing through the intake is measured by the TMAP and relayed to the ECM. If it is TORQUE faulty. These signals. See Ignition Coil Removal / Installation. 2.FUEL DELIVERY / EFI 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. are processed by the ECM and compared to its programming for determining the fuel and ignition requirements during 4. INSTALLATION is performed by reversing the operation.2017 Indian Motorcycle (Full-Size) Service Manual 4. Disconnect vehicle harness from TMAP sensor. Torque TMAP sensor fastener to specification. Remove TMAP sensor fastener w and remove sensor from the intake manifold. 3.

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. METER TEST SPECIFICATIONS (±10%) COMPONENT SETTING CONNECTIONS CYLINDER HEAD 30. See ECM Connector MAP. Measure resistance between pin 8 and pin 15 of the ECM #2 connector and compare to specification.37 . 6. 4. 4 5.5 K Ohms +/.24. page 4. disconnect sensor and measure the resistance through each wire from ECM connector to the sensor connector. If Step 5 continuity is good. Attach test lead adapters to meter leads. resistance. connectors. 2 connector (ECM disconnected).13% @ 25o C (77o F) OHMS Pin #8 to #15 TEMPERATURE SENSOR 9927618 R03 . 2. measure the resistance through the sensor and compare to specification. This will test will cylinder inspect the wiring. FUEL DELIVERY / EFI 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 . Resistance should be less than 1 Ohm (good continuity). See ECM Connector Removal. page 4. 1.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. 3. If resistance is out of specified range. and CHT sensor intake port. Disconnect ECM #2 connector. Set multimeter to measure resistance.35.

Remove the two fasteners y retaining the driver seat to the frame. See Trunk Removal. remove passenger CAUTION seat fastener. Remove fuel tank fasteners u. Remove upper side covers. Using compressed air. 2. page 7. grit. and dirt from entering the intake runner as the injector is removed. 4.38 © Copyright .FUEL DELIVERY / EFI F U E L R A I L R E M O VA L 3. Remove Saddlebags (if equipped). blow any debris away from base of fuel injectors. NOTE To provide access to fuel rail. Remove seat. Always wear eye protection NOTE Cleaning the area with compressed air prevents sand. lift the rear of the fuel tank high enough to insert a small 2x4 piece of wood beneath the fuel tank rear mount. NOTE For models with a passenger seat.29 1. 9927618 R03 . Remove Trunk (if equipped). Roadmaster.2017 Indian Motorcycle (Full-Size) Service Manual 4.

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.39 . Remove the upper two fasteners s securing the baffle plate to the intake. 8. Remove the three fasteners o securing the air filter to the adapter plate and remove air filter. FUEL DELIVERY / EFI 5. Remove the three fasteners a securing the air filter cleaner cover to the air box. adapter plate to the air box assembly and remove adapter plate.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. 4 6. Remove the three fasteners i securing the air 7. NOTE When removing the adapter plate. 9927618 R03 . NOTE Accessory intakes may require a different removal process.

10. 13. 14. Remove the lower fastener d securing the air box 12. 15. Push the rubber multi-plug seal through the back housing to the mounting plate.40 © Copyright . Squeeze the quick connect buttons (one on each side) and hold. Disconnect the multi-plug f from the throttle body. Gently slide fitting straight off the fuel rail. Remove four throttle body fasteners g and remove throttle body. Cover intake h to prevent debris from entering the engine.2017 Indian Motorcycle (Full-Size) Service Manual 4. 11. 9927618 R03 . of the air box housing. Disconnect intake hose and remove air box housing.FUEL DELIVERY / EFI 9. Wrap a clean shop towel around fuel line fitting.

17. Insert FUEL LINE PLUG TOOL (2521832) into fuel line to prevent fuel from leaking. FUEL DELIVERY / EFI 18. wrap a rag around both ends of the fuel rail to collect fuel.41 . NOTE When removing fuel rail from injectors. Always wear eye protection 16.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. 4 19. Carefully remove fuel rail from the right- hand side of the motorcycle. Leave electrical connector in place. 9927618 R03 . Remove o-rings from the top and bottom of the injectors and discard o-rings. Using a 'L' shaped allen wrench remove the two fasteners k securing the fuel rail to the intake manifold. NOTE Listen for an audible “click” to confirm the Fuel Line Plug Tool is fully engaged. remove fuel CAUTION injectors from intake.

38. test the resistance of the fuel injector (s) by measuring between the two pin terminals q. R E M O VA L / I N S TA L L AT I O N 5. indicates a problem with either injector.FUEL DELIVERY / EFI F U E L I N J E C T O R . F U E L I N J E C T O R R E S I S TA N C E T E S T Discard fuel injector AND injector o-rings. See Fuel Rail Installation.2017 Indian Motorcycle (Full-Size) Service Manual 4. connectors before disconnecting them. NOTE Apply oil sparingly and avoid contaminating the The fuel injectors are non-serviceable. page 4. Install fuel injector. Remove fuel rail from injectors.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. 2.4 Ω — 12. Take note of front and rear fuel injector harness silicone-free motor oil. IMPORTANT 3. 4.42 © Copyright .43 1. IMPORTANT Verify that the new top and bottom o-rings are installed in the correct position. Disconnect electrical connector from fuel injector. See Fuel Rail Removal. Install NEW o-rings onto top and bottom of injector Fuel Injector Resistance Specification: 11. IMPORTANT Verify that both of the new o-rings have been lubricated and installed correctly onto the injectors. page 4. Lubricate NEW injector o-rings with clean. If diagnosis pintle valve / jet surface and upper inlet port. 9927618 R03 .

Install NEW o-rings onto top and bottom of injectors PART NUMBER POSITION 1500198 TOP OF INJECTOR 5412891 BOTTOM OF INJECTOR IMPORTANT Always install NEW o-rings when removing the fuel rail or injectors. Install fuel injectors by carefully pressing into intake manifold. 9927618 R03 . Lubricate NEW injector o-rings with clean. silicone-free motor oil. FUEL DELIVERY / EFI F U E L R A I L I N S TA L L AT I O N 1. side of motorcycle. IMPORTANT Verify that the new top and bottom o-rings are installed in the correct position.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. 2. Install replacement fuel rail from the right-hand pintle valve / jet surface and upper inlet port. 3. CAUTION 4 Use care not to fold or displace lower o-ring from seating surface.43 . NOTE Apply oil sparingly and avoid contaminating the 4. IMPORTANT Verify that both of the new o-rings have been lubricated and installed correctly onto the injectors.

correct torque. until finger tight. 6.44 © Copyright . NOTE For ease of installation. Make sure the FUEL RAIL TORQUE TOOL remains in-line with the torque wrench while 5. Install fuel rail fasteners k into the intake manifold torquing fasteners. Torque fuel rail fasteners to specification. IMPORTANT Make sure the FUEL RAIL TORQUE TOOL and the torque wrench remain in-line while torquing fasteners.FUEL DELIVERY / EFI CAUTION IMPORTANT Use care not to fold or displace upper o-ring from Alignment of the special tool is critical to achieve the seating surface. Install a 5 mm allen bit to the hex end of the torque tool as shown. install the front cylinder fuel rail fastener first. 7.2017 Indian Motorcycle (Full-Size) Service Manual 4. Install the FUEL RAIL TORQUE TOOL (5264374) onto a ¼ in drive torque wrench. 9927618 R03 .

Remove special tool from fuel line. Uncover the intake h. Feed the throttle body multi-plug connector through the hole in the air box. Squeeze the quick connect buttons (one on each side) and hold.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. 10. Verify no leaks present with system under pressure.45 . 4 NOTE Use a rag to contain the small amount of fuel that may drain from the fuel line after the special tool is removed. IMPORTANT Verify that BOTH air box o-ring seals are correctly in position before installing the throttle body. 9. NOTE Listen for an audible “click” to confirm the line is fully engaged. 11. Connect intake hose to the air box housing. Connect fuel line to fuel rail. FUEL DELIVERY / EFI TORQUE Fuel Rail Fasteners: 74 in-lbs (8 Nm) 8. IMPORTANT Pressurize the fuel system by powering up the bike and slide the STOP/RUN switch to the RUN position. 9927618 R03 . 12.

2017 Indian Motorcycle (Full-Size) Service Manual 4. Install the lower fastener d securing the air box to the mounting plate. 15. NOTE Make sure that the harness seal is fully seated in the air box cutout. Install four throttle body fasteners g. Torque fastener to specification. Torque fasteners to specification.46 © Copyright .FUEL DELIVERY / EFI NOTE TORQUE Use a small amount of lubricant around the outside of Throttle Body Fasteners: the breather hose when installing to the air box 84 in-lbs (10 Nm) housing. Connect the multi-plug f to the throttle body. 13. 14. 9927618 R03 .

baffle plate to the intake. Install the three air filter adapter plate fasteners a. Install the three fasteners o securing the air filter to the adapter plate. specification.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. Install the upper two fasteners s securing the 17. FUEL DELIVERY / EFI TORQUE TORQUE Air Box Fastener: Upper Intake Fasteners: 31 in-lbs (4 Nm) 84 in-lbs (10 Nm) 16. Torque fasteners to specification.47 . 4 18. Torque fasteners to Torque fasteners to specification. 9927618 R03 .

Torque fasteners to correctly as shown. Verify that both fuel tank isolators are assembled cleaner cover to the air box. Torque fasteners to specification. 21.FUEL DELIVERY / EFI TORQUE TORQUE Air Filter Fasteners: Air Box Cover Fasteners: 62 in-lbs (7 Nm) 84 in-lbs (10 Nm) 19.48 © Copyright . 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual 4. Install the three fasteners i securing the air 20. specification. Remove the small 2x4 piece of wood beneath the fuel tank rear mount and lower fuel tank into position. Install fuel tank fasteners u.

4 25. See Trunk Installation. Install the upper side covers. Roadmaster. Connect the motorcycle to Digital Wrench. Install Trunk (if equipped). Verify no fail codes and no MIL lights are present.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. 9927618 R03 . page 7. install and torque passenger seat fastener. FUEL DELIVERY / EFI TORQUE TORQUE Fuel Tank Fasteners: Seat Fasteners: 84 in-lbs (10 Nm) 84 in-lbs (10 Nm) 22. Install NOTE the two fasteners y retaining the driver seat to the frame. Install Saddlebags (if equipped). Slide front of seat into seat retaining bracket. Torque seat fasteners to specification For models with a passenger seat.49 . 24. Field Test the motorcycle to verify proper operation.30 26. 23.

Remove starter motor. If resistance is correct. Connect an ohmmeter between the pin terminals w and compare resistance readings to specification below. check to see that the sensor lbs (10 Nm) is mounted properly and that the tone wheel has not been damaged and is securely mounted to the crankshaft assembly. 2. Torque the CPS retaining fastener to specification. TEST / REPLACE CPS Test CPS Replacement 1. TORQUE Crankshaft Position Sensor Retaining Fastener: 89 in- 3. Remove the fastener e securing the CPS sensor to the engine case and remove sensor. 4. page 10. 6. Locate the CPS connector q behind the RH front Installation.50 © Copyright . Disconnect the CPS sensor from the vehicle harness and release flying lead from plastic darts and cable ties. 3. 2. 5. page 10. Removal / 1. Installation is performed by reversing the removal procedure.33. and disconnect. Crankshaft Position Sensor: 860 Ohms @ 20°C (68°F) 9927618 R03 . See Starter Motor. down tube.25. See Rectifier / Regulator Replacement.FUEL DELIVERY / EFI CRANKSHAFT POSITION SENSOR. NOTE Apply rubber lubricant to the CPS sensor o-ring to ease installation. Remove regulator / rectifier assembly and bracket.2017 Indian Motorcycle (Full-Size) Service Manual 4.

Measure the resistance through each wire from ECM connector to the sensor connector. With the RH upper side cover removed. Using a multi meter with a low voltage AC frequency scale. Sensors that have been over-tightened or under-tightened CAUTION may set a diagnostic trouble code and cause the MIL to illuminate. Test 2 9. page . be replaced if removed for any reason. If no frequency fluctuation is observed while tapping on the cylinder. Measure the resistance across the detonation sensor pins 1 & 2. FUEL DELIVERY / EFI 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.5–5. Inspect the sensor-side of the connector for connector pins of the detonation sensor. 13. 12. ECM2 Pin 38 to Detonation Sensor Connector Pin 2 should be less than 1Ω. See ECM Connector MAP. 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 Detonation Rearward 520331 4 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 6.35. replace the sensor. 4. Use a properly calibrated torque The detonation sensor is torque sensitive and must wrench during installation. ECM2 Pin 37 to Detonation Sensor Connector Pin 1 should be less than 1Ω.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. If the resistance does not match the specified value. Disconnect the negative battery cable. Replace 9927618 R03 . sensor with a rubber mallet or other non-metallic page 4. Removal. detonation sensor connector q just inside the RH midcasting and disconnect. Lightly tap the front cylinder near the knock ECM connector 2. continuity).0 MΩ 8. locate the for pin locations. or “Knock” sensor is a piezoelectric sensor that advances or retards ignition based on The detonation sensor must be torqued to load. connect the meter leads to the 3. moisture and / or corrosion. Set multi meter to measure resistance. Resistance across Detonation Sensor Connector Pin 1 & Pin 2: Continuity Resistance should be between 4. replace the sensor. page 4. object. specification or it will not perform correctly. 7.24 2. 10. 5.51 . See Resistance should be less than 1 Ohm (good Battery. See ECM Removal / Installation. Watch for frequency fluctuation. Make sure the terminal pins are securely seated in the plug. Allow the signal to stabilize to 0 Hz. 1. Remove the ECM from the motorcycle to access 11.

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. 17. 1.40. TORQUE Detonation Sensor Fastener: 15 ft-lbs (20 Nm) 9927618 R03 .15. remove the sensor from the motorcycle. To remove the Electronic Throttle Control page 10. 19. Torque the detonation sensor fastener to specification.FUEL DELIVERY / EFI 14. see Air Box Removal. page 3. assembly.4.52 © Copyright .2017 Indian Motorcycle (Full-Size) Service Manual 4. 15. Remove the fastener w securing the detonation sensor to the forward cylinder. 18. page 4. Remove the fuel tank. See Ignition Coil Removal / Installation. Noting how the detonation sensor harness is routed. See Fuel Tank Removal. 16. INSTALLATION is performed by reversing the removal procedure.

connect to Digital Wrench to clear active and historic codes. • If a 2nd misfire occurs. Cylinder 2 (Rear) • P0314 (SPN 65590/FMI 7) Misfire Confirmed If a misfire is detected. The check engine indicator lamp will continue to flash until the ignition switch has been moved to the off position. after the 3rd misfire event. the check engine indicator lamp will resume flashing and fuel will once again be cut to the affected cylinder(s). loose spark plug wire has been reattached). A misfire will cause a fluctuation in crankshaft speed. the following events will occur: • The check engine indicator lamp will begin to flash and fuel will be cut to the affected cylinder(s). 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. P0314 misfire fault is determined & set. In cases where cylinder misfire is intermittent. If the MIL turned on solid due to P0314. follow the troubleshooting section below.g. then start the engine and run at idle for a period of approximately 4 minutes. Retest to verify the condition is no longer present. 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. when the ignition is cycled OFF and ON again. Cylinder 1 (Front) • P0302 (SPN 65592/FMI 7) Misfire Detected. Following the 1st or 2nd misfire event. Restarting the engine will clear the flashing indicator and restore fuel to both cylinders. the check engine light will remain on and fuel will 4 be cut to the affected cylinder(s). NOTE DRIVE CYCLE: A drive cycle consists of cycling the ignition from OFF to ON. When P0314 is set. • After the 3rd misfire. or has been repaired in the field (e.53 . 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. 9927618 R03 . timing) IMPORTANT Once the systems is repaired and functioning normally. One or more of the following codes will be set if a misfire occurs: • P0301 (SPN 65591/FMI 7) Misfire Detected. Misfire Detection utilizes a self-healing feature to allow continued operation.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. the MIL will stay on for 3 fault free drive cycles before turning off. the misfire code becomes historic and the MIL turns off. This threshold varies based on engine speed. ECU and Ignition Coil are not damaged. it will stay on until the misfire condition has been removed and 3 fault free drive cycles have occurred. Finally. If this occurs. If it does not turn off. FUEL DELIVERY / EFI CYLINDER MISFIRE DETECTION The ECU monitors crankshaft speed via the crankshaft position sensor. turn off the ignition for approximately 2 1/2 minutes.

With speedometer and ECM connectors plugged in. and the ECM connector unplugged the resistance will be 120Ω.2017 Indian Motorcycle (Full-Size) Service Manual 4. check resistance between the CAN terminals at the speedometer connector. With the speedometer unplugged.FUEL DELIVERY / EFI CAN DIAGNOSTICS CAN (CONTROLLER AREA NETWORK) DIAGNOSTIC OVERVIEW Overview The speedometer and Engine Control Module (ECM) have integrated 120Ω termination resistors. With the speedometer connector plugged in. The resistance should be 120Ω. 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 9927618 R03 .54 © Copyright .

9927618 R03 . The Digital Wrench diagnostic software allows the technician to perform the following tests and observations: • View or clear trouble codes • Analyze real-time engine data • Reflash ECU calibration files 4 • 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. Refer to procedure and carefully follow all instructions provided in Digital Wrench. Diagnostic procedures are added to subsequent versions of Digital Wrench as they become available. In addition. guided diagnostics are also available for many other electrical sub systems. install the Digital Wrench diagnostic software on your computer.55 .com/. downloads and provided in the Digital Wrench Diagnostic Kit to software updates at: http://polaris. FAQs. Check your release version often and upgrade when available to be sure you are using the most current software available.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. visit the NOTE Digital Wrench Knowledge Base for the most current Refer to Section 2. any fault that will turn on the ‘Check Engine’ indicator. New reprogramming files and guided diagnostic procedures are added to these updates as they become available.diagsys. a specific replacement procedure is required to ensure that all essential data contained within the original ECU is transferred to the replacement ECU. ECM REPLACEMENT Although the need for ECM replacement is unlikely. G U I D E D D I A G N O S T I C A VA I L A B L E Guided diagnostics are available within Digital Wrench for most supported Diagnostic Trouble Codes (DTCs). page 4. 3 and 4 in the Instruction Manual troubleshooting information.56. For information on how to determine if you have the latest update available. FUEL DELIVERY / EFI 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 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 OVERVIEW If you experience problems connecting to a vehicle or any other Digital Wrench related problem. see Digital Wrench Version and Update ID. That is.

FUEL DELIVERY / EFI 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. installed will help determine which updates are required. it should be downloaded before using Digital Wrench. com to see if a Wrench diagnostic connector. 3. 5. If a newer update is available. Proceed to http://polaris. 3. Follow these steps to connect the diagnostic interface cable to the vehicle: 1. Unplug the Digital Wrench connector from it’s protective receptacle. proceed with using Digital Wrench. Assemble the SmartLink Module and attach the PC Interface Cable to your laptop. 1.56 © Copyright . Open the Digital Wrench software. Select the appropriate vehicle and wait for the status to display ‘Connected’ in the lower left corner of the screen. 6. below the fuse box. Once connected.2017 Indian Motorcycle (Full-Size) Service Manual 4. Locate the version ID shown on the lower right side of the Digital Wrench start-up screen. Press the ON button to power up the motorcycle electrical system and switch the STOP / RUN switch to the RUN position. NOTE Always operate with the latest update. 4. newer update is available. The serial number is located on the right side of the screen. diagsys. Connect the Vehicle Interface Cable to the Digital 2. NOTE Versions and updates are subject to change. 2. 9927618 R03 . 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.

When the update is complete. save the file to your hard disk and then double-click the icon to start the update process. NOTE Do not "run" or "open" the file from where they are. 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. diagsys. Internet at: http://polaris.com. 8.polarisdealers. Click on Digital Wrench Updates. 3. Click on Digital Wrench Version Updates. FUEL DELIVERY / EFI D I G I TA L W R E N C H U P D AT E S 6. The Digital Wrench portal website should appear in a new web browser. Log on to www. Locate the Service and Warranty drop-down menu. Click on the link shown above.57 . Select "save" and download them to your PC before running the install. 1. download the file. NOTE Versions and updates are subject to change. The Digital Wrench website can also be accessed through the dealer website at: www. Updates will not install if you are using an older version loaded on your PC.polarisdealers. 4 7. If the update file date listed is newer than your Updates are released for Digital Wrench via the current version and update. 4. NOTE You must already have the current version installed before adding an update. com. NOTE Only authorized Indian Motorcycle dealers and distributors can access the dealer website. the version shown on the right side of the Digital Wrench start-up screen should match the update you just downloaded. 5.com. 2.

FUEL DELIVERY / EFI D I G I TA L W R E N C H F E AT U R E M A P 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual 4.58 © Copyright .

• CLOSE NON-ESSENTIAL PROGRAMS: It is recommended that you DO NOT install non-essential 8. Select the “Special Tests” icon. DO NOT CLOSE Digital Wrench or the Request may clog up memory if running in the background Code will be invalid. review the HELP Process Overview section of the diagnostic software before you attempt reprogramming. voltage level above minimum. problem than one dedicated to Digital Wrench 6. there are no numbers in a request code. 1. 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. and be sure successfully reprogram the ECM. an Authorization Key battery voltage is as specified.59 . The process only takes a few minutes.com for specific Request Code is automatically generated by Digital information and FAQs on how to troubleshoot 4 Wrench during the reprogramming process. operate. Start Digital is the most current and complete information Wrench and click on the Special Tests menu icon (red available. The information in the on-line help menu on the Digital Wrench screen. Camera required on the dealer website in the next step. • DEDICATED LAPTOP: Best results are obtained 4. volts and at least 12. Verify the most current update has been Be sure the battery voltage (no load) is at least 13 downloaded and loaded into Digital Wrench. people and in several applications around the dealership is more likely to cause a reprogramming 5.5 volts with the key ‘ON’. process and with computer operation in general • COMMUNICATION PROBLEMS: If you have had before attempting to reprogram an ECM. keyboard. A laptop that is used by a variety of Type” icon. NOTE Failure to follow the reprogramming instructions Reprogramming (Reflash) Procedure: completely and correctly can result in an engine that If you are not familiar with the reprogramming does not run! Replacement ECMs are programmed process. and is best left alone until complete. Open the Digital Wrench program. The communication problems. FUEL DELIVERY / EFI ENGINE CONTROLLER REPROGRAMMING • KNOW THE PROCESS: If you are not familiar with the (REFLASH) entire reprogramming process. Fully charge the battery before you attempt to reprogram. review the “Reprogramming (Reflash) Tips” as “no-start” and require a reflash for them to work. NOTE Request Codes and Authorization Keys must be entered EXACTLY as they appear on the screen. If you encounter a Reprogramming (Reflash) Tips: problem. 9927618 R03 . Check all connections. 2. To and fixed. product line and vehicle using a laptop computer that is “dedicated to Digital description by selecting the “Change Vehicle Wrench”. A technician should be familiar with the familiar with the process. etc. Reflash Authorization site is located under the Service • DON’T DISTURB THE PC: While reprogramming is in and Warranty drop down menu on the dealer website progress. diagnostics only. Follow the on-screen instructions as you progress through the steps. Copy (CTRL +C) the Request Code that will be programs on a Service Department laptop. This should be your first step until you are tool box). • OBTAINING THE LATEST UPDATE: Reprogramming 7. problems communicating with a vehicle while The Digital Wrench Engine Controller performing diagnostic functions. • BATTERY VOLTAGE: The majority of problems with reprogramming can be attributed to a low battery.diagsys. The • Proceed to http://polaris. 3. detection software. Virus Scanners. Select “Engine Controller Reprogramming”. Connect SmartLink Module cables to PC and Connect a battery charger if necessary to bring vehicle. always check the On-Line help for current tips and information. Tool Bars.polarisdealers. must be obtained by entering a Request Code in the box provided on the Reflash Authorization site. before you begin. Click on the ? on the tool The reprogramming feature is in the Special Tests bar or press F11. Integrity Check and obtain a Request Code. do not attempt Reprogramming (or “Reflash”) feature allows reprogramming until the cause has been identified reprogramming of the ECM fuel and ignition map.com.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. don’t move the mouse and don’t touch the at: www. NOTE: All characters are and make it harder for the diagnostic software to letters. Select the model year.

Select the same file type from the list that you selected previously while in Digital Wrench.60 © Copyright . An “Authorization Key” will appear in the upper left corner of the screen. 9927618 R03 . Enter or paste (CTRL +V) the Authorization Key in the box located on the Digital Wrench screen. 14. 12. 15. At this point the reflash process will begin.FUEL DELIVERY / EFI 9. com and click on “ReFlash Authorization” from the “Service and Warranty” drop-down menu. Go to www. 11. Click the ‘Continue’ button and follow instructions provided on the screen to complete reprogramming procedure. Do not touch the vehicle or PC during the process. When completed. click the ‘Finish’ button on the screen. polarisdealers. click the Authorize button once to proceed. Verify the reflash was a success by starting the vehicle. 13. Enter or paste (CTRL +V) the Request Code into the box. Once the ECU reprogramming procedure is complete. 10. Enter the VIN along with the customer’s name and address.2017 Indian Motorcycle (Full-Size) Service Manual 4. Copy (CTRL+C) this key exactly as it appears.

2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4. PA R T 1 PROBLEM POSSIBLE CAUSE AFFECTED PART(S) REPAIR RECOMMENDED Engine turns over with Compression too low See engine section electric starter. proper air gap (gap is preset Fuel delivery timing damaged. installed incorrectly. inspect for no spark. FUEL DELIVERY / EFI 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 . corroded. 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. but won’t start No spark at spark See ignition system plugs No fuel reaching intake Out of fuel Add Fuel tract Blown Fuse Replace Plugged fuel filters / Clean/Replace lines Test / Replace Fuel pump not working Test / Replace Fuel pressure regulator Test / Replace Faulty fuel pump relay Inspect / Repair Open wiring / connector Inspect / Repair 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. valves Valve train problems head 9927618 R03 . faulty but cover. or ECM and wiring harness Inspect cylinder head & wet connector(s) Valve springs. or dirty. CPS wheel must be clean and in good condition). valve. sensor. Ignition problemsLow wires Charge or replace Battery Voltage Battery Unplug connections .inspect Loose. and timing incorrect.61 .

poor wire Replace plugs / diagnose Air leaks connection for ignition or Inspect wiring connections Restricted air intake or fuel injection.62 © Copyright .FUEL DELIVERY / EFI 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 .2017 Indian Motorcycle (Full-Size) Service Manual 4. 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. 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 9927618 R03 . spark plug Refer to battery section Ignition Problem fouled.

) 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.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 4./Charging system 9927618 R03 . FUEL DELIVERY / EFI 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.63 .

D.64 © Copyright . and Re- authorization code Charge Battery When Re- Flash Is Completed Enter Authorization Code Sent With Accessory Kit 9927618 R03 . Calibration I. or calibration During Re-Flash.2017 Indian Motorcycle (Full-Size) Service Manual 4.FUEL DELIVERY / EFI 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 . Attach Battery Charger number. 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.

. . . . . . . . . . . . . . . . .22 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . .14 CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 TORQUE COMPENSATOR . . . . . . . . . . . . . . . . . . . . . .5. . . . . . . . . . . . . . . . . . .5. . . . . . . . . .6 SERVICE PROCEDURES . . . . . . . . . 5. . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 CLUTCH PINION SHAFT BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 SHIFT SHAFT BEARING & SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 CLUTCH . . . . . . . . . . . . . . . . . . . . . .2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . .5. . . . . . . . . . . . . . . . . . 5. . . . . .8 CLUTCH PINION SHAFT SEAL REMOVAL & INSTALLATION . . . . . . . . . . . .2 SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 PRIMARY COVER . . . . .5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. . . .5. . . . . . . . . . . . . . .5. . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH / PRIMARY / SHIFT CHAPTER 5 CLUTCH / PRIMARY / SHIFT GENERAL INFORMATION . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 CLUTCH ASSEMBLY . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 5 CLUTCH PINION SHAFT REMOVAL . .12 CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 TORQUE COMPENSATOR INSTALLATION.2 ASSEMBLY VIEWS. . . . . . . . . . . . .5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 SERVICE INFORMATION . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 PRIMARY COVER REMOVAL . . . . . . . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 TORQUE COMPENSATOR INSPECTION . .19 TORQUE COMPENSATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 CLUTCH PINION SHAFT INSTALLATION . . . . . . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . .12 PRIMARY COVER INSTALLATION . . REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . .9 SHIFT RATCHET REMOVAL & INSPECTION . . . . .5. . . . . .9 SHIFT RATCHET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 CLUTCH INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. . . . . . . . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 CLUTCH PINION SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 CLUTCH RACK. . . . . . . .22 FLYWHEEL INSTALLATION . . . . . . .2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 9927618 R03 . . . . . . . .14 CLUTCH REMOVAL . . . . . . . .5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . .5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. . . . . . . . . . . .5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH / PRIMARY / SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 TORQUE COMPENSATOR REMOVAL . . . . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . .

SPECIFICATION • Lubricate parts during assembly as described in the procedures. the clutch has been used improperly.CLUTCH / PRIMARY / SHIFT 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 frame.8 lbf @ Installed Height Clutch Lever Free Play (Cable) .020-. QTY. Replace any linkage Clutch Stake Nut 125 ft-lbs (170 Nm) components that are damaged or do not move freely. 6657 or https://polaris. • Oil additives of any kind are not recommended by Crankshaft Locking Pin PF-52135 Indian Motorcycle.5) 32.com/ • Indian Motorcycle 20W/40 motorcycle oil is recommended for all operating temperatures. Spring Centered Gearshift Pattern 1-N-2-3-4-5-6 Clutch Spring (Coil Type.060") 9927618 R03 . Pressure Plate Fasteners 88 in-lbs (10 Nm) Primary Cover Fasteners 15 ft-lbs (20 Nm) Stator Fasteners 88 in-lbs (10 Nm) Torque Compensator 83 ft-lbs (112 Nm) Fastener Torque Compensator 88 in-lbs (10 Nm) Locking Plate Fastener 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. If Indian Motorcycle 20W/40 oil is not available.50-1. Burnt clutch plates indicate that a Moly Assembly Paste 2871460 problem exists within the clutch system. Multi-Disk Clutch Operating Mechanism Manual / Cable Operated Torque Compensator Belleville Spring Loaded Cam Assembly Primary Reduction Ratio 1. or plates were Bosch Automotive Service Solutions: 1– 800– 328– contaminated by improper oil or additives.50 mm (. Engine Stand Adapter PF-51240 • Burnt clutch plates are not an indication of defective clutch plates.service-solutions. operation. Using oil additives or oil of the wrong viscosity can have a detrimental affect on Crankshaft Rotation Socket PF-51239 clutch performance. Case Splitting / Assembly PF-51234 • Internal transmission or internal shifting mechanism Tool service requires engine removal and crankcase Clutch Shaft Holder PF-51232 separation. and service life.56 : 1 Clutch / Gear Shift / Linkage Transmission Shift Mechanism Manually Operated.2 © Copyright . and lubricate at regular intervals. Clutch Pinion Shaft Lever 88 in-lbs (10 Nm) • Corroded or sticking shift linkage pivot points can Fastener cause abnormal shifting.2017 Indian Motorcycle (Full-Size) Service Manual 5. a high T O R Q U E S P E C I F I C AT I O N S quality 20W/40 motorcycle oil suitable for use in wet PART DESCRIPTION TORQUE clutch transmissions can be used.

M8 x 1. Primary Cover - 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 5.25 x 35 (QTY.3 . Primary Cover .7) 15 ft-lbs (20 Nm) w Fastener. PART DESCRIPTION TORQUE (IF APPLICABLE) BER q Fastener.M8 x 1.25 x 75 (QTY. CLUTCH / PRIMARY / SHIFT A S S E M B LY V I E W S PRIMARY COVER 5 NUM.7) 15 ft-lbs (20 Nm) e Primary Cover - r Gasket. Primary Cover .

External - w Washer - e Seal.CLUTCH / PRIMARY / SHIFT CLUTCH PINION SHAFT NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q E-Clip. Shaft (Shift Shaft / Clutch Pinion Shaft) - t End Bearing. Pinion Shaft - y Pinion Shaft.1) 88 in-lbs (10 Nm) 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual 5.4 © Copyright .0 x 25 (QTY. Clutch - i Fastener.M6 x 1. Clutch - u Lever. Shaft (Shift Shaft / Clutch Pinion Shaft) - r Bearing. Clutch Lever .

Compensator — M12 x 80 (QTY.5 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 5.0 x 12 (QTY. Compensator - u Slider.3) 88 in-lbs (10 Nm) f Stator - 9927618 R03 .1) 83 ft-lbs (112 Nm) w Fastener. Locking Plate — M6 x 1. Stator — M6 x 1. Compensator - s Rotor. Compensator - t Spring Cup. CLUTCH / PRIMARY / SHIFT T O R Q U E C O M P E N S AT O R 5 NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Fastener. Compensator - y Spring.0 x 35 (QTY. Compensator - i Gear. Stator - d Fastener. Compensator - o Washer - a Sleeve.2) 88 in-lbs (10 Nm) e Locking Plate - r Spring Retainer.

Clutch Rack - r Clutch Rack - t Stake Nut. Clutch Bearing - 9927618 R03 . Seperator (A) - f Plate.5 125 ft-lbs (170 Nm) y Belleville Spring (QTY. Judder Spring - k Spring. Needle - 2# Collar.M20 x 1. Clutch (QTY. Clutch - a Spring.6 © Copyright . Clutch Rack - w Plate.M6 x 1. Clutch . Clutch Lifter - e Bearing.5) 88 in-lbs (10 Nm) o Pressure Plate.2017 Indian Motorcycle (Full-Size) Service Manual 5. Friction (B) - g Plate.CLUTCH / PRIMARY / SHIFT CLUTCH NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Retaining Ring. Friction (C) - j Seat. Pressure Plate .5) - s Plate.1) - i Fastener. Friction (A) - d Plate. Judder - l Clutch Hub - 1( Thrust Washer - 2) Clutch Basket - 2! Gear - 2@ Bearing.1) - u Washer. Flat (QTY. Seperator (B) - h Plate.0 x 45 (QTY.

Removal. page 2. Remove the shim r from the end of the shift shaft noting position for reassembly. Remove the external snap ring w from the clutch cable and withdraw from the mounting boss. CLUTCH / PRIMARY / SHIFT SERVICE PROCEDURES P R I M A R Y C O V E R R E M O VA L 7.9. 8. Remove primary cover fasteners e . 5 10. 5. Release the clutch cable end from the clutch arm. page 7. 2.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 5. See Engine Oil / Filter Change. 3.7 . Place motorcycle in an upright position with the front wheel clamped in a wheel vise. 9927618 R03 .18 4. 1. 9. Tap cover with a soft face mallet to loosen. 6. See Floorboard (Driver). Pull primary cover outward evenly at front and rear of cover to remove. Remove LH floorboard and shift linkage as an assembly. Remove clutch arm fastener q and remove clutch arm from shaft. Drain oil from engine.

Drive seal into place with a suitable driver. 4.2017 Indian Motorcycle (Full-Size) Service Manual 5. 1. Remove the Primary Cover.CLUTCH / PRIMARY / SHIFT 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 E-clip q and washer from the end of Shaft Removal.8 © Copyright . 2. Replace bearings that feel rough. Apply engine oil to the bearings. Temporarily install pinion shaft into primary cover. Remove clutch pinion shaft. Carefully pry seal q out of primary cover. Lubricate outer edge of new seal with engine oil the primary cover. notched. See Clutch Pinion 2. CLUTCH PINION SHAFT BEARING INSPECTION 1.7. 9927618 R03 . page 5. 2. page 5. See Primary Cover I N S TA L L AT I O N Removal. and sealing lip with grease. the clutch pinion shaft as shown.8. 3. Turn shaft by hand. Slide the pinion shaft w out through the bottom of 3. 3. or loose.

Lubricate and install clutch pinion shaft q until 1. See Clutch Removal. Using a 10 mm socket. 9927618 R03 . page 5. Install washer w and E-clip e . remove the fastener q securing the shift star w to the shift drum and remove shift star. See Primary Cover Removal. 3. 4. 2. Shift transmission into neutral. Remove primary cover. 2. page 5. 5 6.9 . front wheel clamped in a wheel vise. remove the fastener r securing the detent lever to the engine case and remove lever. 5.7. Place motorcycle in an upright position with the fully seated in bearings. Using a 4 mm hex wrench. Rotate the detent lever e so the spring is relaxed.14. CLUTCH / PRIMARY / SHIFT 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 1.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 5. Remove clutch assembly.

8. 13. tension to keep the shift shaft centered. 10.CLUTCH / PRIMARY / SHIFT 7. Pull the shift lever and spring assembly t out of 11. Inspect shift shaft u for wear or damage. Inspect fit of rivet o on shift ratchet assembly. 9. Inspect shift shaft return spring y for cracks or loss of tension. The spring should have enough 12. Inspect shift star a . 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual 5. Inspect spring d for cracks or fatigue. Inspect coil spring i for tension. It the bore. The spring should apply enough tension on the shift ratchet mechanism to keep it engaged with the shift star. Inspect detent roller arm s for wear or damage.10 © Copyright . should allow for free movement. but not be excessively loose. 14.

Install clutch assembly. 2. Install detent roller arm e with spring.0 Nm) NOTE Be sure the washer is in place between the shift 4. Torque fastener to specification. page 5. Torque fastener to specification.11 . page 5. TORQUE 5 Shift Star Fastener: 88.5 in-lbs (10.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 5. ratchet and the crankcase upon installation. roller fastener w. See Primary Cover Installation.12.19. 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. Install the primary cover. Rotate the detent arm and ratchet arm out of the 1. that the spring pin w is located between the return spring arms. See Clutch Installation. Apply Loctite 242 (Blue) to clean threads of detent 5. Make sure fastener t. TORQUE Detent Roller Fastener: 89 in-lbs (10 Nm) 9927618 R03 . CLUTCH / PRIMARY / SHIFT S H I F T R AT C H E T I N S TA L L AT I O N 3.

7. 4. Clean gasket surfaces of crankcase and cover. Removal. Carefully pry shift shaft seal q from cover. Moly assembly paste PN: 2871460 5. Drive seal into place with a seal driver slightly smaller than the O. 9. 7. Apply assembly lube to inner & outer surfaces of new bearing. 6. 3. After installing primary cover.CLUTCH / PRIMARY / SHIFT SHIFT SHAFT BEARING & SEAL REPLACEMENT P R I M A R Y C O V E R I N S TA L L AT I O N 1. of seal. page 5.2017 Indian Motorcycle (Full-Size) Service Manual 5.12 © Copyright . Using a suitable arbor and arbor press. rests on snap ring w.D. press bearing w from inside of cover to outside. Apply a thin layer of grease to the shift shaft seal. 4. See Primary Cover Installation. be sure shift shaft returns freely to the centered position after rotating up or down. 3. page 5. Install a new primary cover gasket. 9927618 R03 . Apply a small amount of grease to lip of seal and apply engine oil to outside of seal. 5. 2. Install the thrust washer q onto the shift shaft so it 2. 8. See Primary Cover 1. 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. Press bearing into place with numbered side out until fully seated. Remove primary cover.12. Install the primary cover so the clutch arm is angled correctly and install primary cover fasteners so they are finger tight. Install primary cover.

13 . Torque the primary cover fasteners to specification following the torque sequence. CLUTCH / PRIMARY / SHIFT 6.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 5. TORQUE Primary Cover Fasteners: 15 ft-lbs (20 Nm) Primary Cover Torque Sequence 5 9927618 R03 .

Using an internal snap ring pliers. CAUTION Clutch is under spring pressure. page 5. Remove clutch rack. C L U T C H R E M O VA L 1. A new stake nut must be installed upon assembly. 6. page 5. 1. INSTALLATION: Reverse the removal procedure to install. See Primary Cover Removal. Discard the stake nut. Removal / 3. 5. Remove clutch nut q .14 © Copyright . Remove fasteners and Service. With the clutch assembly resting on a clean.41. Remove clutch assembly from clutch shaft. Remove primary cover.14. alternately loosen the five pressure 3. 2. See Locking the Crankshaft for tension has relaxed. and flat washer e. remove snap ring q and clutch rack w. 9927618 R03 . WEAR EYE PROTECTION.CLUTCH / PRIMARY / SHIFT CLUTCH SERVICE C L U T C H R A C K . springs. page 5. Perform the crankshaft locking procedure plate fasteners e in a star pattern until spring METHOD 2. 4.14. R E M O VA L / I N S TA L L AT I O N C L U T C H D I S A S S E M B LY 1. See Clutch Removal. Remove the clutch. Remove the sleeve q and needle bearing w from the back side of the clutch assembly. 2. Belleville washer w .7. page 3. See Clutch Rack. flat Installation.2017 Indian Motorcycle (Full-Size) Service Manual 5. 2. work surface.

5. Remove thrust washer y. Remove Friction Plate A u. See Clutch. 6. 5 PART DESCRIPTION QUANTITY Friction Plate A (TOP) 1 Friction Plate B (MIDDLE) 5 Friction Plate C (BOTTOM) 1 Seperator Plate A (TOP) 2 Seperator Plate B 4 (BOTTOM) Spring.6. Judder Clutch 1 Seat. Remove pressure plate r. Judder Clutch 1 7. NOTE The clutch assembly consists of three different types of friction plates and two different types of seperator plates. Friction Plate B o and Seperator Plate A i .15 . 9927618 R03 . page 5. Lift the clutch assembly t out of the basket and set aside. Seperator Plate A i .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 5. CLUTCH / PRIMARY / SHIFT 4.

16 © Copyright . Judder Spring f and Judder Spring Seat g . Alternately remove Friction Plates B a and CLUTCH INSPECTION Seperator Plates B s . and outer basket. Lubricate bearing e with engine oil. Clean clutch plates. cracks or damage. 4. 6. Replace parts that fail inspection 5. 9. Remove Friction Plate C d . Inner race should have no detectable radial movement. 9927618 R03 .CLUTCH / PRIMARY / SHIFT 8. Clutch Hub 7. 3. Clutch Basket 2. Inspect spline teeth r for wear. Inspect clutch gear teeth q for wear. Rotate hub bearing. cracks or damage.2017 Indian Motorcycle (Full-Size) Service Manual 5. Inspect inside surfaces w of basket for cracks or wear (grooves) from clutch plates. 1. Check for smooth rotation. inner hub.

008 in (.126 in (3. Inspect clutch rack for broken or damaged teeth. 9927618 R03 . Thickness should be the same at each place. Check all posts y for cracks or damage. or damage. scoring. Inspect plates for distortion by placing each plate on a precision flat surface.17 . or wear on friction surface. Replace plates that fail inspection.20 mm) 11. Insert a feeler gauge between plate and flat surface in several places. MEASUREMENT Clutch Steel Plate Warp Service Limit: . Inspect clutch springs for cracks or distortion. distorted or discolored. 9. Replace clutch rack assembly if necessary. 5 10. 15. Rotate bearing inner race with your finger and check for smooth movement and no play.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 5. 14.2 mm) Clutch Pressure Plate 12. Clutch Release Rack and Bearing NOTE Clutch rack is serviceable as an assembly only. MEASUREMENT Friction Plate Thickness (Minimum): . Inspect lifter bearing visually for any signs or wear or discoloration. CLUTCH / PRIMARY / SHIFT 8. Inspect surface of steel plate guides t on outer 16. Replace plates as a set if any plate is worn or damaged. Measure thickness of friction plates in several places. Visually inspect friction and steel plates for wear or damage on both surfaces. Clutch Springs 13. Replace steel plates if grooved. edge of hub for wear. Inspect pressure plate for cracks. grooves.

9. then judder spring. NOTE Refer to the Clutch Assembly View outlined in this chapter for clutch plate orientation. page 5. Install the thrust washer q and the clutch hub w into the clutch basket. See Clutch.CLUTCH / PRIMARY / SHIFT C L U T C H A S S E M B LY 5. 7. The tallest edge of spring will be outermost. 6. 4. Apply engine oil to hub bearing s . NOTE Judder spring must be installed with concave side facing UP (toward outside of clutch). soak them in clean engine oil for a few minutes before installing. Apply engine oil to judder spring seat e and spring r . Continue stacking oiled clutch plates into clutch basket alternating Friction Plate B y and Seperator Plate B u stopping at the fourth Friction Plate B. Place an oiled Seperator Plate B into clutch basket.6. 2. 1. There should be one Friction Plate B remaining.18 © Copyright .2017 Indian Motorcycle (Full-Size) Service Manual 5. 8. 9927618 R03 . 3. Install the final Friction Plate A a . NOTE If friction plates are new. Apply engine oil to Friction Plate C t and install. Install judder spring seat (flat ring). Install Seperator Plate A i followed by Friction Plate B o and Seperator Plate A i .

CLUTCH / PRIMARY / SHIFT 10.41. Slide the clutch assembly onto the transmission input shaft until fully seated. 11. page 5. Check engine oil and fill to proper level. page 3. 2. Install primary cover. a new spring washer w and a new stake nut e . 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. 5 3. TORQUE Clutch Stake Nut: 125 ft-lbs (170 Nm) 12. Install the pressure plate f and clutch springs and fasteners g . Install the hub bearing and sleeve d into the C L U T C H I N S TA L L AT I O N clutch assembly.19 .12. See Clutch Rack. Torque clutch spring fasteners to specification. Install washer q . 1. 4. See Locking the Crankshaft for Service. Torque the stake nut to specification. Install clutch rack assembly. page 5. 5.14. See Primary Cover Installation. 7. 9927618 R03 . TORQUE Removal / Installation. Lock the crankshaft using Method 2. Clutch Spring Fasteners: 89 in-lbs (10 Nm) 6. IMPORTANT When installing clutch assembly on the input shaft. Alternately tighten the clutch spring fasteners in a star pattern until fully seated.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 5.

20 © Copyright . upper torque compensator ramp y and torque compensator drive gear u from the crankshaft.7. page 5. Removal. Some polishing will be evident between the compensator gear and the compensator slider and is 3. Inspect all parts for excessive galling or damage. Remove the two fasteners q . 2. See Locking the Crankshaft for Service. locking plate w .CLUTCH / PRIMARY / SHIFT T O R Q U E C O M P E N S AT O R S E R V I C E T O R Q U E C O M P E N S AT O R R E M O VA L T O R Q U E C O M P E N S AT O R I N S P E C T I O N 1. MEASUREMENT Compensator Spring Stack Height: 1. retainer assembly r from the crankshaft. NOTE 2. Perform crankshaft locking procedure METHOD 2.5 mm) 9927618 R03 . See Primary Cover 1. Replace assembly if ramps are torque compensator fastener e and spring worn. page 3. a normal condition. Remove primary cover.5–37.2017 Indian Motorcycle (Full-Size) Service Manual 5. Measure free length of torque compensator spring stack.437–1.41. 4.476 in (36. Remove the spring pack t .

Fill engine oil to proper level. Apply engine oil to shaft splines. TORQUE Compensator Fastener: 83 ft-lbs (112 Nm) 8.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 5. Install the torque compensator gear e and upper ramp r . Lock the crankshaft for service using Method 2. installation. washer. 7. page 3. See Locking the Crankshaft for Service. CLUTCH / PRIMARY / SHIFT 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. 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. Install the splined sleeve q . Slide the torque compensator spring assembly 1. See Primary Cover Installation. TORQUE Compensator Fastener Locking Plate: 88 in-lbs (10 Nm) 9. Install compensator locking plate and fasteners i and torque to specification. 4. page 5. Apply Loctite 262 to compensator fastener and torque to specification. flange side down. valleys and sliding ramps before fully seated. 2. sleeve. Install primary cover.12. 10.41. over the crankshaft followed by thrust washer w .21 . 6. onto the crankshaft until the drive plate splines are peaks. 5 3. 9927618 R03 .

2. Remove torque compensator assembly. Install torque compensator. page 5. 9927618 R03 . Remove clutch assembly.14 3. Removal.12. 6. page 5.2017 Indian Motorcycle (Full-Size) Service Manual 5. 6. 1. 3. personal injury. See Torque Compensator Installation. threaded holes on flywheel r.19. flywheel w and install onto crankshaft. page 5. page 5. Grasp the two fasteners and lift the flywheel off of the stator.21. Thread two primary cover fasteners q into the 2.7.22 © Copyright . page 5. See Primary Cover 1. Install primary cover. Thread two primary cover fasteners e into Installation. 4. Install clutch assembly. Remove thrust washer q and compensator sleeve w. See Primary Cover 5.20. 5.CLUTCH / PRIMARY / SHIFT 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. See Torque Compensator Removal. Clean rotor and crankshaft thoroughly. page 5. Remove primary cover. See Clutch Removal. See Clutch Installation. Use caution The flywheel contains powerful magnets. 4. Use caution when lifting flywheel off of stator to avoid personal when installing flywheel onto crankshaft to avoid injury. Check engine oil and add as necessary.

CLUTCH / PRIMARY / SHIFT PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Clutch lever pivot. Oil viscosity too high Oil quality Replace oil & filter creeping) Pressure plate worn. Lever. Driven plates and / or Replace warped or distorted drive plates Weak clutch springs Clutch springs Replace 9927618 R03 . pivots. 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. CLUTCH / PRIMARY / SHIFT TROUBLESHOOTING.23 . Inspect or lifter arm sticking bearings. 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. pivot. Pressure plate Replace warped or distorted Clutch plate(s) worn. cable. Clutch Friction / Replace plates as 5 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.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 5. bushings.

2017 Indian Motorcycle (Full-Size) Service Manual 5.24 © Copyright . 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 9927618 R03 . shift cam Replace bearings that fail bearings inspection Worn gear shift pawl ratchet Shift pawl mechanism Replace parts that fail mechanism inspection Broken or dislodged shift Shift shaft return spring Repair or replace shaft return spring Roller detent arm stuck Roller detent arm Repair or replace parts Bent shift shaft (internal) Shift shaft Repair or replace External shift linkagebinding External shift linkage Repair or replace or damaged Bent or distorted shift forks Shift fork Replace Bent or distorted shift fork Shift fork rail Replace rails Broken transmission Transmission components Repair or replace components Transmission Hard to Improper clutch operation Clutch Inspect. Adjust adjustment Shift shaft damaged Shift shaft components Repair or replace Sticking pivot point. repair Shift Incorrect oil viscosity Oil quality Replace engine oil Incorrect clutch cable .CLUTCH / PRIMARY / SHIFT 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.

. . . . . . . . . . . . . . . . . . . . . . . . .20 STARTER DRIVE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 LEFT CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 CRANKCASE ASSEMBLY . . . . . . . . .6. . . . . . . .6. . . .30 CONNECTING ROD REMOVAL / IDENTIFICATION . . . . . .16 INNER CAM CHAIN COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . .7 CRANKCASE FASTENER LENGTH AND TORQUE PATTERN . . . . . . . . . . . . . . . . . . .39 9927618 R03 . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 CRANKCASE . . . . . . . . . . . . .19 STARTER DRIVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . .26 TRANSMISSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION / CRANKSHAFT CHAPTER 6 TRANSMISSION / CRANKSHAFT GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 STARTER DRIVE INSPECTION . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 CRANKSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . . . . . .6. . . . . . . . .9 SHIFT DRUM / SHIFT FORK . . . . . . . . . .23 TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 BALANCE SHAFT SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . .6. .21 CRANKSHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 BALANCE SHAFT INSTALLATION . . . . . . . . . . . . . . . . .36 RIGHT CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . .31 CONNECTING ROD BEARING CLEARANCE INSPECTION . . . . . . . . . . . . .6. . . . . .31 CONNECTING ROD BEARING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 ASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 BALANCE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . .3 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . .6 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . .34 CRANKSHAFT CLEANING . . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . .35 MAIN BEARING OIL CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . .31 CONNECTING ROD BEARING SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . 6. . . . . . . . . . . . . . . .34 CONNECTING ROD INSTALLATION . 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 GEAR TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 CONNECTING ROD INSPECTION (BIG END) . . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 BALANCE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . .35 MAIN BEARING INSPECTION . . . .20 STARTER DRIVE REMOVAL. . . . . .33 CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . .6. . . . 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 CONNECTING ROD SIDE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . .17 6 INNER CAM CHAIN COVER INSTALLATION . . . . . 6. . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .TRANSMISSION / CRANKSHAFT STAKE NUT INSTALLATION . . . . . . . .42 TROUBLESHOOTING . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 © Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2017 Indian Motorcycle (Full-Size) Service Manual 6. . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . . .43 9927618 R03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

service-solutions. • Label and store parts neatly to speed the assembly process and ensure that matched parts like connecting rods. • The crankcase must be separated to access internal transmission components and crankshaft.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 6.com/ 9927618 R03 . This procedure requires full machine shop capabilities and specialized knowledge. See ENGINE REMOVAL. TRANSMISSION / CRANKSHAFT 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. camshafts and bearings and pushrods can be installed in their original location • Crankshaft main bearing replacement requires line boring.3 . Refer to exploded views • When locking agents are required. use Loctite® Primer N to clean fastener before applying locking agent Primer N reduces cure time of thread locking agent in addition to preparing the surfaces 6 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. • All torque specifications are "dry" unless specified for oil or locking agent. 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”).

1653 ..8891") Main Bearing Oil Left .46 mm (1.01 .1..008 mm 55.42..979 mm - (Cam Side) 9927618 R03 .9273 mm (2.2.. (White) (2.01 ..992 mm / Side) / Journal O.060 mm .8694") I.0635 mm .02 mm 22.1.0087 . Right 24.D.3595") O.0469 .001 .980 .038 mm (2.0080 mm 51. (.D.2.21.4 © Copyright .9703 mm 59.9523 .D.8310") Connecting Rod Big End 54.013 .627") Bearing / Rod Journals Width (1.8670") Connecting Rod Width 21.0460") O.2.9323 mm (2.1665") I.3610") Right Main Bearing Journal 64.9999 mm 51.1653") Connecting Rod Big End 55.50 mm 43.000 .0025") Connecting Rod Small End 22.000 mm 55.52.030 mm (2..9523 .670 .5561") O..30 mm Crankshaft End Play - (.22.5571 .2.9620 mm (2.11 mm 20.992 .76 mm (.42 mm .65 mm (.D.22 .TRANSMISSION / CRANKSHAFT 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 ..673") Crankshaft Rod Journal 51.2.. (2.2017 Indian Motorcycle (Full-Size) Service Manual 6.0005 .9920 .24.D.55.0043") Crankshaft Oil Clearance (..24.D.D.1656") Crankshaft Main Connecting Rod Journal 42.0023") Right .8271 .11 mm (.8173") (. (Red) (2.10 mm (..061mm (..0457") O.55.9703 mm 64.D. (2.8665 .0254 .014 .970 mm (2.0165") Connecting Rod Bearing to .8888 .1668") I.05 .42 .D.59.64. (White) (2. Left (Primary 24.09 mm (.0118") Balance Shaft Journal O.004") Clearance (.51.025") Crankshaft Side Clearance (.. (Red) (1.0024") Left Main Bearing Journal 59.1650 .0019 ..0005 .5578") .0472") Crankshaft Rod Journal 52.3603 .0000 .969 .

001") Shift Drum Shift Drum Groove .05 mm (.2376 .10: 1 Gear Ratio: 5th Gear ..56: 1 Final Reduction Ratio 2. (.4744") Shift Fork I..73: 1 Gear Ratio: 2nd Gear 1.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 6.948 .D.81: 1 9927618 R03 ..D. (. Replace drum if any wear is evident ITEM SPECIFICATIONS Drive Train (General) Transmission 6 Speed (Overdrive) Primary Reduction Ratio 1.4713") Shift Fork Rail Runout .036 .6.136 mm 6.11.2416") Shift Fork Rail 11.86: 1 Gear Ratio: 3rd Gear 1.972 mm 11.4704 .4693") Shift Fork Rail O.12.00 .4725 .2: 1 Drive Train (Gear Ratios) Gear Ratio: 1st Gear 2. (Rail) (.02 mm (.38: 1 6 Gear Ratio: 4th Gear 1.92 mm (.026 mm 12. .025 mm (. TRANSMISSION / CRANKSHAFT Transmission Specifications ITEM PART SPECIFIC STANDARD SERVICE LIMIT Shift Fork 12.4732") 6.5 .94: 1 Gear Ratio: 6th Gear (Overdrive) 0.2370") Shift Fork Pin O.D.

6) 22 ft-lbs (30 Nm) e Bearing. Bearing — y Bearing. Crankcase — M8 x 1. LH — 1( Bearing. Transmission Output Shaft — s Retainer Plate.8 x 12 (QTY.8 x 10 (QTY. Bearing — d Bearing.6 © Copyright . Piston Cooling Jet — M5 x 0. Transmission Input Shaft — g Retainer Plate.25 x 110 (QTY. Bearing Retainer – M5 x 0. Bearing — h Bearing.TRANSMISSION / CRANKSHAFT A S S E M B LY V I E W S CRANKCASE NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Fastener. Shift Drum — f Bearing. Crankcase — M8 x 1. Shift Drum — j Bearing. RH — o Fastener.16) 62 in-lbs (7 Nm) t Retainer Plate. Shift Shaft — 9927618 R03 .2) 62 in-lbs (7 Nm) a Bearing.25 x 100 (QTY. Balance Shaft — u Bearing. Camshaft — r Fastener. Crankshaft (Primary Side) — Non-Serviceable — k Bearing. Crankshaft (Camshaft Side) — Non-Serviceable — i Crankcase.2017 Indian Motorcycle (Full-Size) Service Manual 6. Transmission Input Shaft — l Crankcase.12) 22 ft-lbs (30 Nm) w Fastener.

Crankshaft Main (RH) — Non-Serviceable — w Fastener.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 6. — Serviceable u Fastener. Piston — a Circlip. Connecting Rod Bearing Cap (QTY. TRANSMISSION / CRANKSHAFT CRANKSHAFT 6 NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Bearing.7 . Crankshaft Main (LH) — Non-Serviceable — o Wrist Pin. Connecting Rod (big end) — t Piston — y Tone Ring. Crankshaft Position Sensor — Non.4) 22 ft-lbs (30 Nm) e Bearing Caps.M8 x 1. Connecting Rod — r Bearings.3) 18 ft-lbs (24 Nm) i Bearing. Tone Ring .25 x 16 (QTY. Wrist Pin — 9927618 R03 .

3. 11. 13 & 15 use Long fasteners. TORQUE Crankcase Fasteners: 22 ft-lbs (30 Nm) 9927618 R03 . Torque case fasteners to specification following the torque sequence.2017 Indian Motorcycle (Full-Size) Service Manual 6. All other items use Short fasteners.TRANSMISSION / CRANKSHAFT 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 NOTE Items 1. 4.8 © Copyright .

5th — Drive e Bearing. 2nd — Drive a Snap Ring 9927618 R03 . Gear Dog y Gear Dog.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 6.9 . 4th — Drive o Gear. TRANSMISSION / CRANKSHAFT TRANSMISSION Input Shaft 6 NUMBER DESCRIPTION q Input Shaft. 5th Gear r Bearing. 5th & 6th u Gear. 6th — Drive i Gear. 6th Gear t Slider. Transmission w Gear.

Gear Dog y Gear Dog u Gear.TRANSMISSION / CRANKSHAFT Output Shaft NUMBER DESCRIPTION q Snap Ring w Spacer e Gear.2017 Indian Motorcycle (Full-Size) Service Manual 6.10 © Copyright . Transmission 9927618 R03 . 3rd — Driven i Bearing o Gear. 1st — Driven r Bearing. 2nd — Driven f Bearing. 4th — Driven d Gear. 1st Gear t Slider. 5th — Driven a Gear. 2nd Gear g Output Shaft. 6th — Driven s Gear.

1st & 3rd i Shift Fork.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 6. Shift Drum — Primary Side u Shift Fork. 5th & 6th t Shift Rail y Bearing. TRANSMISSION / CRANKSHAFT SHIFT DRUM / SHIFT FORK 6 NUMBER DESCRIPTION q Bearing. Gear Dog r Shift Fork. Shift Drum — Drive Sprocket Side w Gear Dog e Slider. 2nd & 4th o Shift Drum 9927618 R03 .11 .

Balance Shaft (Outer) — Non-Serviceable - t Springs.12 © Copyright .5 x 40 59 ft-lbs (80 Nm) (QTY.8 x 12 62 in-lbs (7 Nm) (QTY.2017 Indian Motorcycle (Full-Size) Service Manual 6. Balance Shaft - o Balance Shaft - 9927618 R03 .1) w Washer - e Snap-Ring. Balance Shaft Split Gear - r Gear. Pre-Load — Non-Serviceable - y Gear.TRANSMISSION / CRANKSHAFT BALANCE SHAFT NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Fastener.3) i Bearings. Bearing Retainer Plate — M5 x 0. Balance shaft (Inner) — Non-Serviceable - u Fastener. Balance Shaft Gear — M10 x 1.

TRANSMISSION / CRANKSHAFT GEAR TRAIN 1st Gear 6 2nd Gear 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 6.13 .

TRANSMISSION / CRANKSHAFT 3rd Gear 4th Gear 9927618 R03 .14 © Copyright .2017 Indian Motorcycle (Full-Size) Service Manual 6.

2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 6. TRANSMISSION / CRANKSHAFT 5th Gear 6 6th Gear 9927618 R03 .15 .

Bearings should run smooth and quiet and shaft should be a snug fit in bearing. 4. Remove the fastener q and balance shaft gear w . 6. 5. Remove the inner cam cover. Inspect sprocket teeth for wear or damage. or twisting. Check shaft for runout. inner cam chain cover w. page 6. 2. page 6.16. See Inner Cam Chain Camshaft Carrier Removal. Separate the engine cases. Visually inspect bearings for damage. page 3. Rotate right and left balance shaft bearings by hand while observing bearing rotation. 3. 9927618 R03 .23. 7.TRANSMISSION / CRANKSHAFT 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 1.2017 Indian Motorcycle (Full-Size) Service Manual 6. Rotate balance shaft e until counterweights are clear of crankshaft. See Crankcase Separation. Grasp balance shaft and remove it from case.16 © Copyright . Remove inner cam chain cover fasteners q and 2. 8. Remove the camshaft carrier assembly.47. See 1. Cover Removal. IMPORTANT Be sure to collect the woodruff key from the end of the balance shaft once the gear has been removed.

Install the balance shaft drive gear and torque fasteners w to specification. or other suitable tool. balance shaft so the timing marks r are aligned as shown. 9.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 6. Thread the driven balance shaft gear fastener t in until seated. 9927618 R03 . Fit the driven balance shaft gear to the end of the 1. page 6. See Locking the Crankshaft for Service. Place the woodruff key into the end of the balance shaft. page 6. See Crankcase Assembly. TORQUE Balance Shaft Drive Gear: 10 ft-lbs (14 Nm) 6. 2. Woodruff key slot should be facing the cam side of the engine.21. 3. Install the starter drive. 4.41. Place a pin punch.39. 7. TRANSMISSION / CRANKSHAFT B A L A N C E S H A F T I N S TA L L AT I O N 8. Lock the crankshaft for service using Method 1.17 . See Starter Drive Installation. Assemble the engine cases. through hole e and preload split gear teeth so they are aligned. Insert the balance shaft q into the primary side bearing until fully seated. 10. TORQUE Balance Shaft Driven Gear: 59 ft-lbs (80 Nm) 11. Lubricate balance shaft bearings with engine oil. page 3. 6 5. Torque the driven balance shaft gear fastener to specification.

19. Install the inner cam cover. 9927618 R03 . See Inner Cam Chain Cover Installation. Install the spacer y onto the crankshaft.TRANSMISSION / CRANKSHAFT 12.18 © Copyright . 13. page 6.2017 Indian Motorcycle (Full-Size) Service Manual 6.

Clean inner cam chain cover and crankcase mating surfaces with a residue-free degreaser. 4. 9927618 R03 . 2. Install the camshaft carrier assembly. page 3.53.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 6. 3. TORQUE Inner Cam Chain Cover Fasteners: 15 ft-lbs (20 Nm) 5.19 . Apply Loctite flange sealant PN: 8560070 to cover and assemble to crankcase. Thread inner cam chain cover fasteners into crankcase so they are finger tight. See Camshaft Carrier Installation. TRANSMISSION / CRANKSHAFT 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. Tighten inner cam chain cover fasteners following the specified torque sequence.

scoring or damage. Inspect shaft surfaces q and bushing surfaces w lifting the shaft and gear out as an assembly. 4. Remove the torque limiter clutch r and shaft as an assembly.013 mm One-Way Clutch Hub O. 2.007 mm 5.38 mm ±. (Flywheel): 51.D.16.D of the balance shaft gear bearing surface t and the O. 4. Replace gear if wear or damage is evident. page 6.D. Remove the starter drive reduction gear q by 2.71 mm ±. (Balance Shaft Gear): 68. Lift the sprag gear w and one-way clutch e off of 3. cracks or excessive Cover Removal.20 © Copyright . of the flywheel bearing surface y and compare to specification. See Inner Cam Chain 1.TRANSMISSION / CRANKSHAFT 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. e r for excessive wear and scoring. wear. Measure the I. Remove the inner cam cover. MEASUREMENT One-Way Clutch Hub I. 9927618 R03 . Inspect gear teeth for chips. wear. Inspect one-way clutch hub surfaces t y for the crankshaft as an assembly. 3.2017 Indian Motorcycle (Full-Size) Service Manual 6. D.

Install flywheel w over crankshaft and into the Install the starter reduction gear shaft t into 6 one-way clutch bearing until fully seated. crankcase bore followed by the reduction gear y . 4. The raised shoulder on the reduction gear should face the crankcase.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 6. 2. Install the torque limiter shaft e into the crankcase 1.21 . Install one-way starter clutch bearing q into the balance shaft gear hub. NOTE If previously removed. 9927618 R03 . NOTE Install starter clutch so the arrow is facing out. bore followed by the limiter clutch assembly r . TRANSMISSION / CRANKSHAFT S TA R T E R D R I V E I N S TA L L AT I O N 3. install starter motor at this time.

2017 Indian Motorcycle (Full-Size) Service Manual 6. 9927618 R03 . Check engine oil and fill to proper level. Install inner cam chain cover.TRANSMISSION / CRANKSHAFT 5. Install spacer u onto the crankshaft.19. 6. page 6.22 © Copyright . 7. See Inner Cam Chain Cover Installation.

4. page 5. page 3. Remove engine case fasteners.61. page 2. Remove lifters. See Torque PF-51234 on a flat surface and assemble the M6 Compensator Removal.47. page 4. 1. Remove flywheel. 15. Remove cylinders. Remove the balance shaft driven gear and drive gear.16. Remove primary cover. 17. page 8. Remove the starter drive. page 3.16. See Stator Removal. See Clutch Removal. 20. See Drive Sprocket Removal.48.22. Place the Engine Case Splitting / Assembly tool 8. See Inner Cam Chain Cover Removal. Remove the gear position switch.7. Remove the cam chain. 12.23 .14. 2. 16. Drain engine oil. See Cylinder Removal. page 10.30. page 6. page 5. page 3. page 6. See Camshaft Carrier Removal. Remove cylinder heads. See Engine Oil / Filter Change.45. See Lifter Removal. 3. page 6. Remove camshaft carrier assembly. See Primary Cover Removal.12. 14.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 6. marked with the letter A. Remove clutch assembly. See ENGINE REMOVAL. See Cylinder Head Removal. See Sensors — Powertrain Management. See Cam Chain Removal. 18.9. NOTE Collect the two switch contact pins and springs from the end of the shift drum so they do not get lost.20.20. page 5. Rotate the engine stand so the engine is lying flat with the output shaft pointing UP. page 3. See Starter Drive Removal. 5. 6 11. See Balance Shaft Removal. Remove torque compensator. into the main plate e as shown. threaded spacers q and M12 threaded spacer w 9. See Flywheel Removal. 7. 6. 9927618 R03 . Use only holes page 5.43. 10. Remove stator. Remove the inner cam chain cover. page 3. Remove the drive sprocket.76. 13. 21. Remove engine from frame. Mount engine securely on an engine stand using Engine Stand Adapter tool PF-51240. TRANSMISSION / CRANKSHAFT CRANKSHAFT SERVICE C R A N K C A S E S E PA R AT I O N 19.

Install M6 fasteners y and M12 fastener u into threaded spacers and torque to specification.TRANSMISSION / CRANKSHAFT 22. Main plate adjustment: Turn threaded spacers engine case as shown. • Plate height is correct when the plate is resting on the washer and the case splitting adapter contacts the transmission output shaft. lower and level the main should line up with the corresponding engine case plate.24 © Copyright .2017 Indian Motorcycle (Full-Size) Service Manual 6. 25. • All threaded spacers must be in contact with engine case prior to fastening on the plate assembly. 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. TORQUE Main Plate Mounting Fasteners (All): 88 in-lbs (10 Nm) 9927618 R03 . fastener holes. 23. The threaded spacers in or out to raise. Position the main plate assembly r onto the 24. IMPORTANT • Plate surface should be parallel to the surface of the engine crankcase.

STOP. 28. TRANSMISSION / CRANKSHAFT 26. Using a soft-faced mallet. 27.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 6. work around the seam of the engine cases tapping lightly to release the sealed bond. 6 9927618 R03 . Holding nut i stationary with an open ended wrench.25 . then work around the upper case with a mallet until the cases are completely apart. turn the case splitting adapter clockwise until the engine cases begin to part. Alternately turn the case splitting tool in until resistance is felt.

Lift the shift drum w out of the bearing. page 5. lift the input shaft e . 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual 6.16. output shaft CAUTION r . 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. 1. 4. Remove the balance shaft. Remove the shift ratchet assembly. As an assembly.TRANSMISSION / CRANKSHAFT T R A N S M I S S I O N R E M O VA L 5.26 © Copyright . 3. See Balance Shaft Removal. See Shift Ratchet Removal & Inspection. shift forks and shift fork rails t out of the engine case. 2. Gloves should be worn at all times while working on the transmission assembly to avoid personal injury. page 6.9.

32.987 — 28.035 mm r Input Shaft. 39.D. 5th Gear — I. 5th Gear — O.010 — 39. Clutch Collar Journal 29. 38.980 mm i Input Shaft.470 — 29.980 mm e Bushing. 39. 6th Gear — O.D.976 — 29.955 — 38.D.27 .026 mm u Bushing.485 mm t Input Shaft. (Press Fit) 27. 5th — I.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 6.884 — 27.909 mm 9927618 R03 . TRANSMISSION / CRANKSHAFT TRANSMISSION INSPECTION Input Shaft 6 NUMBER MEASUREMENT LOCATION DIAMETER SPECIFICATION q Gear.0 mm (Press Fit) o Gear. 2nd — I.D. 2nd Gear Journal 27.D.026 mm w Bushing.010 — 39. 6th — I. 38. Bearing Journal 29.955 — 38.990 mm (Primary Side) y Gear.010 — 32.D.

980 mm y Gear.010 — 39.955 — 38.015 — 28.980 mm e Bushing. 4th — I.D.008 mm Side) i Bushing.035 mm r Gear. 39.010 — 32. 28. 38.D.990 mm d Output Shaft.D. 2nd Gear — O. 3rd Gear — O.D.010 — 39.010 — 37.TRANSMISSION / CRANKSHAFT Output Shaft NUMBER MEASUREMENT LOCATION DIAMETER SPECIFICATION q Gear.987 — 28.980 mm o Gear. 32.026 mm w Bushing.955 — 38.026 mm t Bushing. 39. 1st— I.040 mm s Bushing.D.D. 2nd — I.955 — 38.010 — 39. 37. 36. 2nd Gear — I.026 mm u Output Shaft. 1st Gear — I. 1st Gear Journal 27.D.D.D. 1st Gear — O.2017 Indian Motorcycle (Full-Size) Service Manual 6.995 — 35.0 mm 9927618 R03 . 38. 39.965 — 36.28 © Copyright . Bearing Journal (Drive Sprocket 34.026 mm a Bushing. 3rd — I. 38. 4th Gear — O.D.

TRANSMISSION / CRANKSHAFT

NOTE 10. Inspect shift drum grooves for wear. Pay close
attention to corners of grooves where forks change
Refer to the Assembly View section in this chapter direction.
for component locations and exploded diagrams.
See Crankcase, page 6.6ASSEMBLY VIEWS, 11. Inspect surface of shift drum star for excessive
page . wear or damage.
Refer to the Service Specifications section in this 12. Inspect right side shift drum bearing.
chapter for complete transmission specifications.
See Service Specifications, page 6.4. 13. Temporarily install shift drum in right hand case
bearing and inspect fit. Spin drum to check for
smooth bearing operation.
Shafts
1. Measure outside diameter of shafts and bearing C R A N K S H A F T R E M O VA L
areas for wear and concentricity. Look closely at 1. Separate RH crankcase from LH case. See
splines for wear. Inspect ends of shafts for signs of Crankcase Separation, page 6.23.
wear:
• Dull finish 2. Rotate balance shaft q until counterweights are
• Discoloration clear of crankshaft.
• Rough or uneven surface
• Measurement outside of specification

Gears
2. Visually inspect:
• Gear internal splines


Gear teeth
Gear dogs for rounding, cracks, chips
6
• 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. Lift crankshaft assembly w straight up until clear
3. Inspect all contact surfaces of each shift fork. of case.
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 NOTE
loose in the bore, or if any side play is detected.
Connecting rod bearings and main bearings are
9. Temporarily install shift drum into bearing and easily damaged. Be careful not to cause damage to
rotate, checking for smooth bearing operation. these parts when servicing items within the
Shift Drum crankcase.

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CONNECTING ROD SIDE CLEARANCE C O N N E C T I N G R O D R E M O VA L / I D E N T I F I C AT I O N
INSPECTION
1. Move connecting rods to one side of crankshaft. NOTE
Insert a feeler gauge q between one connecting The connecting rod caps are marked with paint from
rod and the crankshaft. Compare measurement to the factory, however it is recommended that an
specification outlined in this chapter. See Service additional reference mark be added for clarity. Caps
Specifications, page 6.4. 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
direction as it was removed using the same
fastener.
2. Mark the outside of both connecting rods prior to
removal so they can be assembled in the same
direction in relation to the crankshaft.
2. If clearance recorded exceeds service limit, the
crankshaft, connecting rod or both must be
inspected and worn parts replaced. See
Crankshaft Inspection, page 6.34.

3. Remove connecting rod fasteners and connecting
rod bearing caps.

NOTE
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
rough in appearance, which is a normal condition
due to the manufacturing process. If rod caps are
installed incorrectly and tightened, the precision
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.
1. Refer to Piston Pin / Pin Bore Inspection, page 3.80 TORQUE
for connecting rod small end inspection. Connecting Rod Fasteners:22 ft-lbs (30 Nm)
CAUTION 4. Measure I. D. of connecting rod big end for size
Be sure to match connecting rod caps with their and out of round and compare to specification. See
respective rod and orient the cap properly before Service Specifications, page 6.4.
installing the cap. Secure the big end of rods in a vise 6
equipped with soft, protective jaws before torquing
rod fasteners.

5. Visually inspect connecting rod upper and lower
ends for scoring, damage, or excessive wear.

CONNECTING ROD BEARING INSPECTION
2. Remove bearings and install caps on connecting 1. Inspect bearing inserts for unusual wear, peeling,
rods. Be sure mating surfaces q of rod and cap are scoring, damage etc. Replace as a set if damage is
clean. noted. Inspect bearing clearance and refer to
Bearing Selection Chart. See Connecting Rod
Bearing Selection, page 6.33.

CONNECTING ROD BEARING CLEARANCE
INSPECTION
1. Assemble the connecting rod cap with bearings
and torque to specification.

TORQUE
Connecting Rod Fasteners:22 ft-lbs (30 Nm)

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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
Specifications, page 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.

CONNECTING ROD BEARING SELECTION CHART
6
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
Specifications, page 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.

NOTE
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, 6. Tighten rod cap fasteners:
damage or excessive wear.
TORQUE
4. Crankshaft and connecting rods are identified by
color. Be sure to compare measurements to Connecting Rod Fasteners: 22 ft-lbs (30 Nm)
specifications for the proper color (or non-
marked) connecting rod or crankshaft. 7. Check that the connecting rods rotate smoothly
Measure O. D. of crankshaft rod journal in four and freely on crankshaft journal.
places and compare to specifications.

5. Measure O.D. of main bearing journals.

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CRANKSHAFT CLEANING MAIN BEARING OIL CLEARANCE INSPECTION
1. Remove blind plug q from crankshaft to ensure 1. Measure main bearing I.D. and concentricity with
that passages are clear. a dial bore gauge for right and left side. Compare
to specification. Subtract crankshaft main journal
diameter from main bearing diameter to calculate
oil clearance. See Service Specifications, page 6.4.

2. After cleaning passages, install blind plug and
torque to specification. Plug should be flush with
surface of crankshaft.
2. If crankshaft dimensions are within tolerances and
TORQUE oil clearances are incorrect, the crankcase set
Blind Plug: 15 ft-lbs (20 Nm) must be replaced or new main bearings installed
and line-honed by a competent machinist. 6
NOTE
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 Crankcase, page 6.6. torque specification. See Crankcase, page 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.
• Press on outer race of bearings using an arbor press • Press on outer race of bearings using an arbor press
and a suitable arbor that is slightly smaller than and a suitable arbor that is slightly smaller than
bearing outside diameter bearing outside diameter.
• DO NOT press on inner race of ball bearings • DO NOT press on inner race of ball bearings.
3. Install bearing retainers as required and torque to 3. Install bearing retainers as required and torque to
specification. specification.
4. Install scavenge filter screen assembly. See
Lubrication System, page 3.26.
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
NOTE
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.
6
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
Crankcase, page 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 Installation,
page 6.17.
10. Instal oil pump assembly. See Oil Pump
Installation, page 3.29.
4. Lubricate parts with engine oil. Apply assembly
lube to ends of transmission shafts. 11. Install crankshaft. See Crankshaft Installation,
page 6.37.
5. Install input shaft r and output shaft t, shift forks
and rails y into the left crankcase. Make certain 12. Assemble crankcase. See Crankcase Assembly,
both shafts are fully seated and rotate freely. page 6.39.

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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.

6
4. Remove the drive sprocket spacer w and o-ring e
from the RH crankcase prior to installation.

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7. Install the main plate assembly a to the RH 8. Apply a light even bead of LoctiteTM Ultra Black
crankcase and torque fasteners to specification. 598 to entire case sealing surface.

9. Spread sealant into a thin even layer on entire case
IMPORTANT mating surface. Be sure all areas are covered. DO
NOT ALLOW SEALANT TO DRY. CONTINUE
• Plate surface should be parallel to the surface of ASSEMBLY UNTIL CASES ARE SEALED AND ALL
the engine crankcase. FASTENERS ARE TIGHT.
• All threaded spacers must be in contact with
engine case prior to fastening on the plate 10. Lower the RH case onto the LH case and install the
assembly. case installation adapter onto the transmission
output shaft.
11. Pull crankcase together by tightening nut and
tapping on crankcase with a soft mallet.

NOTE
The cases will mate before the output shaft is drawn
fully into bearing. IMPORTANT! Continue to turn nut
and tap case until sealant squeezes out along the
entire perimeter and resistance is felt when turning
nut.

12. Remove the tool.
13. Install crankcase fasteners and torque to
specification. See Crankcase Bolt Length And
Torque Pattern, page 6.8.
14. Install a new output seal in RH crankcase using
TORQUE seal installer PF-51243.

Main Plate Mounting Fasteners (All): 88 in-lbs (10 15. Install the o-ring and drive sprocket spacer
Nm) removed in STEP 4 with tapered edge toward the
o-ring.
16. Install the gear position switch. See Sensors —
Powertrain Management, page 4.12.
17. Install the drive sprocket. See Drive Sprocket
Installation, page 8.51.
18. Install the balance shaft driven gear and drive
gear. See Balance Shaft Installation, page 6.17.
19. Install the starter drive. See Starter Drive
Installation, page 6.21.

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See Lifter Installation. 26.21. Install cylinder heads. See Inner Cam Chain Cover Installation. page 3. See Torque Compensator Installation.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 6. 28.82.19. 6 31. 30. Install lifters.67. Install engine in frame. Install the flywheel.44. See Flywheel Installation. 22.53. See Cylinder Head Installation. page 3. page 5. page 3. 21. Install the torque compensator. page 6.22. See Cylinder Installation. page 3. 24. Install the primary cover. See Engine Installation.12. Install the inner cam chain cover.46. Install the cam chain. 29. 23. page 3.41 . See Cam Chain Installation. TRANSMISSION / CRANKSHAFT 20. See Stator Installation. 9927618 R03 .19. page 5. page 3. page 10.17. Install the camshaft carrier assembly. See Camshaft Carrier Installation. See Primary Cover Installation. Install the stator. 27. Install the clutch assembly. 25.31. Install cylinders. See Clutch Installation. page 5. page 5.

Use the following procedure to install the stake nuts correctly: 1. Stake the stake nut as shown below using round correctly for proper function side of punch. Torque stake nut to specification. • It is important that they are torqued and staked 4.2017 Indian Motorcycle (Full-Size) Service Manual 6. A new stake nut needs to be installed every time the nut is removed or loosened. IMPORTANT Do not reuse or reinstall any previously used stake nut. 9927618 R03 .42 © Copyright . Thread NEW stake nut onto shaft finger tight. • The Stake nut is located on the clutch side of the 3. Do not use a sharp chisel to stake the nut.TRANSMISSION / CRANKSHAFT S TA K E N U T I N S TA L L AT I O N 2. transmission input shaft. Do not crack or tear staking lip. Clean threads on shaft so there is no oil or contaminants.

Piston Worn. Cam Refer to Engine / Cooling Sprocket / Exhaust chapter 9927618 R03 . Flywheel.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 6. Torque Repair as necessary Cover Compensator. 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. Repair as necessary Small End Bushing Connecting Rod Bushing. Piston Pin. Oil Pump Drive Refer to Engine / Cooling / Exhaust chapter Cam Drive Cam Chain. Oil Pump Drive Oil Pump Oil Pump. chipped or Transmission Gears Repair as necessary broken gear teeth Worn. TRANSMISSION / CRANKSHAFT 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. seized.43 . Bent External Shift Linkage Repair as necessary External Shift Linkage Bent or Distorted Shift Shift Fork Rails Replace Shift Fork Rails Fork Rails 6 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. chipped or Transmission Bearings Repair as necessary broken Transmission Bearings Originates from Primary Clutch. seized.

Sticky.TRANSMISSION / CRANKSHAFT PROBLEM POSSIBLE CAUSE PART(S) AFFECTED REPAIR RECOMMENDED Transmission Hard to Shift Improper Clutch Clutch Refer to Clutch / Primary Operation / Shift chapter 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. Shifter Ratchet Assembly Refer to Clutch / Primary Broken Shift Shaft / Shift chapter Sticking Pivot Point. Bent External Shift Linkage Repair or replace External Shift Linkage components as necessary Bent or Distorted Shift Shift Forks Replace bent shift fork Forks Damaged Shift Drum Shift Drum Replace damaged shift Grooves drum Shift Ratchet Bent / Stuck Shift Ratchet Repair as necessary Bent or Distorted Shift Shift Fork Rails Replace Shift Fork Rails Fork Rails Transmission Jumps Out Broken Shift Stop Pin Shift Stop Pin Replace stop pin of Gear Worn Shift Drum Pawls or Shift Drum or Shift Replace damaged shift Shifter Ratchet Linkage drum or shifter ratchet Broken Shift Ratchet Shift Ratchet Spring Replace spring Spring Damaged Shift Drum Shift Drum Replace shift drum Grooves Bent. 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 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual 6. Worn.44 © Copyright .

26 FRONT FENDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 REAR FENDER INSTALLATION . . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . . . .3 SERVICE NOTES . . . . . . . . . . . . . . . .7. . .1 . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . . . . .9 SEAT . . ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . . . . . 7. . . . . . . . . . .(DARK HORSE). . . . . . . .24 LOWER FAIRING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .19 FOOT PEGS (PASSENGER). .7. . . . . . . . . . .7. . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 FRONT CASTING (MAIN FRAME). . . . .(ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHIEFTAIN / ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 SADDLEBAGS. . . . . . . . . . .7. . . . . . . . . . . .ROADMASTER . . . . . . . . . . . . . . . . . . . . . . .7 SIDE PANELS . . . . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 FRAME . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 FENDERS / SEAT (OPEN STYLE FENDER) . .13 FAIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 FRONT FENDER REMOVAL (OPEN STYLE FENDER) . . . . . . . . . . . . . . . . . REMOVAL / INSTALLATION . . . . . . . . . .ALL (EXCEPT ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 SIDE COVER (UPPER). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 SEAT REMOVAL / INSTALLATION . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 TRUNK INSTALLATION. . . . . . . . . . . . . . . . . . . . .28 FRONT FENDER INSTALLATION (OPEN STYLE FENDER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(ROADMASTER) . . . . . . .7. . . . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 SIDE COVER (LOWER). . . . . . . .6 FLOORBOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . .(ROADMASTER) . .7. . . . . . . . . . . . . . . . . . . ROADMASTER . . . .7. . . . .25 LOWER FAIRING INSTALLATION . . . . . . . 7. . . . . . . 7. . . . . . . . . . . .7. CHIEFTAIN DARK HORSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 7 PASSENGER FOOT PEG BLANKS (DARK HORSE). . . . . . . . . . . . . . . . . . . . . . . .ROADMASTER . . . . . . . . . . . . 7. . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . .ALL (EXCEPT ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 HIGHWAY BAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 FRONT CASTING (MAIN FRAME). . . . . . . . . . . . . . . . . . . . 7. . . . . . . . . . .11 LOWER FAIRING. . . . . .8 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 FLOORBOARD INSTALLATION . . . . . . . . . . . . . . . VINTAGE / SPRINGFIELD . . . . . . . . . . CHIEFTAIN / ROADMASTER . ROADMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 TRUNK REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. . . 7. . . . . . . . . .12 FAIRING. . . . . . . . .25 FRONT FENDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL / INSTALLATION. . . . . . . . . . . . 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 TRUNK. . . . . . . . . . . . . . . . . . . 7. . . . . . . . .3 ASSEMBLY VIEWS. . . . . . . . . .4 FENDERS / SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 SEAT REMOVAL / INSTALLATION . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . FRAME / BODY CHAPTER 7 FRAME / BODY GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 9927618 R03 . . . . . . . .7. . . . . . . . . . . . .18 FLOORBOARD REMOVAL . .7. . . . . .7. .30 TRUNK LOCK REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL / INSTALLATION . . . . . . . . . . . . . .16 BODY / FRAME SERVICE . . . . . . . . . . .15 NACELLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 HIGHWAY BAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . . .3 SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 REAR FENDER REMOVAL . . . . . . . . . . . .7. . . . . REMOVAL / INSTALLATION . .22 SEAT REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(CHIEFTAIN DARK HORSE) . . . . . . . . . . . .43 CHIEFTAIN DARK HORSE . . . . . . . . . . . . . .57 RIDE COMMAND SYSTEM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 OUTER FAIRING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . . . .7.51 OUTER FAIRING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(CHIEFTAIN / ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . .FRAME / BODY CHIEF CLASSIC / CHIEF DARK HORSE / CHIEF VINTAGE / SPRINGFIELD . . . . . . . . . . . . . . . . .58 9927618 R03 .51 INNER FAIRING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . . . . .7. . .7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 INSTRUMENT PANEL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(CHIEFTAIN DARK HORSE) . . . . . . . . . . . .2017 Indian Motorcycle (Full-Size) Service Manual 7. . . . . .7. . . . . . . .(CHIEFTAIN / ROADMASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . .(CHIEFTAIN / ROADMASTER) .47 INNER FAIRING INSTALLATION . . . . . . . . . . . . .(CHIEFTAIN DARK HORSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 NACELLE REMOVAL . . .40 INSTRUMENT PANEL REMOVAL / INSTALLATION . . . . . . . . . . . .55 RIDE COMMAND SYSTEM REMOVAL . . . . . .7. . . . . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . . .53 INNER FAIRING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . . .41 NACELLE INSTALLATION . . . . . . . . . .50 CHIEFTAIN / ROADMASTER . . . . . . . . . . . . . . . . . . .(CHIEFTAIN DARK HORSE) . .48 OUTER FAIRING INSTALLATION . . . . . .7.45 INNER FAIRING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . .(CHIEFTAIN DARK HORSE) .54 OUTER FAIRING INSTALLATION . . . . . . . . . . . .2 © Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . .(CHIEFTAIN / ROADMASTER) . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

hoses and tie straps that have been removed during disassembly must be replaced per factory standards during assembly. assemblies and systems. FRAME / BODY 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.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. Any deformation on the panel around the fastener is an indication that the fastener is too tight.service-solutions. Cables. SPECIAL TOOLS TOOL DESCRIPTION PART NUMBER PV-49955 Body Panel Tool Kit Bosch Automotive Service Solutions: 1-800-328- 6657 or https://polaris. Do not over tighten body components in order to avoid damage. Caution should be used when tightening body panels. Pay close attention to assembly procedures and torque specifications.com/ 7 9927618 R03 .3 .

FRAME / BODY A S S E M B LY V I E W S F E N D E R S / S E AT NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Passenger Seat Fastener 18 ft-lbs (24 Nm) w Driver Seat Fastener 18 ft-lbs (24 Nm) e Strut Cover Fastener 84 in-lbs (10 Nm) r Rear Fender Upper Fastener 84 in-lbs (10 Nm) t Rear Fender Lower Stud / Ball 84 in-lbs (10 Nm) y Fender Fastener 84 in-lbs (10 Nm) u Caliper Cover Acorn Nut 18 in-lbs (2 Nm) i Front Fender Fastener 18 ft-lbs (24 Nm) 9927618 R03 .4 © Copyright .2017 Indian Motorcycle (Full-Size) Service Manual 7.

5 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. FRAME / BODY 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 Nm) w Driver Seat Fastener 18 ft-lbs (24 Nm) e Strut Cover Fastener 84 in-lbs (10 Nm) r Rear Fender Upper Fastener 84 in-lbs (10 Nm) t Rear Fender Lower Stud / Ball 84 in-lbs (10 Nm) y Fender Fastener 84 in-lbs (10 Nm) u Front Fender Fastener 18 ft-lbs (24 Nm) 9927618 R03 .

1) e Fastener.2) 18 ft-lbs (24 Nm) 9927618 R03 . Rear Lower Subframe — M8 x 1. Down Tube (Lower LH) — M10 x 1.5 x 100 (QTY.75 x 120 (QTY.FRAME / BODY FRAME NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Fastener. Engine Bracket — M8 x 1.75 x 50 (QTY.25 x 20 (QTY.4) 45 ft-lbs (60 Nm) w Fastener. Rear Subframe — M10 x 1.4) 18 ft-lbs (24 Nm) i Fastener.6 © Copyright .2) 45 ft-lbs (60 Nm) r Fastener — M12 x 1.2017 Indian Motorcycle (Full-Size) Service Manual 7.5 x 60 (QTY. Down Tube (Upper) — M10 x 1.5 x 25 45 ft-lbs (60 Nm) (QTY.3) 75 ft-lbs (102 Nm) y Fastener.5 x 35 (QTY. Midcast — M12 x 1.3) 75 ft-lbs (102 Nm) t Fastener. Down Tube (Lower)— M10 x 1.6) 35 ft-lbs (48 Nm) u Fastener.25 x 20 (QTY.

4) 35 ft-lbs (48 Nm) e Fastener.2) 18 ft-lbs (24 Nm) w Fastener. Floorboard Support — M10 x 1.5 x 30 (QTY. Pushrod - a Passenger Foot Peg Support Bracket - s Passenger Foot Peg - 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7.0 x 15 (QTY.25 x 120 (QTY. FRAME / BODY FLOORBOARDS NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) 7 q Fastener. Floorboard Pivot — M8 x 1.2) 84 in-lbs (10 Nm) r Shifter Toe Pedal 18 ft-lbs (24 Nm) t Floorboard Pan - y Floorboard Pad - u Brake Pedal Pad - i External Snap Ring (Brake Pedal and Shifter) - o Retaining Pin.7 . Brake Pedal Pad — M6 x 1.

3) r Side Cover. Right Hand Sprocket Cover — M6 x 1.2) i Fastener.0 x 15 84 in-lbs (10 Nm) (QTY. Right Hand Upper — 9927618 R03 . Right Hand Sprocket Cover — M6 x 1. Right Hand Lower — u Fastener.FRAME / BODY S I D E PA N E L S NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Side Cover. Left Hand Lower — t Rubber Isolator — y Side Cover.2) o Side Cover. Left Hand Upper — w Rubber Grommet — e Fastener.2017 Indian Motorcycle (Full-Size) Service Manual 7.0 x 40 84 in-lbs (10 Nm) (QTY. Left Hand Lower Side Cover — M6 x 1.0 x 70 84 in-lbs (10 Nm) (QTY.8 © Copyright .

9 .4) (except Dark Horse) y Washer (QTY.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. FRAME / BODY S E AT .1) (except Dark Horse) – u Washer (QTY.2) 18 ft-lbs (24 Nm) Fastener.25 x 16 (QTY.1) (except Dark Horse) – 9927618 R03 .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.0 x 15 (QTY.M x 84 in-lbs (10 Nm) t 1.M8 x 1.M8 x 1. Seat . Seat .25 x 20 (QTY. Passenger (except Dark Horse) w Seat. Passenger to Driver Seat . Driver – e Fastener.1) 84 in-lbs (10 Nm) r (except Dark Horse) Fastener.

10 © Copyright . Trunk – w Strap .2017 Indian Motorcycle (Full-Size) Service Manual 7.R O A D M A S T E R NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Harness.1) – 9927618 R03 .4) 14 in-lbs (2 Nm) a Washer (QTY.2) 8 ft-lbs (11 Nm) o Fastener (QTY.Passenger Seat – e Heated Seat Assembly – r Wire Cover – t Cable Tie – y Fastener .1) 84 in-lbs (10 Nm) u Fastener.M6 x 1.1) – s Washer (QTY.25x16 (QTY.FRAME / BODY S E AT .M8 x 1.0 x 25 (QTY. Strap .25 x 20 (QTY.M8 x 1.2) 18 ft-lbs (24 Nm) i Fastener. Seat .

Cup - t Washer.2) 12 in-lbs (1 Nm) e Luggage Rack - r Washer. Luggage Rack .M6 x 1.0 x 20 (QTY. Lower - u Fastener.11 .10) 13 ft-lbs (18 Nm) w Fastener.M6 x 1. ROADMASTER 7 NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Fastener.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. FRAME / BODY TRUNK. Trunk Base . Upper - y Washer.25 x 20 (QTY.0 x 20 (QTY.4) 12 in-lbs (1 Nm) 9927618 R03 .M8 x 1. Trunk Back .

Inner to Outer Fairing .(QTY. Clamp .10) 36 in-lbs (4 Nm) w Fastener. R O A D M A S T E R NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Fastener.12 © Copyright .0 x 16 .(QTY 6) 36 in-lbs (4 Nm) 9927618 R03 .M6 x 1.2017 Indian Motorcycle (Full-Size) Service Manual 7.FRAME / BODY L O W E R FA I R I N G .

0 (QTY.13 . RH — y Speaker Grill. Headlight Bracket — M6 x 1. LH — 9927618 R03 . FRAME / BODY FA I R I N G . Fairing — NOTE: Fasteners differ in size See Fairing Installation (Frame / Body chapter) t Speaker Grill.3) NA r Fastener. Bezel — M6 x 1.0 x 40 (QTY.2) 36 in-lbs (4 Nm) w Headlight Bezel — e Fastener. C H I E F TA I N D A R K H O R S E NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) 7 q Fastener.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7.

C H I E F TA I N / R O A D M A S T E R NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE) q Fastener.14 © Copyright .2) 36 in-lbs (4 Nm) w Headlight Bezel — e Fastener. Bezel — M6 x 1. RH — y Speaker Grill. Fairing — NOTE: Fasteners differ in size See Fairing Installation (Frame / Body chapter) t Speaker Grill.2017 Indian Motorcycle (Full-Size) Service Manual 7.0 (QTY. Headlight Bracket — M6 x 1. LH — u Fastener. Speaker 36 in-lbs (4 Nm) 9927618 R03 .FRAME / BODY FA I R I N G .0 x 40 (QTY.3) NA r Fastener.

Saddle Bag Mount (QTY. .4) w Bracket.4) - y Spacer.4) - s Hinge.25 x 25 (QTY.4) - e Fastener . Rubber (QTY.M5 x 0.2) - 9927618 R03 . Saddle Bag Mount (QTY.4) - o Fastener.M6 x 1.4) - u Bushing. Lid (QTY. Hinge .2) - k Handle.M6 x 1. Latch Asm.8 x 12 (QTY. 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 Pad.M8 x 1. Anchor (QTY.0 x 16 (QTY.4) 36 in-lbs (4 Nm) t Washer. Saddlebag Lock (QTY.0 x 20 (QTY.2) - h Seal.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7.7 x 16 (QTY.4) 45 in-lbs (5 Nm) f Fastener. Lock (QTY.4) - i Pin.4) 25 ft-lbs (34 Nm) a Spool (QTY. FRAME / BODY S A D D L E B A G S . Latch Striker .2) - j Lock Cylinder (QTY.4) - d Fastener.15 .M4 x 0. Latch (QTY. Saddlebag Latch (QTY.16) 84 in-lbs (10 Nm) r Fastener.4) 65 in-lbs (7 Nm) g Actuator. Spool . Rubber (QTY.

3) - a Fastener .2) - 1( Cover.1) - w Fastener .3) - o Fastener .2) - f Carrier. Front Headlight(QTY.1) - d Spring. Headlight Flange (QTY.6 (QTY. Nacelle Bezel (QTY.0 x 16 (QTY.#8-18 x .4) 75 in-lbs (8 Nm) k Fastener .4) - j Fastener .FRAME / BODY N A C E L L E .M6 x 1.4) 12 in-lbs (1 Nm) e Retaining Ring.16 © Copyright .1) - r Fastener. Bulb (QTY.1) - 9927618 R03 . Headlight (QTY. Flat (QTY.1) - 2) Spacer.2017 Indian Motorcycle (Full-Size) Service Manual 7.3) - y Bracket.4 x 10 x 1. 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.10-16 (QTY.6. Headlight Adjuster (QTY. Headlight (QTY. Headlight Adjuster (QTY.2) - t Bushing.3) - i Washer . Rear Nacelle (QTY.0 x 15 (QTY.50” (QTY. Headlight (QTY.1) - u Isolator.2) 36 in-lbs (4 Nm) l Clip.M6 x 1. Speed Nut (QTY. Front Nacelle (QTY.1) 12 in-lbs (1 Nm) s Grommet (QTY.1) - h Washer.M6 x 1.0 x 35 (QTY.1) - g Cover.

to disengage each tab from rubber grommet in frame. 3. during side cover removal and /or installation. 1. pull 1. FRAME / BODY BODY / FRAME SERVICE S I D E C O V E R ( U P P E R ) .21 from both sides of the motorcycle. R E M O VA L / S I D E C O V E R ( L O W E R ) . Pull back slightly on the RH lower side panel to disengage from the front rubber grommet. 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. Remove theCross Over Pipe Removal. 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. remove the passenger foot pegs. Working from the right side of the motorcycle.88. If applicable. 5. Working from the LH side of the motorcycle. use a 6 mm hex wrench to remove the 3 fasteners w securing the panel to the frame. 2. Remove panel.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. page 7. page 3. 9927618 R03 .17 . 2. 4. page 7.17 from corners of the upper cover evenly straight outward both sides of the motorcycle. pull corners of the upper cover evenly straight 7 outward to disengage each tab from rubber grommet in frame. Pull the rear edge of the RH lower side panel straight out to disengage the two rubber grommets q. Working from the left hand side of the motorcycle. 6. Remove the upper side covers.

7 located in this chapter. mation. Using a mild soapy water Secure the motorcycle in an upright position. Remove fastener q and passenger foot peg blank w. please see the FLOORBOARD ASSEMBLY VIEW. Disengage pushrod from the brake pedal assembly.2017 Indian Motorcycle (Full-Size) Service Manual 7. R E M O VA L / I N S TA L L AT I O N 1. TORQUE Foot Peg Blank Fastener: 35 ft-lbs (48 Nm) CAUTION Do not bend or kink flexible brake line during floorboard removal. page 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. Torque fasteners to specification.FRAME / BODY 7.18 © Copyright . 9927618 R03 . 2. Remove cotter pin and washer q from brake LH Side Cover Fasteners: 84 in-lbs (10 Nm) master cylinder pushrod. TORQUE 1. Installation is performed by reversing the removal procedure. Master cylinder assembly should be kept in an upright position and properly supported at all times. 2. solution on the rubber grommets will make it For detailed floorboard assembly / disassembly infor- easier to press the side covers into position. 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 ) . Loosen the jam nut w and remove the brake master cylinder from the RH floorboard assembly and move out of the way.

Working from the left side of the motorcycle. Working from the LH side of the motorcycle. Remove the two fasteners t securing the LH floorboard to the frame and remove floorboard assembly. lift the floorboard assembly into position and torque the two fasteners q to specification. TORQUE Shift Rod Fastener: 84 in-lbs (10 Nm) 9927618 R03 . Lift the shift rod into position at the inside of the shift arm and torque shift rod fastener w to specification. 1. 4. 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. Working on the RH side of the motorcycle. support bracket to the frame. 7 5. TORQUE Floorboard Bracket Fasteners: 35 ft-lbs (48 Nm) 2. remove the rear shift rod fastener r and move shift rod out of the way.19 . FRAME / BODY 3.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7.

linkage. Working on the RH side of the motorcycle. 4. Floorboard Bracket Fasteners: 35 ft-lbs (48 Nm) Bleed brakes if necessary.20 © Copyright . TORQUE Master Cylinder Jam Nut: 35 ft-lbs (48 Nm) 9927618 R03 . Lower the master cylinder assembly onto the floorboard bracket and torque the jam nut r to specification.FRAME / BODY 3.2017 Indian Motorcycle (Full-Size) Service Manual 7. Test foot brake and verify that the pedal feels TORQUE good and no air has entered the hydraulic circuit. 6. Apply a thin coat of grease to the pushrod pivot floorboard assembly into position and torque the pin t and connect the pushrod to the foot pedal two fasteners e to specification. lift the 5.

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 . Remove the passenger seat fastener w. remove the two 2. Using a 6 mm hex wrench. INSTALLATION is performed by reversing the removal procedure. TORQUE Passenger Foot Peg Fasteners: 35 ft-lbs (48 Nm) 9927618 R03 . 2. 3. 4. NOTE It may be necessary to lift the seat skirt to access the side fasteners on some models. 7 3. Remove fasteners q securing foot peg bracket to 1. Torque passenger foot peg bracket fasteners q to specification.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7..17 frame. fasteners q securing the driver’s seat to the frame. Remove left and right side covers.21 .A L L I N S TA L L AT I O N (EXCEPT ROADMASTER) 1. FRAME / BODY F O O T P E G S ( P A S S E N G E R ) . page 7. Remove foot peg / bracket as an assembly.

6. 1.FRAME / BODY 4. Torque the seat fasteners to specification. See Trunk Removal. 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. Roadmaster. Remove left and right side covers. 4.. Remove the passenger seat fastener w. 5. 3. Using a 6 mm hex wrench.17 2.29.2017 Indian Motorcycle (Full-Size) Service Manual 7.22 © Copyright . page 7. remove the two fasteners q securing the driver’s seat to the frame. page 7. TORQUE Seat Fasteners (All): 84 in-lbs (10 Nm) NOTE It may be necessary to lift the seat skirt to access the side fasteners on some models. INSTALLATION is performed by reversing the removal procedure. 9927618 R03 . Remove trunk assembly.

TORQUE Seat Fasteners (All): 84 in-lbs (10 Nm) 9927618 R03 . Torque the seat fasteners to specification.23 . page 7. 7. Remove left and right side covers. 1. Using a 6 mm hex wrench. If applicable. FRAME / BODY 5. INSTALLATION is performed by reversing the removal procedure.. NOTE It may be necessary to lift the seat skirt to access the side fasteners on some models. 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 . 3. 6. disconnect the trunk harness q and heated seat connector w. 9. Lift the rear of the seat and pull rearward to 7 disengage front retaining arms from the bracket behind the fuel tank. Remove the seat assembly.( D A R K disengage front retaining arms from the bracket HORSE) behind the fuel tank.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. INSTALLATION is performed by reversing the Seat Fasteners (All): 84 in-lbs (10 Nm) removal procedure. TORQUE 4.17 2. NOTE Mark the vehicle side connectors with tape for reference during seat installation. 8. remove the two fasteners q securing the driver’s seat to the frame.

removal. particularly the front fender. CAUTION Hold the highway bar assembly in place while removing the top fasteners so it doesn’t swing down and damage the front fender.24 © Copyright . TORQUE Upper Highway Bar Fasteners: 18 ft-lbs (24 Nm) Lower Highway Bar Fasteners: 35 ft-lbs (48 Nm) 3. 2. remove the top two fasteners w from the highway bar assembly.FRAME / BODY H I G H WAY B A R R E M O VA L H I G H WAY B A R I N S TA L L AT I O N Place the motorcycle on the side stand. Place the motorcycle on the side stand. Using an 8 mm hex wrench. remove the lower two 1. Turn the han- dlebar all the way to the left. 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. Carefully maneuver the highway bar out from the frame / fender area. particularly the front fender. Turn the han. 2. CAUTION CAUTION Protect chrome and painted surfaces prior to Protect chrome and painted surfaces prior to removal. Using a 6 mm hex wrench. Install the lower mounting fasteners w and torque upper and lower fasteners to specification. 1. finger tight.2017 Indian Motorcycle (Full-Size) Service Manual 7. 9927618 R03 . dlebar all the way to the left.

• The center (outer) fairing clamp is attached last and does not have a locating mark.25 . during removal and installation. Be sure you have a safe location to store painted body components NOTE before they are removed. • The lower fairing clamp is positioned to the outside of the locating mark w. • The upper fairing clamp is positioned against the 1. Install the upper and lower clamp fasteners finger tight. outer fairing assembly. 9927618 R03 . 3.( R O A D M A S T E R ) L O W E R FA I R I N G I N S TA L L AT I O N - (ROADMASTER) CAUTION 1. Remove the inner fairing assembly and associated clamps from the highway bars. FRAME / BODY L O W E R FA I R I N G R E M O VA L . Remove fasteners q and carefully remove the locating dowel q.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. Position the inner fairing assembly over the highway bar so the clamps line up with the fastener holes. Install the upper and lower fairing clamps onto the Painted surfaces can be easily scratched or damaged highway bars as shown. 2. 2. 7 3. Remove fasteners w from clamps securing the inner fairing assembly to the highway bars.

8. TORQUE Lower Fairing Clamp Fasteners: 36 in-lbs (4 Nm) 6. TORQUE Inner to Outer Fairing Fasteners: 36 in-lbs (4 Nm) 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual 7. Remove the three fasteners r from each side of the fender. 1. Alternately tighten outer fairing fasteners to specified torque. NOTE 5. Noting their position for reinstallation. CAUTION Use care not to scratch or damage painted surfaces during fender removal and / or installation. 2.FRAME / BODY 4. followed by the Motorcycle should be parked on a level surface lower and center clamps. Install the five fasteners r securing the outer nacelle. 3. locate the connector and disconnect. Starting with the upper clamp. 4. cut the cable ties that are securing the fender light wire harness to the brake line.26 © Copyright . torque all clamp resting on the side stand. Position the center (outer) fairing clamp onto the F R O N T F E N D E R R E M O VA L highway bar and line up with the fastener hole in the fairing. fairing to the inner fairing finger tight. Remove two acorn nuts q and fastener w from each side of the motorcycle and remove the caliper covers e. Follow the fender light harness up into the fairing / 7. Carefully position the outer fairing assembly over the inner and align the fastener holes. fasteners e to specification.

make sure the fender is stored safely TORQUE until it is reinstalled. Turn the handlebar all the way to the left and right to verify proper operation and freedom of movement. 9927618 R03 . line up. Front Fender Fasteners: 18 ft-lbs (24 Nm) F R O N T F E N D E R I N S TA L L AT I O N 3. resting on the side stand. FRAME / BODY 5. Torque to specification. Route the fender light wire harness into the fairing / nacelle and reconnect. Gently squeeze the sides of the front fender and fender and squeeze the sides together while “roll” the fender into position so the fastener holes “rolling” the fender out from the fork legs. 18 in-lbs (2 Nm) 6. Install caliper cover. 2.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. 7 IMPORTANT Once fender has been removed from the motorcycle. Stand in front of the motorcycle facing the front 1.27 . 5. Install cable ties to secure fender light harness Motorcycle should be parked on a level surface away from moving parts. NOTE 4. Install the three fasteners q on each side of the fender and torque to specification. CAUTION TORQUE Use care not to scratch or damage painted surfaces Caliper Cover Acorn Nuts: during fender removal and / or installation.

during fender removal and / or installation. IMPORTANT TORQUE Once fender has been removed from the Front Fender Fasteners: 18 ft-lbs (24 Nm) motorcycle. 9927618 R03 . 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. “roll” the fender into position so the fastener holes line up. fender and torque to specification. 1. 2.2017 Indian Motorcycle (Full-Size) Service Manual 7. Stand in front of the motorcycle facing the front fender and squeeze the sides together while 2. Gently squeeze the sides of the front fender and fender. Remove the two fasteners q from each side of the 1. Turn the handlebar all the way to the left and right to verify proper operation and freedom of movement.FRAME / BODY 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 S T Y L E FENDER) FENDER) NOTE NOTE Motorcycle should be parked on a level surface Motorcycle should be parked on a level surface resting on the side stand.28 © Copyright . resting on the side stand. 3. Install the two fasteners q on each side of the “rolling” the fender out from the fork legs. make sure the fender is stored safely until it is reinstalled.

and remove the trunk lock fastener q from each trunk latch. Disconnect the trunk harness multi-plug w.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. R O A D M A S T E R 4. remove the left and right saddlebags motorcycle.29 . If applicable. FRAME / BODY T R U N K R E M O VA L . Lift up on the rear of the trunk r and slide rearward t to release the trunk from the 1. Lift the trunk latches e to unlock the trunk from the mount. 7 3. 2. 9927618 R03 .

if equipped. Push the trunk locking levers e down until fully seated and the trunk is held securely in place. 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. install the mounting fasteners t into left and right locking levers. Reconnect the trunk harness connector r. If applicable. 4.FRAME / BODY T R U N K I N S TA L L AT I O N . Install saddlebags. CAUTION Use care when installing the trunk assembly so that no electrical wires / connectors get pinched. 2. R O A D M A S T E R 3.30 © Copyright . 9927618 R03 . 1. Slide the trunk forward q onto the mounting bracket and lower w the rear of the trunk until fully seated.2017 Indian Motorcycle (Full-Size) Service Manual 7. 6. 5.

double sided tape) when the bezel is reinstalled. 9927618 R03 . INSTALLATION 9.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7.ROADMASTER 5. 7 4. 10. 8. NOTE It is recommended that the trunk is removed from the motorcycle prior to disassembly.g. 6. 2. Remove the two fasteners e from the lock actuator bracket and disconnect electrical connector. Install the latch / lock actuator assembly and tighten fasteners finger-tight. 3. Insert body panel tool (PV-49955) or similar into the relief holes w cut into the bezel and gently pry bezel off of the trunk base.31 . disconnect the lock actuator cable from the latch assembly to separate the components. REMOVAL 1. See TRUNK REMOVAL as outlined in this chapter. NOTE Bezel is held in place with pressure sensitive adhesive. Remove the trunk from the motorcycle and place on flat work surface. Torque latch fasteners to specification following the torque sequence. Open the trunk lid completely. If replacing individual components. FRAME / BODY TRUNK LOCK REPLACEMENT . It will be necessary to replace the adhesive with a suitable alternative (e. Lift the trunk liner q up to remove from trunk base. Remove the four fasteners r securing the lock assembly to the trunk. Remove the latch and lock actuator together as an assembly. 7.

32 © Copyright . Operate lock and latch assembly to verify proper operation. 14. 13.FRAME / BODY TORQUE Trunk Latch Fasteners: 36 in-lbs (4 Nm) 11. Torque lock actuator fasteners to specification.2017 Indian Motorcycle (Full-Size) Service Manual 7. 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. TORQUE Lock Actuator Fasteners: 13 ft-lbs (18 Nm) 12. 9927618 R03 . Install trunk liner.

33 . 7 11. Loosen the four fasteners u on the underside of the fender. FRAME / BODY R E A R F E N D E R R E M O VA L 9. remove the saddlebag mounting cylinders q from both sides of the fender. page 7. 5. Using a 6mm hex wrench. Locate the rear harness connector y and disconnect. if equipped. 2. CAUTION Be careful not to damage painted surfaces. turn it over and clip the cable ties. Remove upper side panels. Remove saddlebags. Remove the three plastic darts i on the upper. 1. 8. Lift the fender off of the motorcycle. Remove fasteners r and t from both sides of the forward lip of the fender. Removal / Installation. Remove the strut cover fasteners w and the strut covers e from both sides of fender. Remove seat.21 3. 7. See Side Cover (Upper). See Seat Removal / Installation . 6. 10.All (except Roadmaster). 4. 12. if equipped.17. page 7. NOTE There is enough slack in the antenna wire to remove fender.17. fender. Remove lower side panels. page 7. Removal / Installation. 9927618 R03 . See Side Cover (Lower).2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. Disconnect the antenna cable from the mast.

1.FRAME / BODY R E A R F E N D E R I N S TA L L AT I O N 4. Place the rear fender assembly onto the motorcycle so the top fastener holes line up and install fasteners q so they are finger tight. Install forward fender fasteners t on both sides of the fender and torque to specification. 6.2017 Indian Motorcycle (Full-Size) Service Manual 7. Line up the holes of the dust cover and install the three plastic darts w as shown. 5.34 © Copyright . CAUTION Use care not to scratch or damage painted surfaces during fender removal and / or installation. 3. Install the four fasteners e on the inside of the fender so they are finger tight. Plug the rear harness connector r into the chassis harness. 2. TORQUE Forward Fender Fasteners t: 84 in-lbs (10 Nm) 9927618 R03 . Route the rear harness and antenna cable along the rear fender and secure with cable ties.

TORQUE Mounting Cylinder Fasteners: 25 in-lbs (34 Nm) 11. Inside Fender Fasteners e: 84 in-lbs (10 Nm) 2. 8. 14. torque to specification. page 7. Severe personal injury 8.15.17. Disconnect the negative cable from the battery.35 .33. See Highway Bar Removal. R E M O VA L TORQUE WARNING Top Fender Fastener q: 84 in-lbs (10 Nm) Care should be taken to be sure the motorcycle will not tip or fall while elevated. 10. 9927618 R03 . Torque the lower inside fender fasteners e to or death could occur if the motorcycle tips or falls.17. See Head Pipe Removal. specification. if equipped. Install saddlebags. See Oil Cooler Removal. 12. Install saddlebag mounting cylinders and mounting cylinder fasteners y. 13. 7 11. See Side Cover (Lower). Strut Cover Fasteners: 84 in-lbs (10 Nm) 5. See Side Cover (Lower). 7. Battery Removal. 9. page 7. 15.24. page 7. If applicable. Remove the driver floorboard assemblies.90. page 8. Removal / Installation.26. Place the motorcycle in an upright position with the TORQUE front wheel clamped in a wheel vise.17.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. See and torque to specification. See Floorboard Removal. 10. F R O N T C A S T I N G ( M A I N F R A M E ) . Removal / Installation. page 2. Remove the lower side covers. 1. Remove the highway bar assembly. See Side Cover (Upper). if equipped. Install upper side panels. Torque top fender fasteners q to specification. See Triple Clamp Removal. page 7. Install strut covers i and strut cover fasteners u 3.30.18. Removal / Installation. Install lower side panels. Remove the upper fasteners q from the left side down tube. page 3. page 3. disconnect the oil cooler from the down tubes. Connect antenna cable to mast. and 6. page 4. Install seat as outlined in this chapter. Remove the front triple clamps. See Fuel Tank Removal. Remove the fuel tank. Unclip the harness conduit from the front casting. TORQUE 4. Remove the head pipes. FRAME / BODY 7. 9. page 7.

2017 Indian Motorcycle (Full-Size) Service Manual 7. NOTE Remove the upper spacer from between the mid- casting and the engine. Remove fasteners r from the mid casting. Move the front casting toward the right hand side of the motorcycle to release dowels i and o. 13.FRAME / BODY 12. Remove fastener t and loosen fasteners y and u dowels can be released from the front casting. 15.36 © Copyright . on the right side mid-casting. Loosen lower fasteners w and e enough so the 14. 9927618 R03 .

F R O N T C A S T I N G ( M A I N F R A M E ) . 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. I N S TA L L AT I O N 1.37 . 9927618 R03 . 2. Lower the front casting into position over the engine. FRAME / BODY 16.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. 7 IMPORTANT The upper engine spacer will not be installed during the initial torque and measurement stage of this procedure. Remove the front casting from the motorcycle.

Loosely install the upper down tube fasteners e 5. through the front casting. DO NOT install the upper engine spacer r at this time. o and a to specification. LH Down Tube Fasteners i: 45 ft-lbs (60 Nm) Lower.FRAME / BODY 3. LH Down Tube Fasteners o & a: 45 ft-lbs (60 Nm) 9927618 R03 . Torque left hand down tube fasteners i.2017 Indian Motorcycle (Full-Size) Service Manual 7. Torque front casting fasteners u to specification.38 © Copyright . Starting with the lower engine mount y Front Cast to Mid-Cast Fasteners u: 75 ft-lbs (102 torque mid-cast fasteners t and y to specification. Nm) 6. TORQUE Upper Mid-Cast Fasteners t: 35 ft-lbs (48 Nm) Lower Mid-Cast Fastener y: 75 ft-lbs (102 Nm) TORQUE Upper. TORQUE 4.

RH Down Tube Fasteners s: 45 ft-lbs (60 Nm) 8. measurement is correct.5 mm — 10. TORQUE Upper Engine Mount Fastener: 45 ft-lbs (60 Nm) 9927618 R03 . 11. Torque lower right hand down tube fasteners s to 10. Torque upper engine mount fastener to specification.10 from the removal procedure to complete installation.0 mm 7 9. the upper spacer can be installed and the upper fastener torqued to specification. Measure the gap d between the engine and mid- cast where the upper spacer should be. repeat STEPS 4-8 until gap specification. Reverse STEPS 2 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. FRAME / BODY 7. TORQUE Lower.39 . If the gap is correct. Upper Engine Spacer Gap: 6. If the gap is incorrect.

15. Remove fasteners q securing bracket to speedometer head and remove fasteners w securing the speedometer bracket to the console cover. Torque speedometer bracket fasteners to specification. Using a mild soapy water solution on the rubber seal will make it easier to press the instrument panel into position.2017 Indian Motorcycle (Full-Size) Service Manual 7. Remove the console cover. 6.FRAME / BODY CHIEF CLASSIC / CHIEF DARK HORSE / CHIEF 5. 9927618 R03 .40 © Copyright . page 4. INSTALLATION is performed by reversing the removal procedure. See STEPS 1–5 of Fuel Tank Removal. 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. 3. Position the motorcycle on it’s side stand on a flat surface. Remove the bezel from the speedometer and lift Nm) the speedometer head out of the rubber grommet. TORQUE Speedometer to Bracket Fasteners: 15 in-lbs (2 Nm) Bracket to Console Cover Fasteners: 43 in-lbs (5 4. 7. 2. Remove the rubber grommet e from the console V I N TA G E / S P R I N G F I E L D cover.

FRAME / BODY N A C E L L E R E M O VA L 4. 9927618 R03 .41 . CAUTION During disassembly.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. 7 3. Remove windshield assembly. CAUTION Protect painted surfaces on the front fender and fuel tank prior to beginning the following procedure. Pull the rear portion of the nacelle assembly back toward the fuel tank to expose the handlebar risers. Rotate the auxiliary lamp assembly forward and lower out of the way. 7. Always route electrical wiring the same way as it was removed to avoid damaging wires and connectors. Loosen the front handlebar clamp fasteners r and rotate the handlebar up so the rear portion of the nacelle can be removed. if equipped. Use care when removing the nacelle so the chrome does not get scratched. Remove two fasteners per side e securing the windshield mounting bracket assembly. 6. 1. Remove two fasteners q at the top of the nacelle assembly. Remove two fasteners w securing the console cover to the fuel tank and lift console back and set on protected fuel tank. 5. 2. pay close attention to harness routing and connector orientation.

Disconnect all multi-plugs between the switch cube and chassis harness and route through the front portion of the nacelle. Pull the front portion of the nacelle out far enough to access the four fasteners y securing the 11. Some of the connectors are unmarked and interchangeable. Disconnect the auxiliary light switch (if equipped) 10. 13. Remove nacelle.42 © Copyright . Pull the headlamp bucket out far enough to and remove the rear portion of the nacelle t. carefully clip the six cable ties headlamp bucket and remove. Using a side cutter.2017 Indian Motorcycle (Full-Size) Service Manual 7. 12. securing the harness to the front portion of the nacelle assembly. disconnect the headlamp connector and remove the bucket assembly u. 9.FRAME / BODY 8. 9927618 R03 . IMPORTANT Use a marker or tape to index each multi-plug before disconnecting.

1. pay close attention to harness routing and connector orientation. Move the front portion of the nacelle into position and feed the wire harness through the center hole as shown. Install the four headlamp bucket fasteners q and torque to specification. Always route electrical wiring the same way as it was removed to avoid damaging wires and connectors. 5. 4. Secure harness to the front portion of the nacelle using the newly installed cable ties. TORQUE Headlamp Bucket Fasteners: 75 in-lbs (8 Nm) 7. Position the headlamp bucket in front of the nacelle and reconnect the headlamp bulb. FRAME / BODY N A C E L L E I N S TA L L AT I O N 6. 7 3. Install new cable ties into all six fir tree clips. Paying attention to the natural form of the wiring harness. 9927618 R03 . CAUTION During installation of the nacelle assembly.43 . IMPORTANT Pay attention to index marks placed on connectors during disassembly when reconnecting as some of them are interchangeable. reconnect all of the multi-plugs between the chassis and switch cubes. Lower the rear portion of the nacelle w into position and reconnect the auxiliary light switch (if equipped).2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. 2.

44 © Copyright . 15. if equipped. Rotate the handlebar into the desired position and 11. Torque the auxiliary light bar bracket fasteners r Tighten Front fasteners First. Install the two fasteners t located at the top of the torque the riser clamp fasteners e to nacelle and torque to specification. Verify that all controls are operating correctly and the handlebar turns freely from lock to lock. TORQUE Console Cover Fasteners: 84 in-lbs (10 Nm) 14. TORQUE TORQUE Upper Nacelle Fasteners: 36 in-lbs (4 Nm) Riser Clamp Fasteners: 18 ft-lbs (24 Nm) 12. Then Rear to specification. Move the light bar / turn signal assembly into position and install the four fasteners r finger 13.FRAME / BODY 8. Move the console cover into position and torque tight. Auxiliary Light Bar Bracket Fasteners: 18 ft-lbs (24 Nm) 10. Install windshield assembly. TORQUE 9.2017 Indian Motorcycle (Full-Size) Service Manual 7. Push the front and rear portions of the nacelle together into position around the triple clamp. 9927618 R03 . specification. NOTE Verify that the rubber grommets securing the auxiliary light / turn signal harness have been slid into place. fasteners to specification.

FRAME / BODY C H I E F TA I N D A R K H O R S E 3. It is imperative that the fasteners are reinstalled in the same positions they are removed from or damage to outer fairing may occur. to capture the T-nuts as they are not captive. Remove the five fasteners q from the windshield the LH e and RH r speaker grill out of the inner and remove windshield.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. CAUTION Fasteners removed in STEPS 3 & 5 are different lengths. 4. 7 NOTE 5. NOTE Some fasteners are longer than others.45 .( C H I E F TA I N D A R K the fairing assembly. make sure to note placement of fasteners when removing. Using the Body Panel tool (PV-49955). Place the motorcycle on a flat surface resting on it’s side stand. Remove six fasteners t from the inner fairing When removing the five windshield fasteners be sure assembly. gently pry 2. 1. HORSE) NOTE Place the power windshield in the FULL UP position prior to fairing removal. Remove the four LONG fasteners w from the top of O U T E R FA I R I N G R E M O VA L . 9927618 R03 . fairing assembly.

8. 7. Remove three fasteners u and withdraw the head light assembly far enough to disconnect electrical connector.FRAME / BODY 6.2017 Indian Motorcycle (Full-Size) Service Manual 7. Remove fairing assembly. 9927618 R03 .46 © Copyright . Remove two fasteners y and head light bezel.

See Outer Fairing Removal . page 7.(Chieftain Dark Horse). Always route electrical wiring the same way as it was removed to avoid damaging wires and connectors. FRAME / BODY I N N E R FA I R I N G R E M O VA L . 7.2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7.( C H I E F TA I N D A R K 5. 9927618 R03 . carefully clip the outboard HORSE) cable ties e. Use a marker or tape to index each multi-plug before disconnecting.47 . Lift the inner fairing assembly off of the triple clamp studs and route wire through the access hole.45. page 7. power windshield actuator and speakers intact. Disconnect the 12V accessory socket connector and fog lamp button. 7 8. 6. 4. 2. pay close attention to harness routing and connector orientation. Remove the instrument cluster. Disconnect all multi-plugs between the fairing and chassis harnesses. Using a side-cutter. carefully clip the four cable ties w securing the wiring harness to the inner fairing. See Instrument Panel Removal / Installation . Remove the four nuts and washers q as shown.(Chieftain Dark Horse). Some of the connectors are unmarked and interchangeable. 1. CAUTION During disassembly. NOTE The inner fairing assembly can be removed with the radio module.50. Remove the outer fairing. Using a side-cutter. IMPORTANT 3.

Install the outer fairing assembly. 7. pay close attention to harness routing and connector 5. 11. 8. 1. 10.FRAME / BODY I N N E R FA I R I N G I N S TA L L AT I O N . Pay attention to index marks placed on connectors during disassembly when reconnecting as some of 3.(Chieftain Dark Horse). page 7. Install the inner fairing assembly on the four triple them are interchangeable.(Chieftain Dark Horse). See Outer Fairing Installation . 6. reconnect all of the multi-plugs between the chassis and inner faring.49 12. Carefully route all loose wires through the access hole in the inner fairing mount. Verify that no wires or connectors have been pinched between the inner fairing and the triple clamp and torque mounting nuts to specifications. 9927618 R03 . Rest the inner fairing assembly on the lower mounting studs q and tilt forward. and reconnect. page 7. Always route electrical wiring the same socket harnesses so they can be secured by their way as it was removed to avoid damaging wires and respective cable ties e.48 © Copyright . IMPORTANT 2. clamp studs w and install washers and nuts finger tight. Install the instrument cluster. Route the fog lamp button and 12V accessory orientation. 9. Paying attention to the natural form of the wiring harness. Position the wiring harness so it can be secured by the four cable ties. connectors. Replace the cable ties securing the fog lamp button and 12V accessory socket to the inner fairing.2017 Indian Motorcycle (Full-Size) Service Manual 7. Connect the radio antenna and radio multi-plugs. See Instrument Panel Removal / Installation .50 4.( C H I E F TA I N D A R K TORQUE HORSE) Inner Fairing Mounting Nuts: CAUTION 12 ft-lbs (16 Nm) During installation of the inner fairing. Remove the cut cable ties from the four fir tree clips and install new cable ties.

It is imperative that the fasteners are installed in the correct location or damage to outer fairing may occur. 9927618 R03 . Install the LH and RH speaker grills. TORQUE Head Light Bezel: 36 in-lbs (4 Nm) 4.( C H I E F TA I N D A R K 3. Install the six fasteners r into the inner fairing assembly and torque to specification. Install outer fairing assembly q onto fairing subframe as shown.49 . Install head light bezel and torque fasteners e to HORSE) specification. 2. TORQUE Head Light Bracket Fasteners: TORQUE 75 in-lbs (8 Nm) Inner Fairing Fasteners: 36 in-lbs (4 Nm) 5. Reference the drawing below for proper fastener locations. CAUTION Fasteners installed in STEPS 4 & 6 are different lengths. make sure the correct placement of fasteners when installing. Some fasteners are longer than others. FRAME / BODY O U T E R FA I R I N G I N S TA L L AT I O N .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. Install the head light assembly w and torque fasteners to specification. 1. 7 NOTE Refer to the notes made when removing the fasteners.

alternately lift the LH side q and RH side w of the instrument panel until the rubber retainer is free. 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. Lift instrument panel out of the fairing mount and disconnect the single multi-plug. 2.2017 Indian Motorcycle (Full-Size) Service Manual 7.FRAME / BODY 6. 4. INSTALLATION is performed by reversing the removal procedure. Using Body Panel tool (PV-49955) or a similar tool.50 © Copyright . Using a mild soapy water solution on the rubber seal will make it easier to press the instrument panel into position. TORQUE Upper Fairing Fasteners: 36 in-lbs (4 Nm) 7. 3. TORQUE Windshield Fasteners: 36 in-lbs (4 Nm) 9927618 R03 . Position the motorcycle on it’s side stand on a flat surface. Install the windshield and torque fasteners y to specification. CAUTION Do not use alcohol on seal for installation. ( C H I E F TA I N D A R K H O R S E ) 1.

Remove two fasteners q and head light bezel. Place the power windshield in the FULL UP position prior to fairing removal. Remove the five fasteners e from the windshield and remove windshield. Remove the four fasteners r from the top of the fairing assembly. Remove three fasteners w and withdraw the head light assembly far enough to disconnect electrical connector. FRAME / BODY 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 . NOTE When removing the five windshield fasteners be sure to capture the T-nuts as they are not captive. 1. Place the motorcycle on a flat surface resting on it’s side stand. 3.( C H I E F TA I N / R O A D M A S T E R ) NOTE 4. 2. 9927618 R03 .51 .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. 7 5.

side speaker grills t. Remove two short fasteners. four longer fasteners y and two washers u from the inner fairing assembly.FRAME / BODY 6. make sure to note placement of fasteners when removing. 9927618 R03 .2017 Indian Motorcycle (Full-Size) Service Manual 7. NOTE Some fasteners are longer than others. Pull speaker grills bottom out and then downward to remove. 7. Remove two fasteners from both the left and right 8.52 © Copyright . Remove fairing assembly.

53 .57 3. Always route electrical wiring the same way as it was removed to avoid damaging wires and connectors. See Ride Command System Removal.(Chieftain / Roadmaster). Remove four nuts q and washers securing the inner fairing support to the triple clamp assembly. page 7.51 2. CAUTION During disassembly. pay close attention to harness routing and connector orientation. 7 4. 9927618 R03 . Remove the outer fairing. Remove the instrument cluster. Some of the connectors are unmarked and interchangeable. Disconnect all multi plugs in harness holder bracket. See Outer Fairing Removal .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7. Lift the inner fairing assembly off of the triple ROADMASTER) clamp studs and route wire through the access hole. page 7. 1. FRAME / BODY I N N E R FA I R I N G R E M O VA L .( C H I E F TA I N / 5. IMPORTANT Use a marker or tape to index each multi-plug before disconnecting.

1. 4. Verify that no wires or connectors have been pinched between the inner fairing and the triple clamp and torque mounting nuts to specifications. See Ride Command hole in the inner fairing mount. Carefully route all loose wires through the access 8. System Installation. Rest the inner fairing assembly on the lower mounting studs q and tilt forward. See Outer Fairing Installation . Connect all multi plugs in harness holder bracket. 6. reconnect all of the multi-plugs between the chassis and inner faring. Install the inner fairing assembly on the four triple clamp studs w and install washers and nuts finger tight.( C H I E F TA I N / 5. TORQUE Inner Fairing Mounting Nuts: 12 ft-lbs (16 Nm) 9927618 R03 . Paying attention to the natural form of the wiring harness.2017 Indian Motorcycle (Full-Size) Service Manual 7. 7.FRAME / BODY I N N E R FA I R I N G I N S TA L L AT I O N . Install the outer fairing assembly. page 7.54 © Copyright .(Chieftain / Roadmaster). Always route electrical wiring the same way as it was removed to avoid damaging wires and connectors.58 3.55 2. ROADMASTER) CAUTION During installation of the inner fairing. IMPORTANT Pay attention to index marks placed on connectors during disassembly when reconnecting as some of them are interchangeable. Install the instrument cluster. page 7. pay close attention to harness routing and connector orientation.

36 in-lbs (4 Nm) 4. 7 TORQUE Head Light Bracket Fasteners: 75 in-lbs (8 Nm) NOTE Some fasteners are longer than others. Install one washer u per side between the lower fasteners and the fairing. Install outer fairing assembly onto fairing subframe as shown.( C H I E F TA I N / 3. FRAME / BODY O U T E R FA I R I N G I N S TA L L AT I O N .2017 Indian Motorcycle (Full-Size) Service Manual © Copyright 7.55 . make sure to note placement of fasteners when removing. Install two short fasteners and four longer fasteners y into the inner fairing assembly. Install head light bezel and torque fasteners q to ROADMASTER) specification. TORQUE Inner Fairing Fasteners: 36 in-lbs (4 Nm) 9927618 R03 . TORQUE Head Light Bezel: 2. Torque fasteners to specification. Install the head light assembly w and torque fasteners to specification. 1.

TORQUE Upper Fairing Fasteners: 36 in-lbs (4 Nm) 9927618 R03 . TORQUE TORQUE Speaker Fasteners: Windshield Fasteners: 36 in-lbs (4 Nm) 36 in-lbs (4 Nm) 6. specification. Torque to specification.56 © Copyright .2017 Indian Motorcycle (Full-Size) Service Manual 7. Install two fasteners into both the left and right side 7.FRAME / BODY 5. Install the four fasteners r into the top of the fairing assembly and torque to specification. Install the windshield and torque fasteners e to speaker grills t.

Speedometer. 5.(Chieftain / Roadmaster). See Outer