Page 1 PRINTED P/N 99-846 CD P/N 99-821...
Page 3: Foreword
Procedures for removal and installation, disassembly, motorcycles require regular maintenance in accordance cleaning and inspection of component parts and with the recommendations of Indian Motorcycle assembly are included when more extensive repairs or Company. This manual describes all the necessary a complete overhaul is required.
Page 4 NOTES INDIAN CHIEF SERVICE MANUAL...
Page 5: Table Of Contents
INDIAN CHIEF SERVICE MANUAL TABLE OF CONTENTS GENERAL INFORMATION FOREWORD ..............1 Organization and Content .
Page 6 TABLE OF CONTENTS INDIAN CHIEF SERVICE MANUAL Fork Oil Replacement ............33 Fork Tube Procedures .
Page 7 INDIAN CHIEF SERVICE MANUAL TABLE OF CONTENTS AIR CLEANER AIR CLEANER AND FILTER ELEMENT SERVICE ........95 Air Cleaner .
Page 8 TABLE OF CONTENTS INDIAN CHIEF SERVICE MANUAL Rocker Box Procedures ........... . 134 Pushrod and Tube Removal and Installation .
Page 9 INDIAN CHIEF SERVICE MANUAL TABLE OF CONTENTS Starter Relay ............224 CHARGING SYSTEM CHARGING SYSTEM SERVICE .
Page 10 TABLE OF CONTENTS INDIAN CHIEF SERVICE MANUAL viii INDEX ............... 283...
Page 11: Finding The Information You Need
INDIAN CHIEF SERVICE MANUAL GENERAL INFORMATION FEATURES OF THE 2003 INDIAN CHIEF MOTORCYCLE The Indian Chief motorcycle is a classic design with its Engine and Related Systems heritage going back to the beginning of the twentieth century. Today, the motorcycle carries forth the Basic engine —...
Page 12 GENERAL INFORMATION INDIAN CHIEF SERVICE MANUAL Fuel system — The fuel system includes dual tanks with a total capacity of 5.5 gallons including the 1.2-gallon reserve. Fuel is gravity fed to a Mikuni HSR carburetor mounted at the left side of the engine between the cylinder heads.
Page 13 INDIAN CHIEF SERVICE MANUAL GENERAL INFORMATION Transmission and Drive Rear drive — The rear drive uses a cogged, arimid- reinforced belt, 1-7/16” wide, connecting the transmission output drive sprocket with the rear wheel Primary drive — A dual-track drive chain links the sprocket.
Page 14: Motorcycle Identification
GENERAL INFORMATION INDIAN CHIEF SERVICE MANUAL MOTORCYCLE IDENTIFICATION There are three signiﬁcant identiﬁcation numbers on Within the ﬁrst 11 positions, the number provides the motorcycle. The numbers include the chassis information such as vehicle type, make, model, model Vehicle Identiﬁcation Number (VIN) along with year, engine, etc.
Page 15: Engine Serial Number
Note: A “note” (placed in italic type) indicates information that may be important in understanding the Note: Indian Motorcycle Corporation continuously signiﬁcance of a procedure or useful in performing the strives for improvements in product design, quality and maintenance, adjustment or repair procedure.
Page 16 NOTES INDIAN CHIEF SERVICE MANUAL...
Page 17: Maintenance
INDIAN CHIEF SERVICE MANUAL MAINTENANCE MAINTENANCE Maintenance requirements for the Indian Chief motorcycle include three levels of service performed at speciﬁc mile- age intervals. The three levels of service include the following: Primary Service — at 500 miles, 5,000 miles and every 10,000 miles thereafter Interval Service —...
Page 18: Renewal Service
MAINTENANCE INDIAN CHIEF SERVICE MANUAL Renewal Service 15. Inspect the fuel ﬁlter screen; clean or replace it as required ( page 98 ). Perform the following 33 Renewal Service checks and 16. Check the enrichner operation and adjust it as procedures at 10,000 miles and at every 10,000 miles required ( page 109 ).
Page 19: Troubleshooting
INDIAN CHIEF SERVICE MANUAL TROUBLESHOOTING CHASSIS TROUBLESHOOTING Brakes Brakes Weak or Do Not Hold Normally Problem Remedy Master cylinder(s) low on ﬂuid. Reﬁll with recommended brake ﬂuid. Brake fade from heat build-up (excessive braking). Let brakes cool. Downshift to cause engine braking. Brake fade due to brake pad hang-up or dragging.
Page 20: Engine Troubleshooting
TROUBLESHOOTING INDIAN CHIEF SERVICE MANUAL ENGINE TROUBLESHOOTING Symptom-Related Diagnostics Engine difﬁcult to start: • Battery low on charge Carburetor • Spark plugs in bad condition, have improper gap or are partially fouled Engine ﬂoods: • Incorrect spark plugs • Excessive pumping of throttle before or while •...
Page 21: Basic Engine Tests
INDIAN CHIEF SERVICE MANUAL TROUBLESHOOTING Starter does not operate or does not turn engine over: • Exhaust pipe — indicates a defective exhaust valve • Engine stop switch in OFF position • Head gasket — indicates defective head gasket, • Ignition switch not in ON position cylinder head surface or cylinder surface •...
Page 22: Emission Control System Troubleshooting
TROUBLESHOOTING INDIAN CHIEF SERVICE MANUAL EMISSION CONTROL SYSTEM TROUBLESHOOTING Evaporative System Checks • Check the electrical circuit supplying power to the solenoid for continuity and appropriate power. Repair the circuit as necessary. Problems with the evaporative emission system are primarily the result from the failure of the air valve to •...
Page 23 INDIAN CHIEF SERVICE MANUAL TROUBLESHOOTING Tools required: With the transmission in neutral, turn both the ignition key switch to the ON position and engine start switch 5/32 " hex bit to the RUN position. 13/16 " deep-well socket Depress the start switch and observe the tester’s SENSOR indicator light as the engine turns over.
Page 24 TROUBLESHOOTING INDIAN CHIEF SERVICE MANUAL • Indicator light does not cycle on and off — The Clean the spark plug area of the cylinder heads with speed sensor is malfunctioning or it is improperly compressed air. positioned in the transmission housing and not Remove the spark plugs, using a 13/16”...
Page 25 INDIAN CHIEF SERVICE MANUAL TROUBLESHOOTING Connect the ignition cover (trigger plate) three-pin Using the cable supplied with diagnostic kit 88-990, terminal to the chassis harness connector. connect the computer to the diagnostic port at the center of the motorcycle’s ignition module. Ignition Module Operational Check A laptop or personal computer and the SmartLink™...
Page 26 TROUBLESHOOTING INDIAN CHIEF SERVICE MANUAL Figure 39 — Typical operation check screen...
Page 27: Carburetor Troubleshooting
INDIAN CHIEF SERVICE MANUAL TROUBLESHOOTING CARBURETOR TROUBLESHOOTING Overﬂow or Flooding Problem Remedy Loose ﬂoat bowl or damaged ﬂoat bowl seal ring. Tighten ﬂoat bowl screws. Replace seal ring as neces- sary. Improper fuel level in ﬂoat bowl. Adjust needle actuating tab on ﬂoat to correct fuel level.
Page 28 TROUBLESHOOTING INDIAN CHIEF SERVICE MANUAL Poor Idle Problem Remedy Damaged or restricted fuel tank vent system. Repair or unclog vent system. Loose ﬂoat bowl or damaged ﬂoat bowl seal ring. Tighten ﬂoat bowl screws. Replace seal ring as neces- sary. Improper fuel level in ﬂoat bowl.
Page 29 INDIAN CHIEF SERVICE MANUAL TROUBLESHOOTING Poor Full Throttle Performance Problem Remedy Leaks in intake between carburetor and cylinder heads. Repair leaks or replace parts as required. Damaged or restricted fuel tank vent system. Repair or unclog vent system. Dirty air cleaner element. Clean or replace as required.
Page 30: Transmission And Drive Troubleshooting
TROUBLESHOOTING INDIAN CHIEF SERVICE MANUAL TRANSMISSION AND DRIVE TROUBLESHOOTING Transmission Shifts Hard Problem Remedy Primary drive housing overﬁlled with lubricant. Drain and reﬁll with proper amount of lubricant. Clutch dragging slightly. Check and adjust clutch and clutch cable. Transmission lubricant too heavy (operation in cold Run until transmission warms.
Page 31 INDIAN CHIEF SERVICE MANUAL TROUBLESHOOTING Clutch Drags or Does Not Release Problem Remedy Clutch controls improperly adjusted. Adjust as necessary. Primary case lubricant level too high. Drain and reﬁll with proper amount of lubricant. Clutch discs warped. Check and replace components as necessary. Primary chain badly misaligned.
Page 32: Electrical Troubleshooting
TROUBLESHOOTING INDIAN CHIEF SERVICE MANUAL ELECTRICAL TROUBLESHOOTING Electrical Troubleshooting Charts Alternator Alternator Does Not Charge Problem Remedy Voltage regulator not grounded. Inspect and repair ground as necessary. Engine ground wire loose or broken. Inspect and repair ground as necessary. Faulty voltage regulator. Test and replace as necessary.
Page 33: Battery Testing
INDIAN CHIEF SERVICE MANUAL TROUBLESHOOTING Battery Testing Always turn the battery load tester OFF before General connecting leads to battery terminals. Connecting leads with tester ON can cause a spark resulting in a Refer to CHARGING SYSTEM SERVICE for battery battery explosion and result in serious personal removal, installation and inspection procedures.
Page 34: Ground Path Tests
TROUBLESHOOTING INDIAN CHIEF SERVICE MANUAL Using the Battery Charger Battery Charging Rate Charge the battery if any of the following conditions Battery 2.1 Amp exist: Battery Rating Voltage Charge Rate • Vehicle lights are dim. 12.6 1.75 Hours • Starter motor cranks slowly or sounds weak. •...
Page 35: Current Draw/Leak Test
INDIAN CHIEF SERVICE MANUAL TROUBLESHOOTING Battery to Starter Check for current ﬂow on a scale that is safe for the ammeter. The ammeter should read zero current ﬂow. Set your meter to ohms (resistance). Place a probe upon If current ﬂow reads zero on a higher scale, recheck on the negative post of the battery and the other probe a milliampere scale of the ammeter.
Page 36: Charging System Tests
TROUBLESHOOTING INDIAN CHIEF SERVICE MANUAL • While observing the voltage output, slowly increase the tester load until a steady 13-volt output reading is obtained. • Read the current output. It should be at least 18 amperes. Bring the rpm to idle and stop the engine. Remove the load tester from the battery supply circuit of the regulator and reconnect the black wire to the circuit breaker, using a 3/8”...
Page 37 INDIAN CHIEF SERVICE MANUAL TROUBLESHOOTING Stator Resistance Check Connect the leads from a volt-ohmmeter across the stator terminals and set the meter to read AC voltage. Connect the leads of a volt-ohmmeter between one of the two terminals at the stator. With the meter set to the ohm’s scale, the resistance reading should be between 0.1 to 0.2 ohms.
Page 38: Starting System Tests
TROUBLESHOOTING INDIAN CHIEF SERVICE MANUAL Starting System Tests The following starting system tests are helpful in isolating the cause of a system problem at the solenoid, the starter motor or the circuit wiring. Note: The battery must be in good condition and at a full state of charge prior to conducting the following tests.
Page 39 INDIAN CHIEF SERVICE MANUAL TROUBLESHOOTING should read zero resistance on the meter. If you Power at EHC don’t get a reading or anything above .06, replace Start at the J-4 connector by unplugging the J-4 out of the wire. the socket. Check the pin # 3 at the EHC socket. You should have 12v power.
Page 40 TROUBLESHOOTING INDIAN CHIEF SERVICE MANUAL Resistance Tests Replace the battery power cable and perform the voltage drop test again. An ohmmeter can be used to check for continuity in If the voltage drop is 0.5 volt DC or less, then the cable circuits and components to ﬁnd open, shorted or is operating satisfactory.
Page 41 INDIAN CHIEF SERVICE MANUAL TROUBLESHOOTING — Positive side: 0.5 volt DC With the solenoid mounted on the starter motor, disconnect the starter motor cable from the starter — Negative side: 0.4 volt DC terminal on the solenoid and conduct the following —...
Page 42: Front Suspension
FRONT SUSPENSION INDIAN CHIEF SERVICE MANUAL FRONT SUSPENSION SERVICE General Information The oil seal on the ILM suspension is recessed into the top of the fork slider and is retained with a snap ring. The Paioli has a dust wiper, which extends above the Early-production Indian Chief motorcycles are fork slider.
Page 43: Fork Oil Replacement
INDIAN CHIEF SERVICE MANUAL FRONT SUSPENSION Fork Oil Replacement Fork Tube Procedures Tool required: Tools required: #3 Phillips screwdriver 6 mm hex bit 8 mm hex bit Procedure 1/2" hex bit Place a drain pan under the right fork tube. Remove 21 mm open end wrench the drain plug and copper sealing washer from the lower rear of the fork using a #3 Phillips screwdriver.
Page 44 FRONT SUSPENSION INDIAN CHIEF SERVICE MANUAL Using a tie, secure the caliper to the frame in a position Remove the fork tube cap from each fork tube, using a out-of-way. 1-3/8" wrench. Figure 59 — Remove fork tube cap Figure 57 — Securing caliper out-of-way Slide the fork tube assembly from the upper and lower Remove the front wheel.
Page 45 INDIAN CHIEF SERVICE MANUAL FRONT SUSPENSION Fork Tube Disassembly Figure 61 — Fork assembly (ILM) If not already done, use a #3 Phillips screwdriver to Set the plug aside and remove the long spacer, washer remove the drain plug and washer from the fork slider and spring from the upper fork tube.
Page 46 FRONT SUSPENSION INDIAN CHIEF SERVICE MANUAL With the assembly securely clamped in the vise, Slide the short top out spring onto the damping tube remove the damping tube retainer screw and washer, from the tapered bottom end. With the spring in using a 6 mm hex bit.
Page 47 INDIAN CHIEF SERVICE MANUAL FRONT SUSPENSION Slide the upper bushing onto the fork tube and into Using an 8 mm hex bit, install the two mounting position at the top of the slider. Next, place a suitable screws securing the brake caliper to the left fork driver in position over the slider bushing.
Page 48: Steering Components
STEERING COMPONENTS INDIAN CHIEF SERVICE MANUAL STEERING COMPONENT SERVICE The steering components consist of the upper and Note: Flat spotting of a bearing race may occur from a lower fork brackets (triple clamp) and the handlebars. heavy blow, typically from wheelies, collisions with cars, the The lower fork bracket has an integral stem that is the cycle being dropped from a truck, etc.
Page 49 INDIAN CHIEF SERVICE MANUAL STEERING COMPONENTS Return the wheel back to center and perform the same Bearing Preload Adjustment test to the left. Fall-away to the left will occur earlier because of the weight of the brake caliper. With the motorcycle supported on a lift and the front wheel off the ground, adjust bearing preload using this procedure.
Page 50 STEERING COMPONENTS INDIAN CHIEF SERVICE MANUAL Flatten the tab washer, using a punch and hammer. Insert the spanner wrench under the upper fork clamp and engage the adjusting nut at the top of the stem. Tighten or loosen the adjusting nut depending on the “fall away”...
Page 51: Steering Stem Disassembly And Assembly
INDIAN CHIEF SERVICE MANUAL STEERING COMPONENTS Steering Stem Disassembly and Flatten the tab of the washer used to secure the upper fork bracket crown nut, using a punch and hammer. Assembly If either triple clamp, the stem or bearings are worn or damaged in any way, the unit can be disassembled and parts replaced as required.
Page 52 STEERING COMPONENTS INDIAN CHIEF SERVICE MANUAL Remove the upper triple clamp and handlebar as an Slide the lower triple clamp out of the frame. Remove assembly. Place the triple clamp and handlebar in a the lower bearing from the triple clamp. secure position out-of-way.
Page 53 INDIAN CHIEF SERVICE MANUAL STEERING COMPONENTS Bearing Race Removal Install the upper bearing and bearing dust cover over the stem and into position on the upper bearing race. To remove the upper race from the frame stem tube, place a suitable bearing race remover in position on the upper race.
Page 54: Handlebar Replacement
STEERING COMPONENTS INDIAN CHIEF SERVICE MANUAL Install the upper fork bracket onto the stem. Install the Handlebar Replacement tab washer and crown nut to secure the upper fork bracket. DO NOT tighten the crown nut at this time. The handlebar can be removed as an assembly with switches, brake, clutch and throttle controls remaining in place and positioned out-of-way for service of the steering stem bearings.
Page 55 INDIAN CHIEF SERVICE MANUAL STEERING COMPONENTS Remove the retaining screws from the brake lever and Remove the handlebar clamp cover screws, using a master cylinder assembly, using a 5/32” hex bit. 3/16” hex bit, and remove the cover. Remove the assembly from the handlebar. Secure it in a position out-of-way.
Page 56 STEERING COMPONENTS INDIAN CHIEF SERVICE MANUAL Handlebar Installation Apply blue threadlock to the threads of the four handlebar clamp screws. Place the handlebar in position over the clamp base on the upper fork bracket. While supporting the handlebar in position on the clamp base, install the upper clamp plate and retaining screws.
Page 57: Rear Suspension
INDIAN CHIEF SERVICE MANUAL REAR SUSPENSION REAR SUSPENSION SERVICE Shock Absorber Figure 89 — Rear shock absorber assembly Tools required: 3/16" hex bit 1/4" hex bit 9/16" wrench and/or socket 1-1/16" wrench Spanner wrench with 2-3/4" pin centers Torque wrench...
Page 58 REAR SUSPENSION INDIAN CHIEF SERVICE MANUAL Shock Absorber Removal Shock Absorber Inspection and Adjustment Remove the seat and rear fender following procedures Inspect the shock absorber for any damage to the under FRAME AND ACCESSORIES SERVICE. spring and for oil leaks from the body. Disconnect the battery cables and remove the battery Inspect the rubber bushing on each end of the shock for following the procedures under CHARGING SYSTEM...
Page 59 INDIAN CHIEF SERVICE MANUAL REAR SUSPENSION Insert the mounting bolts and thread on the nuts. Figure 93 — Shock absorber installation Using a 1/4” hex bit to keep the mounting bolts from turning, tighten the nuts to speciﬁcation with a 9/16” socket and torque wrench.
Page 60: Swingarm
REAR SUSPENSION INDIAN CHIEF SERVICE MANUAL Swingarm Figure 94 — Rear swingarm assembly Tools required: 3/8" hex bit 15/16" wrench and/or socket Bearing driver Torque wrench Arbor or hydraulic press...
Page 61 INDIAN CHIEF SERVICE MANUAL REAR SUSPENSION Swingarm Removal Remove the rear wheel following the procedure under WHEEL AND TIRE SERVICE. Remove the shock absorber as described in this section. Using a 15/16” wrench, remove the nuts from the swingarm pivot bolts. Use a 3/8” hex bit to keep the pivot bolts from turning as the nuts are being loosened.
Page 62: Wheels And Tires
WHEELS AND TIRES INDIAN CHIEF SERVICE MANUAL WHEEL AND TIRE SERVICE Front Wheel Removal and Remove the axle nut, lock washer and ﬂat washer from the left side of the axle, using a 3/4” socket. Use a 1/2” Installation hex bit to prevent the axle from turning as the axle nut is being removed.
Page 63 INDIAN CHIEF SERVICE MANUAL WHEELS AND TIRES Note: One method of supporting the wheel and tire Note: The axle, spacers, washers and nut can be assembly for removal of the axle is to adjust the motorcycle reinstalled in fork sliders for safe keeping until it is time to lift so that the front wheel is just touching the ground.
Page 64 WHEELS AND TIRES INDIAN CHIEF SERVICE MANUAL Align the wheel hub with the axle and slide the axle Tighten the right-side axle pinch bolt to speciﬁcation, through the wheel. Install the large spacer onto the axle using an 8 mm hex bit. before the axle is inserted into the left fork slider.
Page 65: Rear Wheel Removal And Installation
INDIAN CHIEF SERVICE MANUAL WHEELS AND TIRES Attach a magnetic based dial indicator set onto the Obtain the correction spacer, install the wheel, axle and outer edge of the brake rotor. Position the dial indicator spacer and tighten the axle to speciﬁcation. against the axle center.
Page 66 WHEELS AND TIRES INDIAN CHIEF SERVICE MANUAL Using a 6 mm hex bit, remove the two mounting Loosen the two axle adjuster nuts, using a deep 1/2” screws securing the brake caliper to the right fork of wrench or deep-well socket. Loosen them in equal the swingarm.
Page 67 INDIAN CHIEF SERVICE MANUAL WHEELS AND TIRES Align the wheel hub with the axle and slide the axle all Note: One method of supporting the wheel and tire the way through the hub and the swingarm at the assembly for removal of the axle is to adjust the motorcycle right.
Page 68: Hub Bearing Cleaning And Inspection
WHEELS AND TIRES INDIAN CHIEF SERVICE MANUAL Check the belt tracking by rotating the wheel in both Install the rear fender following the procedure in the forward and rearward directions. The belt should track FRAME AND ACCESSORIES SERVICE section. from side-to-side (right to left in forward direction; left Lower the motorcycle to the ground and remove the to right in rearward direction) in approximately 15 lift.
Page 69 INDIAN CHIEF SERVICE MANUAL WHEELS AND TIRES Remove the seal from the left side of the wheel hub, using a seal removal tool or screwdriver. Remove the seal from the left side of the wheel hub, using a seal removal tool. Clean the seal and inspect it for wear or damage.
Page 70: Wheel Sprocket And Brake Rotor Removal And Installation
WHEELS AND TIRES INDIAN CHIEF SERVICE MANUAL Repeat this procedure to clean, inspect and install the Place the rotor in position on the wheel hub. If the rotor bearing and seal on the right side of the hub. is being reused, align it in the same position as originally installed.
Page 71: Wheel Rim, Hub And Spokes Inspection
INDIAN CHIEF SERVICE MANUAL WHEELS AND TIRES Rear Wheel Sprocket The wheel sprocket is attached to the rear wheel hub on the left side with ﬁve screws. Using a 3/8” hex bit, remove the ﬁve mounting screws and separate the sprocket and spacer from the wheel hub.
Page 72: Tire Inspection And Pressure Check
WHEELS AND TIRES INDIAN CHIEF SERVICE MANUAL Tighten spokes that are found to be loose, using a 6 mm open-end wrench. Tap each spoke as it is tightened, noting the tone. Figure 126 — Tightening spokes Once the spokes are tight, visually inspect the rim and hub for dents, cracks and out-of-roundness.
Page 73: Tire And Tube Replacement
INDIAN CHIEF SERVICE MANUAL WHEELS AND TIRES As the tire heats up, air inside the tire expands, raising Again, hot tires will show a pressure increase. DO NOT the tire pressure. Typically, this rise is on the order of let air out of a hot tire to bring it down to the cold two to six psi with the bike fully loaded and traveling pressure setting.
Page 74 WHEELS AND TIRES INDIAN CHIEF SERVICE MANUAL Tools required: Using the tire irons and protectors, pry the lower bead over the rim edge and into the center. Press the bead Tire irons against the lower seat of the rim. Rim protectors Partially inﬂate the tube for easier installation.
Page 75: Wheel Lacing
INDIAN CHIEF SERVICE MANUAL WHEELS AND TIRES WHEEL LACING Lacing 16-Inch, 60-Spoke Wheels • Rear wheel — 15/16" Repeat the process at two more locations on the rim. This procedure applies for both front and rear wheels. References to left and right sides of the wheel refer to The 60-spoke wheels are ﬁtted with hook-type spokes, its mounting on the motorcycle.
Page 76 WHEELS AND TIRES INDIAN CHIEF SERVICE MANUAL the front wheel, the valve stem hole is on the side keep them out of the way while spokes in the left (lower) are opposite the brake rotor mounting surface of the hub. being assembled to the rim.
Page 77: Aligning The Hub And Rim (Truing)
INDIAN CHIEF SERVICE MANUAL WHEELS AND TIRES Aligning the Hub and Rim (Truing) Tools required: 1/4" spoke wrench 3/16" hex bit Wheel stand with pointer (e.g., Chrome Spe- cialties, No. 400341) Straightedge Alignment Procedure Starting at the valve stem hole, divide the spokes into Figure 135 —...
Page 78 WHEELS AND TIRES INDIAN CHIEF SERVICE MANUAL Repeat this process at the three remaining tape-marked Slowly turn the rim and check for uniform clearance groups. between the pointer and the tire bead seat. The clearance should not vary by more than 1/32” between For spokes outside of the four marked groups, turn the high and low spots.
Page 79: Brake System
INDIAN CHIEF SERVICE MANUAL BRAKE SYSTEM BRAKE SYSTEM SERVICE Brake Fluid Level and Condition The ﬂuid level should be within 1/4” from the top of the reservoir. Add ﬂuid if needed. Brake ﬂuid level and condition must be checked at the 500-mile service interval and thereafter, at each 2500-mile interval.
Page 80: Brake Pad Replacement
BRAKE SYSTEM INDIAN CHIEF SERVICE MANUAL View the bottom of the reservoir for any debris. Check the thickness of the brake pads. Remove the old ﬂuid and ﬂush the system if necessary. The ﬂuid level should be within 1/4” from the top of the reservoir.
Page 81 INDIAN CHIEF SERVICE MANUAL BRAKE SYSTEM Brake Caliper Shimming Brake shim part numbers: Tools required: Thickness Part No. Feeler gauge Shim, .396˝ ID x .812˝ OD x .010˝ thick˝ 97-010 Torque wrench Shim, .396˝ ID x .812˝ OD x .030˝ thick 97-011 Ratchet driver Shim, .396˝...
Page 82 BRAKE SYSTEM INDIAN CHIEF SERVICE MANUAL When the correct clearance is achieved, apply Blue Slip the caliper from the mounting bracket and off the Loctite 242 to the caliper mounting screws (5) and brake rotor. tighten to 23-30ft/lbs Remove the push pin from the brake pad retaining pin and slide the retaining pin from the caliper.
Page 83: Brake Caliper Service
INDIAN CHIEF SERVICE MANUAL BRAKE SYSTEM Brake Caliper Service Remove the two mounting screws securing the caliper to the bracket on the left fork leg, using a 6 mm hex bit. Tools required: 5 mm hex bit 6 mm hex bit 9/16"...
Page 84 BRAKE SYSTEM INDIAN CHIEF SERVICE MANUAL Figure 147 — Front brake caliper assembly Installation Position the brake line ﬁtting to the caliper. Make sure one copper sealing washer is on each side of the ﬁtting. Slide the caliper over the front brake rotor and into Thread the ﬁtting bolt into the caliper and tighten to position on the mounting bracket on the left fork leg.
Page 85 INDIAN CHIEF SERVICE MANUAL BRAKE SYSTEM Rear Caliper Removal and Installation Note: There are no serviceable components for these calipers. If the caliper is damaged or worn in any way, replace the caliper as a unit. Figure 148 — Rear brake caliper Removal Remove the bolt securing the brake line ﬁtting to the caliper, using a 9/16”...
Page 86: Brake Rotor Service
BRAKE SYSTEM INDIAN CHIEF SERVICE MANUAL Brake Rotor Service Support the master cylinder outlet ﬁtting, using a 9/16” wrench, while removing the brake line. Rotor Inspection Remove the outlet ﬁtting and copper sealing washer from the master cylinder, using a 9/16” wrench. Inspect the front and rear brake rotors and check for Inspect the washer and replace as necessary.
Page 87 INDIAN CHIEF SERVICE MANUAL BRAKE SYSTEM Installation Install the outlet ﬁtting with copper sealing washer and tighten to speciﬁcation, using a 9/16” wrench. Insert the pushrod through the dust boot and into the Thread the hydraulic brake line onto the outlet ﬁtting. master cylinder piston.
Page 88 BRAKE SYSTEM INDIAN CHIEF SERVICE MANUAL Rear Master Cylinder Removal and Installation Installation Slide the rear master cylinder over the end of the brake pedal pushrod and align the cylinder with the screw Removal holes in the support bracket. Clean the exterior of the rear master cylinder. Apply red threadlock to the two rear master cylinder retaining screws.
Page 89 INDIAN CHIEF SERVICE MANUAL BRAKE SYSTEM Make sure the ports in the bottom of the reservoir are clear of debris or sediment. Make sure the vent holes in the reservoir cover are open. Thoroughly clean the piston and the master cylinder reservoir and cylinder bore, using a suitable brake cleaning solvent.
Page 90: Hydraulic Brake Line Replacement
BRAKE SYSTEM INDIAN CHIEF SERVICE MANUAL Rear Master Cylinder Disassembly Hydraulic Brake Line Replacement Remove the rear master cylinder assembly from the Tools required: support bracket. Refer to Rear Master Cylinder Removal and Installation in this section for procedures. 3/8" wrench Remove the dust boot and then, remove the snap ring 7/16"...
Page 91: Replacing Brake Fluid And Bleeding The Hydraulic System
INDIAN CHIEF SERVICE MANUAL BRAKE SYSTEM Installation Installation Thread the new brake line onto the outlet ﬁtting of the Route the new rear brake line as noted during removal. master cylinder and tighten to speciﬁcation, using a Make sure the line reaches both front and rear 7/16”...
Page 92 BRAKE SYSTEM INDIAN CHIEF SERVICE MANUAL Tools required: Remove the protective cap from the front caliper bleeder screw and install the 1/4” diameter clear Suction gun tubing onto the screw. 11 mm wrench Place the opposite end of the tube into a clear catch container.
Page 93: Frame And Accessories
INDIAN CHIEF SERVICE MANUAL FRAME AND ACCESSORIES FRAME AND ACCESSORIES SERVICE Seat Removal and Installation Lift up on the rear of the seat and pull the seat rearward to disengage the seat front retainer bracket from the frame. Remove the seat. Tool required: 5/32 "...
Page 94: Fender Removal And Installation
FRAME AND ACCESSORIES INDIAN CHIEF SERVICE MANUAL Fender Removal and Installation Carefully remove the front fender to avoid scratching the paint surface. It is helpful to apply light pressure to the sides of the fender, squeezing them inward just Tools required: enough to clear the mounting pads on the sliders.
Page 95 INDIAN CHIEF SERVICE MANUAL FRAME AND ACCESSORIES Rear Fender Removal With the help of an assistant, place the rear fender assembly in position on the motorcycle. Remove the seat following the instructions described under Seat Removal and Installation in this section. Cut the tie strap holding the four-pin rear light harness connector to the connector anchor.
Page 96: Chassis Fairing Removal And Installation
FRAME AND ACCESSORIES INDIAN CHIEF SERVICE MANUAL Chassis Fairing Removal and Dash Removal and Installation Installation Tool required: Tool required: 5/32 " hex bit 5/32 " hex bit Procedure Procedure To remove the dash, remove the screw at the rear of the panel, using a 5/32”...
Page 97: Front Turn Signal, Spotlight And Headlight Procedures
INDIAN CHIEF SERVICE MANUAL FRAME AND ACCESSORIES Front Turn Signal, Spotlight and Place the lens seal and lens in position in the housing. Install the retainer ring and screw to secure the lens. Headlight Procedures Assembly Removal and Installation Tools required: The spotlight housing is part of an assembly that includes a mounting pad for the signal light and a #2 Phillips screwdriver...
Page 98 FRAME AND ACCESSORIES INDIAN CHIEF SERVICE MANUAL Remove the upper screw completely and remove the Headlight Housing Removal spotlight assembly from the motorcycle. Remove the headlight trim ring, using a #2 screwdriver to remove the self-tapping screw at the bottom of the ring.
Page 99 INDIAN CHIEF SERVICE MANUAL FRAME AND ACCESSORIES Support the right spotlight bracket and remove the Position the right spotlight bracket to the headlight upper screw. Swing the lower end of the spotlight housing half and install the upper screw through the bracket out of the lower screw to remove the assembly.
Page 100: Fender-Mounted Light Procedures
FRAME AND ACCESSORIES INDIAN CHIEF SERVICE MANUAL Apply blue threadlock to the 10 screws used to attach Fender-Mounted Light Procedures the headlight to the housing. Tools required: Place the lens housing assembly in the headlight housing. #2 Phillips screwdriver 7/16 " socket 1/2 "...
Page 101: Floorboard And Buddy Peg Removal And Installation
INDIAN CHIEF SERVICE MANUAL FRAME AND ACCESSORIES To install the housing assembly, reverse the order of To install the housing assembly, reverse the order of disassembly. Route the wire lead along the six nylon disassembly. Route the wiring harness through the mounting blocks and through the hole at the left side of rubber splash guard and secure it with new tie straps at the fender.
Page 102: Mirror Assembly Removal, Installation And Adjustment
FRAME AND ACCESSORIES INDIAN CHIEF SERVICE MANUAL Buddy Peg Procedure Kickstand Removal and Installation The buddy pegs provide folding foot rests for the rear Tools required: seat passenger. The indexed pegs are mounted in the stanchions at the left and right sides of the frame just 6 mm hex bit forward of the rear wheel.
Page 103: Frame Inspection And Repair
INDIAN CHIEF SERVICE MANUAL FRAME AND ACCESSORIES Frame Inspection and Repair Figure 181 — Indian Chief frame The frame is the backbone of the motorcycle. It is a Cleaning and Inspection very durable component requiring little attention providing the motorcycle is properly maintained and Clean the frame thoroughly, removing all accumulated ridden under normal operating conditions.
Page 104 FRAME AND ACCESSORIES INDIAN CHIEF SERVICE MANUAL Repair Severe wear or damage uncovered during cleaning and inspection must be repaired. Slightly bent tubes can be straightened and weld repairs made. However, caution must be exercised whenever heat is applied in the process.
Page 105: Air Cleaner
INDIAN CHIEF SERVICE MANUAL AIR CLEANER AIR CLEANER AND FILTER ELEMENT SERVICE Air Cleaner To gain access to components such as the carburetor or engine for service, remove the air cleaner as a unit. Tools required: 1/2" combination wrench Slip-joint pliers Flat-blade screwdriver Removal Loosen the two 5/16”...
Page 106: Air Filter Element
AIR CLEANER INDIAN CHIEF SERVICE MANUAL Align the air cleaner brackets with the studs on the engine mounting bracket and under the nuts and washers. Push the air cleaner onto the carburetor air inlet until fully seated. Figure 185 — Remove air cleaner cover Remove the bottom two air ﬁlter element cover screws, using a 1/8”...
Page 107 INDIAN CHIEF SERVICE MANUAL AIR CLEANER Remove the three screws securing the ﬁlter element rear cover and air cleaner housing to the air cleaner-to- carburetor adapter. Use a 1/8” hex bit to remove the screws. Figure 190 — Remove air cleaner housing-to-bracket nuts Figure 188 —...
Page 108 AIR CLEANER INDIAN CHIEF SERVICE MANUAL Installation Align the ﬁlter element rear cover with the air cleaner housing. Note the orientation of the rear cover to the housing. The location of the crankcase vent ﬁttings is to Lubricate the air cleaner-to-carburetor adapter seal. the left.
Page 109 INDIAN CHIEF SERVICE MANUAL AIR CLEANER Install the air ﬁlter element and front cover onto the Position the air cleaner cover over the air ﬁlter element ﬁlter element rear cover in the air cleaner housing. and air cleaner housing. Align the holes in the cover with the threaded lugs of Install and tighten the ﬁve air cleaner cover screws to the air cleaner housing.
Page 110: Fuel System
FUEL SYSTEM INDIAN CHIEF SERVICE MANUAL FUEL SYSTEM SERVICE Fuel Filtration Maintenance Turn the petcock (fuel supply valve) to the off position. General Information Just like the engine, the fuel tank will contain a small amount of debris that needs to be removed. To accomplish this need, the fuel system is equipped with a ﬁlter screen in the petcock (fuel supply valve) to trap the particulates.
Page 111: Fuel Line Inspection And Replacement
INDIAN CHIEF SERVICE MANUAL FUEL SYSTEM Clean the screen using a tank solvent. Stubborn Fuel Line Inspection and material can sometimes be removed with carburetor Replacement cleaner. Visually check all fuel line hoses for deterioration, abrasion damage or cuts. Replace the hose sections as necessary with hose of the speciﬁed type.
Page 112 FUEL SYSTEM INDIAN CHIEF SERVICE MANUAL Remove the throttle/switch housing screws, using a Carefully place the top throttle housing section onto 5/32” hex bit. Slowly remove the top housing half, the bottom section. Install the two mounting screws being careful not to inadvertently dislodge the small and tighten very lightly.
Page 113: Fuel Tank Removal And Installation
INDIAN CHIEF SERVICE MANUAL FUEL SYSTEM Throttle Cable Adjustment Start the engine and let it idle. Move the handlebars left and right to the fork stops. The rpm of the engine should not increase. If it does, loosen the forward Adjustment of throttle cable free play is accomplished throttle cable adjuster until the engine rpm does not using the threaded adjusters located under the...
Page 114 FUEL SYSTEM INDIAN CHIEF SERVICE MANUAL Remove the screw at the rear of the dash panel, using a Disconnect and remove the vent and crossover tubes. 5/32” hex bit. Figure 209 — Fuel crossover tube and fuel supply line Figure 207 — Dash panel rear retaining screw Remove the screw in the dash panel, using a 5/32”...
Page 115 INDIAN CHIEF SERVICE MANUAL FUEL SYSTEM Support the tank and remove the mounting screws at Remove the right tank in the same manner by the upper front and center of the tank, using a 1/2” removing the three mounting screws at the lower front, wrench.
Page 116 FUEL SYSTEM INDIAN CHIEF SERVICE MANUAL Connect the fuel line from the shutoff valve on the left Using a 5/32” hex bit, tighten the rear screw to tank to the carburetor. speciﬁcation. Figure 216 — Fuel crossover tube and fuel supply line Figure 218 —...
Page 117: Carburetor Service
INDIAN CHIEF SERVICE MANUAL FUEL SYSTEM CARBURETOR SERVICE Carburetor Circuit Description The Idle Circuit The idle circuit is in operation between closed throttle The carburetor is divided into four interdependent and approximately 1/8 throttle opening. Some notable systems or circuits that provide the appropriate components of the idle circuit are: air/fuel mixture for all engine operating ranges.
Page 118 FUEL SYSTEM INDIAN CHIEF SERVICE MANUAL Jet Needle (1/4 to 3/4 throttle) Do not disassemble the throttle lever linkage. It is not normally necessary to remove the throttle shaft bolt to change position of the jet needle. If the bolt is removed, perform the following: 1.
Page 119: Air Leaks
INDIAN CHIEF SERVICE MANUAL FUEL SYSTEM Accelerator Pump Settings and Adjustments Gasoline is ﬂammable and explosive. Work in a well- The #1 screw is normally adjusted to establish a gap of ventilated area when draining gasoline and drain it approximately 0.080” (2 mm) between the white plastic into an approved container for gasoline storage.
Page 120 FUEL SYSTEM INDIAN CHIEF SERVICE MANUAL Remove the enrichener (choke) control cable from the upper engine mounting bracket, using a 9/16” wrench. Use a 7/16” wrench to keep the jam from turning if necessary. Figure 226 — Carburetor removal Installation Install the carburetor with the throttle-bore ﬂange Figure 224 —...
Page 121: Carburetor Maintenance
INDIAN CHIEF SERVICE MANUAL FUEL SYSTEM Connect the throttle control cables to the carburetor. Figure 230 — Air cleaner mounting brackets To secure the air cleaner, tighten the two bracket nuts Figure 228 — Throttle cables installed to speciﬁcation, using a 1/2” combination wrench. Install the enrichener (choke) control cable on the engine mounting bracket, using a 9/16”...
Page 122 FUEL SYSTEM INDIAN CHIEF SERVICE MANUAL The distance from the bottom surface of the carburetor Place the clip in the ﬁrst groove from the top of the to the top of the ﬂoat should be 16–20 mm. needle. Place the clip, open-end up, against a hard surface. Again, cover the clip area with your hand and press down on the needle to snap the clip into place.
Page 123: Carburetor Illustrations
INDIAN CHIEF SERVICE MANUAL FUEL SYSTEM Carburetor Illustrations Figure 232 — Carburetor (right side)
Page 124 FUEL SYSTEM INDIAN CHIEF SERVICE MANUAL Figure 233 — Carburetor (left side)
Page 125 INDIAN CHIEF SERVICE MANUAL FUEL SYSTEM Figure 234 — Carburetor exploded view...
Page 126 FUEL SYSTEM INDIAN CHIEF SERVICE MANUAL Carburetor Exploded View Legend 1. Top Cover Screw 22. Bolt Lock Tab Plate 43. Throttle Stop Screw 64. Pilot Jet 2. Top Cover Screw 23. Screw 44. Throttle Stop Nut 65. Main Jet Extender 3.
Page 127: Ignition System
INDIAN CHIEF SERVICE MANUAL IGNITION SYSTEM IGNITION SYSTEM SERVICE Spark Plug Replacement Using a 3/8” wrench, remove the retaining nuts and wires from the primary terminals at each end of the coil. Carefully twist and pull to disconnect the spark Tools required: plug wires from the terminals at the back of the coil.
Page 128: Ignition Cover Housing/Rotor Removal And Installation
IGNITION SYSTEM INDIAN CHIEF SERVICE MANUAL Place a new gasket in position and install the ignition Note: For easier access to the spark plugs and wires at cover housing. Apply blue threadlock to the threads of the right side of the motorcycle, remove the air cleaner the cover screws and install the screws.
Page 129: Lubrication System
INDIAN CHIEF SERVICE MANUAL LUBRICATION SYSTEM LUBRICATION SYSTEM SERVICE Engine Oil and Oil Filter Screw the ﬁlter into the ﬁlter mount until the gasket contacts the seating surface. Tighten another 1/2–3/4 Replacement of a revolution. Engine oil should be checked when warm and the Tools required: motorcycle is vertical.
Page 130: Oil Line Inspection And Replacement
LUBRICATION SYSTEM INDIAN CHIEF SERVICE MANUAL Clean the screen with a suitable oil removal product. Inspection at Oil Tank Inspect the screen for any metal chips. Chips may be removed with brake clean, carburetor clean, etc. If The oil tank has four points of inspection. If a leak is chips cannot be removed, replace the screen with a new found, the 90-degree ﬁtting can be tightened to part (#01-185).
Page 131: Oil Pump Removal And Installation
INDIAN CHIEF SERVICE MANUAL LUBRICATION SYSTEM Inspection at Cam Cover and Engine Block The cam cover and engine block each have one point of inspection. If leaking, tighten the oil ﬁtting at the bottom of the cam cover or bottom of the engine block, using a 12 mm open-end wrench.
Page 132: Oil Tank Removal And Installation
LUBRICATION SYSTEM INDIAN CHIEF SERVICE MANUAL Oil Tank Removal and Installation Figure 245 — Oil tank assembly Tools required: Loosen the clamps, using a ﬂat-blade screwdriver, and disconnect the four oil lines at the right front corner of 5/32 " hex bit the tank.
Page 133 INDIAN CHIEF SERVICE MANUAL LUBRICATION SYSTEM Connect the four oil lines at the right front corner of the tank and tighten the clamps securely. Proper connection is as follows: Cam cover vent — top left Pump bypass — top center Filter return —...
Page 134: Emission Control System
EMISSION CONTROL SYSTEM INDIAN CHIEF SERVICE MANUAL EMISSION CONTROL SYSTEM SERVICE Evaporative System Figure 246 — Evaporative system Description The evaporative system prevents fuel vapors (hydrocarbons) from escaping into the atmosphere. The system consists of an air valve at the inlet port on To control emissions in the state of California, Indian the back of the air cleaner housing, tank vapor valve, a motorcycles are equipped with an evaporative...
Page 135: Carbon Canister Removal And Installation
INDIAN CHIEF SERVICE MANUAL EMISSION CONTROL SYSTEM When the engine is shut down and the ignition switch Using a ﬂat-blade screwdriver, remove the clamps and is “off,” the air valve at the air cleaner intake is closed, disconnect the vent and purge hoses at the carbon blocking the outﬂow of fuel vapors.
Page 136: Exhaust System
EXHAUST SYSTEM INDIAN CHIEF SERVICE MANUAL EXHAUST SYSTEM SERVICE Mufﬂer, Heat Shields and Exhaust Remove the mufﬂer from the exhaust pipe, exercising care to avoid damaging the exhaust pipe assembly. Header To install the mufﬂer, reverse the order of disassembly. Tighten the mufﬂer mounting bolts to speciﬁcation.
Page 137: Engine
INDIAN CHIEF SERVICE MANUAL ENGINE ENGINE REMOVAL AND INSTALLATION Tools required: 5/32 " hex bit 3/16 " hex bit 1/4 " hex bit 3/8 " hex bit 1/2 " socket/wrench 9/16 " socket/wrench 3/4 " socket/wrench 1-1/2 " socket Drain pan Figure 250 —...
Page 138 ENGINE INDIAN CHIEF SERVICE MANUAL Using a 3/16” hex bit, remove the two bright-ﬁnish Remove the screws securing the air cleaner housing to mounting screws at the bottom front of the fuel tanks. the upper engine-mounting bracket and remove the air Then, using a 1/2”...
Page 139 INDIAN CHIEF SERVICE MANUAL ENGINE Remove the upper support bracket from the cylinder Using a 1/2” wrench, remove the two bolts retaining heads and the frame. The ignition coil can remain the mufﬂer to the bracket. Remove the exhaust pipe attached to the bracket.
Page 140: Engine Removal
ENGINE INDIAN CHIEF SERVICE MANUAL Engine Removal If the engine is to be removed from the chassis, complete all of the steps listed under Removing Chassis Components and Engine Accessories. Then, continue with the steps below. Place a drain pan under the drain plug at the bottom of the primary chain housing.
Page 141 INDIAN CHIEF SERVICE MANUAL ENGINE Loosen the chain adjuster, using a 9/16” socket, and slide the adjuster down to provide maximum slack in the chain. Figure 264 — Electrical leads to oil pressure switch and stator Remove the breather clamps and hoses from the ﬁttings at the breather valve and the bottom of the cam Figure 262 —...
Page 142: Engine Installation
ENGINE INDIAN CHIEF SERVICE MANUAL Remove the front and rear engine mounting bolts, Engine Installation using a 9/16” socket. Before installling the engine, remove any debris from the frame & engine mounting surfaces. Install a new rubber O-ring in the groove on the engine-to-primary housing mounting ﬂange on the crankcase.
Page 143: Installing Chassis Components And Engine Accessories
INDIAN CHIEF SERVICE MANUAL ENGINE Apply a thin coat of blue threadlock to the four inner Installing Chassis Components and primary housing-to-engine mounting screw threads. Engine Accessories Install the screws and tabbed lockwashers, using a 1/4” hex bit. Tighten the screws to 16–18 foot-pounds Place the upper support bracket in position and install and bend the washer tabs up to lock the screws in the bracket-to-frame bolt, using a 3/4”...
Page 144: Engine Disassembly And Assembly
ENGINE INDIAN CHIEF SERVICE MANUAL ENGINE DISASSEMBLY AND ASSEMBLY Rocker Box Procedures The procedures covered under Disassembly and Assembly can be done as separate operations with the engine mounted in-chassis or as a complete rebuild The following procedures apply for both the front and with the engine removed from the chassis.
Page 145 INDIAN CHIEF SERVICE MANUAL ENGINE Removal • Check the rocker arms, shafts and support brackets for cracks, nicks or other damage. Check the contact pads for wear. Using a 3/16” hex bit, remove the four screws retaining the rocker cover. •...
Page 146 ENGINE INDIAN CHIEF SERVICE MANUAL Rocker Shaft Assembly Slide the slotted end of the shafts into the right support bracket and align the slots with the mounting screw holes. Slide the left support bracket onto the other end Apply clean engine oil to the rocker shafts and insert of the shafts.
Page 147 INDIAN CHIEF SERVICE MANUAL ENGINE Installation If removed for service, place the rocker shaft assembly in position on the base. Make sure that the three dowel pins are in place and that the slots in the rocker shafts Clean the mating surfaces of the rocker box base and are properly aligned with the mounting screw holes in the cylinder head.
Page 148: Pushrod And Tube Removal And Installation
ENGINE INDIAN CHIEF SERVICE MANUAL Pushrod and Tube Removal and Installation Tool required: Small ﬂat-blade screwdriver Figure 277 — Pushrod and tube assemblies (early 2003 models)
Page 149 INDIAN CHIEF SERVICE MANUAL ENGINE Removal Inspect the three O-rings and washer and discard if damaged. Remove the pushrods from the bores in the cylinder Remove the second pushrod tube repeating the head. Be sure to note the location of each pushrod as it previous steps.
Page 150: Pushrod Adjustment
ENGINE INDIAN CHIEF SERVICE MANUAL Pushrod Adjustment With spring pressure released, slide the lower pushrod tubes upward to reveal the pushrods. Use elastic bands and clips to hold the lower tubes up and out of the way ™ Later model POWERPLUS 100 engines are now for adjustment.
Page 151: Cylinder Head Procedures
INDIAN CHIEF SERVICE MANUAL ENGINE With pushrod shortened to achieve end play and Repeat the above procedure for the other front cylinder locknut (2) loose, lengthen the pushrod by holding the pushrod. ball end adjuster (3), using either a 3/8” or 7/16” With adjustment ﬁnished, remove the elastic bands wrench, and turning the pushrod (3) with your ﬁngers.
Page 152 ENGINE INDIAN CHIEF SERVICE MANUAL Figure 285 — Cylinder head assembly...
Page 153 INDIAN CHIEF SERVICE MANUAL ENGINE Removal Turn the driving screw out to release pressure on the spring and remove the cylinder from the tool. Remove the rocker box assembly (see Rocker Box Remove the upper collar and spring set from the top of Procedures).
Page 154 ENGINE INDIAN CHIEF SERVICE MANUAL If the valve guide is to be removed, use valve guide Ream the bore of the new guides to the following ® tool, JIMS 34740-84, and a hammer to drive the guide speciﬁed diameters, then ﬁnish hone and thoroughly out from the head.
Page 155 INDIAN CHIEF SERVICE MANUAL ENGINE Installation cleaner ﬁtted with a spray tube. Fully insert the spray tube into the bolt and work out from the base of the threads. Use compressed air to ﬁnal clean and dry the Install the two dowel pins in the cylinder and install a threads.
Page 156: Cylinder And Piston Assembly Procedures
ENGINE INDIAN CHIEF SERVICE MANUAL Cylinder and Piston Assembly Procedures Tools required: ® Dental pik, 2361 (available from JIMS ® Piston lock ring tool (available from JIMS • Driver, 96780-58A-2 (requires modiﬁcation) • Collar, 96781-72-2 (requires modiﬁcation) Refer to the SPECIAL TOOL REQUIREMENTS section for tool modiﬁcation prints.
Page 157 INDIAN CHIEF SERVICE MANUAL ENGINE Cylinder and Piston Removal Cylinder Inspection Remove the cylinder heads (see Cylinder Head Check that the cylinder gasket surfaces are free from Procedures). burrs and scratches. Turn the sprocket shaft until both pistons are Check the cylinder-to-cylinder head and cylinder-to- positioned at mid-stroke in the cylinders.
Page 158 ENGINE INDIAN CHIEF SERVICE MANUAL Piston Inspection and Ring Replacement Check the side clearance for each piston ring. Replace the rings, the piston, or both if the ring side clearance is not within speciﬁcation (see Speciﬁcations). Use a carbon scraper to remove excessive carbon deposits from the pistons.
Page 159 INDIAN CHIEF SERVICE MANUAL ENGINE Install the second compression ring with the dot facing Remove the rod alignment tool from the connecting upward. rod and lubricate the wrist pin and connecting rod with clean engine oil. Place the piston in position on the connecting rod with the notched skirt facing the middle of the engine.
Page 160 ENGINE INDIAN CHIEF SERVICE MANUAL Insert the tool into the piston and wrist pin and drive Lubricate the cylinder bore, pistons and rings with the spiral lock into place in the piston pin bore. clean engine oil. Figure 303 — Installing spiral lock Figure 305 —...
Page 161: Alternator Rotor/Stator Removal And Installation
INDIAN CHIEF SERVICE MANUAL ENGINE Alternator Rotor/Stator Removal Place blue threadlock on the stator plug setscrew. Install and tighten the setscrew to 2 to 2-1/2 turns from and Installation lightly seated. Tools required: Lifter Block Removal and Installation 5/32" hex bit Torque wrench Tools required: Removal...
Page 162: Oil Pump Removal And Installation
ENGINE INDIAN CHIEF SERVICE MANUAL Oil Pump Removal and Cleaning and Inspection Installation Clean the lifter blocks with a suitable oil removal product. Remove the tappet screen plug, using a 1/4” hex bit. Inspect the lifters and lifter blocks for wear or damage. Then, remove the spring and tappet screen.
Page 163: Ignition Cover Housing/Rotor Removal And Installation
INDIAN CHIEF SERVICE MANUAL ENGINE Ignition Cover Housing/Rotor Inspect the leads and connector for the sensor sealed in the cover. If damaged, repair or replace as necessary. Removal and Installation Position the rotor on the end of the camshaft with the alignment pin in the shaft slot.
Page 164: Cam, Breather Valve And Pinion Gear Removal And Installation
ENGINE INDIAN CHIEF SERVICE MANUAL Cam, Breather Valve and Pinion Pinion gear installer/puller (available from ® JIMS Gear Removal and Installation • Screw, 96830-51-2 Tools required: • Puller, 96830-51-3 Rod alignment tool, 1010 (available from 3/16" hex bit ® JIMS Cam cover puller (to be fabricated —...
Page 165 INDIAN CHIEF SERVICE MANUAL ENGINE Removal Note: If the engine is not being disassembled and only the breather valve or cam is to be removed, then align the Remove the rocker box assemblies, pushrods and timing marks on the gears before removing the breather valve tubes, lifter block assemblies and ignition cover and or cam.
Page 166 ENGINE INDIAN CHIEF SERVICE MANUAL To remove the pinion gear nut, the crankshaft must be To remove the pinion gear, install the pinion nut puller ® locked in position. Use a mainshaft sprocket locknut and screw, JIMS 96830-51-3 and 96830-51-2, as shown. ®...
Page 167 INDIAN CHIEF SERVICE MANUAL ENGINE Installation Install the inner key, oil pump gear, spacer, and outer key and pinion gear on the pinion shaft. Figure 319 — Pinion shaft, cam and breather valve assemblies Apply a thin coating of red threadlock to the threads Lubricate the pilot bearing in the crankcase and the on the pinion shaft.
Page 168 ENGINE INDIAN CHIEF SERVICE MANUAL Make sure that the timing marks of the breather valve Apply blue threadlock to the threads of the cam cover and camshaft gears are properly aligned. mounting screws. Install the cam cover and the seven screws around the perimeter of the cover.
Page 169: Crankcase Disassembly And Assembly
INDIAN CHIEF SERVICE MANUAL ENGINE Crankcase Disassembly and Disassembly Assembly ® Mount the sprocket shaft holder, JIMS 1034, in a vise. Place the crankcase assembly, sprocket shaft down, in Tools required: the holder. 7/16" 12-point socket 1/2" 12-point socket Brass hammer Cam bearing tool, 97272-80-1 (available from ®...
Page 170 ENGINE INDIAN CHIEF SERVICE MANUAL ® With the case bolts removed, tap the case with a brass Install the crank disassembly/removing tool, JIMS hammer to separate the halves and lift the right case 1047-TP, on the left case half and tighten the mounting half (pinion side) off the assembly.
Page 171 INDIAN CHIEF SERVICE MANUAL ENGINE ® Cleaning and Inspection Apply a thin coating of Teﬂon thread dope to the drain plug and install the plug in the left case half, using a 5/16” hex bit. Tighten the plug to Clean the right and left case halves in a suitable 18 foot-pounds.
Page 172 ENGINE INDIAN CHIEF SERVICE MANUAL Assembly Install the outer bearing and spacer on the output shaft, using the sprocket shaft bearing installation tool ® set, JIMS 97225-55, and the mainshaft sprocket Inspect the ﬂywheel and crankshaft assembly to make ® locknut wrench, JIMS 94660-37A.
Page 173 INDIAN CHIEF SERVICE MANUAL ENGINE Lubricate and install the sprocket shaft spacer and Make sure that the connecting rods are centered in the position the seal in the case. The seal must be cylinder bores and place the right case half in position positioned with the rounded edge facing outward, on the pinion shaft.
Page 174: Primary Drive
PRIMARY DRIVE INDIAN CHIEF SERVICE MANUAL PRIMARY DRIVE SERVICE Primary Chain Inspection The primary drive chain should be inspected and the primary housing lubricant should be drained and reﬁlled at the ﬁrst 500-mile (800 km) service interval and thereafter, at the 5,000-mile (8 000 km) service interval.
Page 175: Primary Drive Removal, Installation And Adjustment
INDIAN CHIEF SERVICE MANUAL PRIMARY DRIVE Primary Drive Removal, Installation Using a 3/16” hex bit, remove the 15 screws around the perimeter of the outer primary drive housing. and Adjustment The primary chain, compensator and sprocket and clutch assembly and sprocket must be removed as an assembly.
Page 176 PRIMARY DRIVE INDIAN CHIEF SERVICE MANUAL Figure 341 — Chain tensioner assembly Loosen the chain tensioner nylock nut, using a 9/16” Slide the tensioner assembly down, to provide hex socket or wrench. maximum slack in the chain. Figure 342 — Removing chain tensioner nylock nut Figure 343 —...
Page 177 INDIAN CHIEF SERVICE MANUAL PRIMARY DRIVE Bend over the locking tabs from the two lower bolts. Working at the clutch end of the primary chain, remove Remove the two lower bolts, using a 7/16” wrench. the six clutch pressure plate retaining screws and Remove the upper nylock nut and washer.
Page 178 PRIMARY DRIVE INDIAN CHIEF SERVICE MANUAL Remove the clutch hub retaining nut, using a 1-3/16” Remove the starter motor drive pinion assembly from hex socket. the inner primary drive housing. Figure 348 — Remove clutch hub retaining nut Figure 350 — Removing starter motor drive pinion assembly Slide the clutch hub assembly, primary drive chain and engine sprocket off the engine crankshaft and...
Page 179 INDIAN CHIEF SERVICE MANUAL PRIMARY DRIVE Remove the inner primary drive housing from the Installation engine and transmission ﬂanges. Slide the housing bearing evenly off the transmission input shaft. Install a new O-ring in the groove on the engine-to- inner primary housing mounting ﬂange on the engine crankcase.
Page 180 PRIMARY DRIVE INDIAN CHIEF SERVICE MANUAL Tighten the six inner screws to speciﬁcation, using a Slide the large spacer for the engine compensator 1/2” hex socket. To prevent the screws from backing sprocket onto the splines of the crankshaft and next to out, bend the tabs of the lock washers back over a ﬂat the alternator rotor.
Page 181 INDIAN CHIEF SERVICE MANUAL PRIMARY DRIVE Install the clutch pressure plate onto the clutch hub and sprocket assembly. Correct application of threadlock to the compensator retaining nut must be achieved. Applying excessive Note: If the clutch friction and steel discs have been threadlock can cause an incorrect torque reading and removed, refer to the CLUTCH SERVICE section for cause severe binding of the nut on the sprocket shaft.
Page 182 PRIMARY DRIVE INDIAN CHIEF SERVICE MANUAL Loosely tighten the two lower bolts into the chain Loosen the chain adjuster nylock nut and adjust the tensioner. Loosely install the nylock nut and washer chain adjustment shoe up or down to achieve the onto the carriage bolt.
Page 183: Engine And Transmission Alignment
INDIAN CHIEF SERVICE MANUAL PRIMARY DRIVE Position the outer housing to the inner housing and Remove the three inspection cover screws, inspection install the 15 screws with washers. Apply blue cover and gasket. Fill the primary drive housing threadlock to the ﬁrst four threads of the housing through the inspection cover opening, using the screws before installation.
Page 184 PRIMARY DRIVE INDIAN CHIEF SERVICE MANUAL • If needed, add shims to the transmission ﬁfth nut (17). • P/N: 97-001, .015” transmission shim • P/N: 97-002, .030” transmission shim • P/N: 97-003, .040” transmission shim • Torque transmission ﬁfth nut (17) to 33 foot pounds. •...
Page 185: Rear Drive
INDIAN CHIEF SERVICE MANUAL REAR DRIVE REAR DRIVE SERVICE Rear Drive Belt Inspection, To access the rear drive belt, remove the primary drive components, starter motor and other necessary Removal and Installation components. Inspection The rear drive belt should be inspected and adjusted if necessary, at the ﬁrst 500-mile (800 km) service interval and thereafter, at the 2,500-mile (4 000 km) service interval.
Page 186: Rear Wheel Alignment And Drive Belt Tension Adjustment
REAR DRIVE INDIAN CHIEF SERVICE MANUAL Installation Slip the rear drive belt over the wheel sprocket. Slip the rear drive belt over the transmission sprocket. Align the cogs in the belt with the cogs in the sprocket. Figure 372 — Installing rear drive belt over wheel sprocket When reassembled, adjust the rear wheel alignment and rear drive belt tension and deﬂection.
Page 187 INDIAN CHIEF SERVICE MANUAL REAR DRIVE Rear Wheel Alignment Measure the center-to-center distance between the swing arm pivot bolt and the axle, using the alignment tool. The rear wheel must be correctly aligned before belt tension is adjusted. Remove the plastic thread protectors from the right-hand and left-hand axle adjusting studs.
Page 188 REAR DRIVE INDIAN CHIEF SERVICE MANUAL If adjustment is required, loosen or tighten the axle adjusting nuts on both sides equally, using a 1/2” In severe cases of excessive drive belt travel or force, wrench. This adjusts rear drive belt tension, while at the belt can completely ride off the sprocket.
Page 189: Drive Belt Handling And Storage
INDIAN CHIEF SERVICE MANUAL REAR DRIVE Drive Belt Handling and Storage Similarly, DO NOT bend the belt backward (teeth spreading) in a circle any smaller than 10” in diameter. The rear drive belt is extremely durable when handled and installed properly. Damage can occur, however, if the incorrect tools are used to remove and install a belt or it is stored improperly.
Page 190: Clutch
CLUTCH INDIAN CHIEF SERVICE MANUAL CLUTCH SERVICE The Indian Chief motorcycle is equipped with a wet- type clutch that is controlled by a hand lever (on left handlebar) and cable. The clutch assembly incorporates 9 steel discs sandwiched between 10 friction discs keyed to the rear drive sprocket.
Page 191: Clutch Inspection And Adjustment
INDIAN CHIEF SERVICE MANUAL CLUTCH Clutch Lever Bracket Removal and Adjustment Procedure Installation Raise the motorcycle to a comfortable working height, using a lift. The clutch lever bracket, clutch cable and mirror can easily be removed from the handlebar as an assembly. Place a drain pan under the primary drive housing under the drain plug.
Page 192 CLUTCH INDIAN CHIEF SERVICE MANUAL Loosen the cable adjustment jam nut, using a 7/16” Grasp the cable end ferrule and pull it away from the wrench on the jam nut while holding the cable ferrule clutch lever bracket. At the same time, turn the cable nut with a 1/2”...
Page 193: Clutch Plate Removal And Installation
INDIAN CHIEF SERVICE MANUAL CLUTCH Using a 3/16” hex bit, remove the chain adjuster access Removal cover from the outer primary housing and discard the gasket. Raise the motorcycle to a comfortable working height, using a lift. To remove the complete clutch assembly (clutch pack, hub and sprocket case), refer to the PRIMARY DRIVE SERVICE section for instructions.
Page 194 CLUTCH INDIAN CHIEF SERVICE MANUAL Remove the pressure plate. Remove the judder spring and judder spring seat. Figure 391 — Removing pressure plate Figure 393 — Judder spring and seat Remove the 10 friction and 9 steel discs from the clutch Clean and inspect the discs, springs and pressure plate hub and sprocket case.
Page 195 INDIAN CHIEF SERVICE MANUAL CLUTCH Install the 10 friction discs and 9 steel discs, alternately, Place the pressure plate in position on the clutch hub. If on the hub. not already done, loosen the clutch adjuster jam nut and back out or remove the adjusting screw. Install the friction spacer disc (2) ﬁrst.
Page 196: Clutch Disassembly And Assembly
CLUTCH INDIAN CHIEF SERVICE MANUAL Apply blue threadlock to the ﬁve clutch cover screws. Clutch Disassembly and Assembly Place a new gasket in position on the clutch cover and install the cover. Tighten the cover screws to If the complete clutch assembly (clutch pack, hub and speciﬁcation, using a 3/16”...
Page 197 INDIAN CHIEF SERVICE MANUAL CLUTCH Inspect the sprocket case for wear in the friction disc tab slots. Deep notches can prevent the discs from DO NOT remove the spiral lock ring and washer separating properly when releasing the clutch. Replace from the inside bore of the hub.
Page 198 CLUTCH INDIAN CHIEF SERVICE MANUAL Figure 403 — Clutch assembly...
Page 199: Transmission
INDIAN CHIEF SERVICE MANUAL TRANSMISSION TRANSMISSION MAINTENANCE Transmission Shift Control Linkage Loosen the shift lever pinch bolt, using a 1/4” hex bit. Push the shift lever inward to create clearance between Maintenance and Adjustment the inner primary housing and pivot bolt head. If this does not provide the necessary clearance, remove the Frequent lubrication of the shift rod pivots decreases shift lever and index it one spline counterclockwise.
Page 200 TRANSMISSION INDIAN CHIEF SERVICE MANUAL Remove the rear pivot bolt, using a 3/16” hex bit. Note: It may be necessary to loosen the jam nut and adjust the shift rod length at the rear pivot to maintain adequate thread engagement at both socket ends. Install the front pivot bolt and check the operation of the foot control through the shift points.
Page 201: Transmission Oil Change
INDIAN CHIEF SERVICE MANUAL TRANSMISSION If adjustment is needed, loosen the locknut, using a The ﬁll plug dipstick is located at the front on the 17 mm box-end wrench. chrome right-side housing cover. The magnetic drain plug is also located on the right side of the transmission, in the trapdoor just below the housing cover.
Page 202 TRANSMISSION INDIAN CHIEF SERVICE MANUAL If equipped, install the exhaust pipe-to-transmission Check the oil level on the dipstick. The level should be bracket and fasteners, using a 1/2” wrench and a 1/4” between the two notches on the dipstick. hex bit. Remove the ﬁll plug and ﬁll the transmission with ®...
Page 203: Transmission Removal And Installation
INDIAN CHIEF SERVICE MANUAL TRANSMISSION TRANSMISSION REMOVAL AND INSTALLATION When it is necessary, the transmission can be removed • If the transmission oil has been drained, remove from the chassis for overhaul or replacement. chrome clutch-control cover and secure it out-of-way.
Page 204 TRANSMISSION INDIAN CHIEF SERVICE MANUAL Remove the shift rod rear pivot bolt, using a 3/16” hex Remove the starter motor. Refer to the STARTING bit. SYSTEM SERVICE section for the removal procedure. Figure 417 — Removing shift rod pivot bolt Figure 419 —...
Page 205: Transmission Installation
INDIAN CHIEF SERVICE MANUAL TRANSMISSION Loosen the axle adjusting nuts at the ends of the swing Lift the transmission up from the mounting pad and arm, using a 1/2” wrench. The nuts should be loosened remove it from the motorcycle. in equal increments.
Page 206 TRANSMISSION INDIAN CHIEF SERVICE MANUAL Place the transmission in position on the mounting Install the inner primary housing and primary drive pad, making sure the mounting studs are aligned with assembly following the procedure in the PRIMARY the holes and all shims are in place. DRIVE SERVICE section.
Page 207 INDIAN CHIEF SERVICE MANUAL TRANSMISSION Install the fairings at each side of the rear swing arm stanchion, using a 5/32” hex bit. Install the left fairing ﬁrst, then the right. Figure 429 — Installing fairings Lower the motorcycle to the ground and remove the lift.
Page 208: Transmission Overhaul
TRANSMISSION INDIAN CHIEF SERVICE MANUAL TRANSMISSION OVERHAUL Tools required: 3/16" hex bit socket 1/4" hex bit 5 mm hex bit socket ® 1-7/8" socket available from JIMS 1-1/16" socket Internal retaining ring pliers External retaining ring pliers Arbor or hydraulic press ®...
Page 209 INDIAN CHIEF SERVICE MANUAL TRANSMISSION Remove the shift drum cover from the top of the Pull the shift pawl away from the pins in the shift transmission, using a 3/16” hex bit socket. drum. Lift the shift drum and end supports from the transmission housing.
Page 210 TRANSMISSION INDIAN CHIEF SERVICE MANUAL Remove the drive sprocket nut using a 1-7/8” Loosen the nuts on the end of the mainshaft and ® Mainshaft Sprocket Locknut Wrench from JIMS countershaft, using a 1-1/16” socket. Do not remove pneumatic gun. The sprocket nut has left-hand threads, the nuts at this time.
Page 211 INDIAN CHIEF SERVICE MANUAL TRANSMISSION Remove the mainshaft and countershaft with all the Remove the sprocket spacer from the splined gear (5th gears by pulling on the trapdoor. If the trapdoor is gear or main gear) protruding from the left side of ®...
Page 212 TRANSMISSION INDIAN CHIEF SERVICE MANUAL ® Remove the main bearing using a JIMS 5-Speed Main Bearing Remover or press. The bearing must be replaced after using this tool. Figure 444 — Removing main drive gear Main Gear (5th Gear) Roller Bearing Figure 446 —...
Page 213 INDIAN CHIEF SERVICE MANUAL TRANSMISSION ® The JIMS tool will set the seal to the correct depth. Figure 448 — Pressing in main bearing Install a new retaining ring with the sharp edge facing Figure 450 — Installing new main seal out, toward the main seal.
Page 214 TRANSMISSION INDIAN CHIEF SERVICE MANUAL Main Gear (5th Gear) Needle Bearing Place the trapdoor on the bench with the shafts pointing upward. Place the mainshaft on the left side Inspection and Replacement just as it came from the transmission. Inspect both main gear (5th gear) needle bearings for pitting or grooving of the needles.
Page 215 INDIAN CHIEF SERVICE MANUAL TRANSMISSION Slip 2nd gear and thrust washer from the countershaft Remove the 3rd gear retaining ring. and inspect each for damage. Figure 457 — Removing the 3rd gear retaining ring Remove the 3rd gear from the countershaft and inspect for damage.
Page 216 TRANSMISSION INDIAN CHIEF SERVICE MANUAL Slip 2nd gear from the mainshaft and inspect for Gently pry the split cage roller bearing from the damage. mainshaft and inspect the needles for pitting or grooving. Figure 459 — Removing 2nd gear from mainshaft Remove the 3rd gear retaining ring and then, remove the thrust washer from the mainshaft.
Page 217 INDIAN CHIEF SERVICE MANUAL TRANSMISSION Press the mainshaft from the trapdoor bearing, using Gently pry the split cage roller bearing from the ® JIMS Transmission Cover Bearing Remover and mainshaft and inspect the needles for pitting or Installer. Make sure to catch the shaft and gears as they grooving.
Page 218 TRANSMISSION INDIAN CHIEF SERVICE MANUAL Make sure the bearings are fully seated. Place a retaining ring onto the mainshaft capturing 1st gear, using snap ring pliers. Install new retaining rings with the sharp edges toward the bearing. Shaft Assembly Coat each of the parts with transmission oil before installation.
Page 219 INDIAN CHIEF SERVICE MANUAL TRANSMISSION Countershaft Slip 1st gear onto the countershaft with engagement dogs ﬁrst. Figure 474 — Countershaft {trapdoor end to right} Slip a thrust washer onto the countershaft from the trapdoor side of the shaft. Figure 477 — Installing 1st gear onto countershaft Slip 4th gear onto the countershaft with spacer side ﬁrst.
Page 220: Installation Of Shafts Into Trapdoor
TRANSMISSION INDIAN CHIEF SERVICE MANUAL Installation of Shafts into Trapdoor Figure 481 — Stepped spacer and spacer without step Slip the mainshaft into the tapered spacer (with step) Mainshaft through the left side trapdoor bearing. Place the countershaft tapered spacer (without step) Orient the trapdoor on the bench with the alignment onto the right trapdoor bearing.
Page 221 INDIAN CHIEF SERVICE MANUAL TRANSMISSION Gear Stacking Slip 3rd gear onto the mainshaft with the engagement dogs facing upward (away from trapdoor). Slip another thrust washer onto the mainshaft followed by Place the trapdoor on the bench with the shafts facing a retaining ring.
Page 222 TRANSMISSION INDIAN CHIEF SERVICE MANUAL Countershaft Slip a new split cage roller bearing onto the countershaft. Slip 3rd gear onto the countershaft with the shift fork groove facing away from the trapdoor. Figure 489 — Installing split bearing onto countershaft Slip 2nd gear onto the countershaft with engagement Figure 487 —...
Page 223 INDIAN CHIEF SERVICE MANUAL TRANSMISSION Slip 5th gear onto the countershaft followed by a With the shafts facing upward, lower the transmission retaining ring. case over the shafts. Align the mainshaft with the main gear and the countershaft with the needle bearing. Align 5th gear of the mainshaft to 5th gear of the countershaft.
Page 224 TRANSMISSION INDIAN CHIEF SERVICE MANUAL Place a new square-cut seal onto the main drive gear (transmission output). Figure 497 — Installing spacer onto main drive gear Figure 494 — Square-cut seal Grease a new main drive gear seal on the inside and outside diameter.
Page 225 INDIAN CHIEF SERVICE MANUAL TRANSMISSION Slip the driver over the guide and seat the seal, using a Tap the driver with a mallet until the seal is fully ® hammer. The tool is designed to set the seal to a depth seated.
Page 226: Shift Fork Inspection And Installation
TRANSMISSION INDIAN CHIEF SERVICE MANUAL Shift Fork Inspection and Orient the transmission with the trapdoor to the left. Load all forks with the pin facing you. Loading Installation sequence is from left to right. Load the 4th gear fork onto the groove in 1st gear of the Inspection mainshaft.
Page 227 INDIAN CHIEF SERVICE MANUAL TRANSMISSION Align the shift fork pins to the grooves in the shift Slip the A.N. ﬂat washers onto the four 1/4” hex head drum. To move the forks and gears you may have to bolts. Apply blue threadlock to the bolts. Slip the bolts spin the mainshaft.
Page 228 TRANSMISSION INDIAN CHIEF SERVICE MANUAL If adjustment is needed, loosen the locknut, using a Clutch Cover Installation 17 mm socket or box end wrench. Replace the clutch cable O-ring with a new one. Thread the clutch cable into the clutch cover. Figure 510 —...
Page 229 INDIAN CHIEF SERVICE MANUAL TRANSMISSION Flip the ramp back over and place in the original Clean the threads of the sprocket nut and mating position within the housing. threads on the mainshaft with alcohol or brake cleaner. Apply red threadlock to the threads of the nut. Slide the rear drive belt sprocket onto the mainshaft.
Page 230: Starting System
STARTING SYSTEM INDIAN CHIEF SERVICE MANUAL STARTING SYSTEM SERVICE General Information Procedures for removal and installation of system components are included in this section. Procedures for testing the system are included under Electrical System The starting system includes the starter motor, the Tests in the TROUBLESHOOTING section.
Page 231: Starter Drive Pinion Assembly
INDIAN CHIEF SERVICE MANUAL STARTING SYSTEM Starter Drive Pinion Assembly Remove the 15 screws at the perimeter of the outer primary housing, using a 3/16” hex bit. Remove the outer housing half and discard the gasket. Tools required: 3/16 " hex bit 5/16 "...
Page 232: Starter Motor
STARTING SYSTEM INDIAN CHIEF SERVICE MANUAL Drive Pinion Installation Install a new gasket and install the outer primary housing and retaining screws, using a 3/16” hex bit. Tighten the screws to speciﬁcation. Place the drive pinion and shaft assembly (pinion, spring, coupling, snap ring and shaft) in the inner Apply blue threadlock to the shift rod screw.
Page 233 INDIAN CHIEF SERVICE MANUAL STARTING SYSTEM Disconnect the battery positive cable from the solenoid Starter Installation terminal, using a 12 mm socket. Disconnect the start switch wire lead at the solenoid terminal by Place the starter motor in position against the unplugging the spade terminal.
Page 234: Starter Solenoid
STARTING SYSTEM INDIAN CHIEF SERVICE MANUAL Starter Solenoid Tools required: 5/32 " hex bit Tools required: Small ﬂat-blade screwdriver 3/8 " wrench/socket Starter Relay Replacement 12 mm wrench/socket Remove the seat from the motorcycle following the Flat-blade screwdriver procedure in the FRAME AND ACCESSORIES SERVICE section.
Page 235: Charging System
INDIAN CHIEF SERVICE MANUAL CHARGING SYSTEM CHARGING SYSTEM SERVICE General Information Battery ﬂuid contains sulfuric acid. Do not allow this The charging system includes the alternator assembly, ﬂuid to come in contact with eyes, skin or clothing. In a transistorized voltage regulator, the battery and case it does, immediately ﬂush the area with water cables, an ignition switch to energize the system and all and seek medical attention if necessary.
Page 236: Alternator Replacement
CHARGING SYSTEM INDIAN CHIEF SERVICE MANUAL Disconnect and remove the battery hold-down strap Alternator Replacement from the battery box. Remove the battery from the motorcycle. Tools required: 5/32 " hex bit 3/16 " hex bit 5/16 " hex bit 9/16 " socket 3/4 "...
Page 237 INDIAN CHIEF SERVICE MANUAL CHARGING SYSTEM Remove the 15 screws at the perimeter of the outer Using a 1-1/2” socket, remove the compensator primary housing, using a 3/16” hex bit. Remove the retaining nut and remove the assembly from the outer housing half.
Page 238 CHARGING SYSTEM INDIAN CHIEF SERVICE MANUAL Using a 3/32” hex bit, loosen the set screw retaining Install the inner primary drive housing, the starter the connector in the engine crankcase. Push the stator motor and drive pinion and the primary drive chain, connector through the crankcase ﬂange and remove the sprockets and tensioner.
Page 239: Voltage Regulator Replacement
INDIAN CHIEF SERVICE MANUAL CHARGING SYSTEM Voltage Regulator Replacement Disconnect the regulator battery wire leads at the connector under the frame crossmember at the front engine mount. The regulator is a non-serviceable part. If it is faulty, it must be removed and replaced. Using a 7/16”...
Page 240: Chassis Electrical
CHASSIS ELECTRICAL INDIAN CHIEF SERVICE MANUAL POWER DISTRIBUTION, LIGHTING AND INSTRUMENT SERVICE Electrical Equipment Check Toggle the Engine Stop switch to the RUN position. Make sure the green transmission neutral light is on. Pull the clutch lever in and quickly depress the START The ignition key switch controls the ignition and lights button.
Page 241: Speedometer And Warning Light Replacement
INDIAN CHIEF SERVICE MANUAL CHASSIS ELECTRICAL The four circuit breakers that are an integral part of the Dash Removal electronic control module are not replaceable. If there is a fault in any one of the four, there is a problem with To gain access to the speedometer and warning lights, the control module, and the module must be replaced the dash panel must be removed.
Page 242: Road Light Replacement
CHASSIS ELECTRICAL INDIAN CHIEF SERVICE MANUAL Speedometer Handlebar Switch Replacement To remove the speedometer assembly, place the dash The following procedure covers the replacement of an panel upside down on the pad. Remove the two nuts individual switch in one of the switch housings as well retaining the assembly in the instrument bezel, using a as the replacement of a complete switch and harness 9 mm wrench.
Page 243 INDIAN CHIEF SERVICE MANUAL CHASSIS ELECTRICAL Remove the throttle/switch housing screws, using a Again, check for proper throttle rotation. 5/32” hex bit. Slowly remove the top housing half and Apply blue threadlock to the two master cylinder and then remove the small ferrules to disconnect the brake lever assembly clamp screws.
Page 244 CHASSIS ELECTRICAL INDIAN CHIEF SERVICE MANUAL Match the wires from the switch to the proper harness Cut the nylon tie strap, release the tabs and lift the wire ends. Twist the wires together and solder the joint, electronic control module from its housing. using rosin core solder.
Page 245 INDIAN CHIEF SERVICE MANUAL CHASSIS ELECTRICAL Remove the handlebar clamp cover screws, using a When the harness terminal ends clear the opening at 3/16” hex bit, and remove the cover. the handlebar grip, disconnect and remove the harness from the cable. Leave the cable in the handlebar for installation of the harness.
Page 246: Circuit Wiring Repair
CHASSIS ELECTRICAL INDIAN CHIEF SERVICE MANUAL Installing the Right Handlebar Switches Carefully place the top housing section onto the bottom section. Install the two mounting screws and Install the switches (start, engine stop, turn signal and tighten very lightly. Align the switch housing so that brake light) in the respective housing sockets and the parting line is parallel with the ground and tighten install the retaining brackets, using a Phillips...
Page 247: Specifications
INDIAN CHIEF SERVICE MANUAL SPECIFICATIONS CHASSIS SPECIFICATIONS & TORQUE VALUES Brakes GENERAL DATA Item Description/Speciﬁcation Brake pad Ferodo, P/N 50-061 (front) Ferodo, P/N 50-062 (rear) Brake pad thickness 0.205–0.215 in. (new) 0.062 in. (worn, minimum) Brake rotor Minimum allowed thickness (0.180 in.) FASTENER TORQUE Part Torque Value...
Page 248: Front Fork And Suspension
SPECIFICATIONS INDIAN CHIEF SERVICE MANUAL FASTENER TORQUE Part Torque Value Axle retaining nut 50–55 ft-lbs (front) 60–65 ft-lbs (rear) Rear axle adjuster nuts 50-60 in-lbs Rear wheel sprocket mounting bolts 65 ft-lbs Front Fork and Suspension Torque Values FASTENER TORQUE Torque Value Part Paioli...
Page 249: Frame And Accessories
INDIAN CHIEF SERVICE MANUAL SPECIFICATIONS Frame and Accessories Torque Values FASTENER TORQUE Part Torque Values Bezel-to-dash screws 40 in-lbs Buddy pegs 78 ft-lbs Center fairing screws 6–9 in-lbs Clutch cable guide screw 22 in-lbs Clutch cable guide-to-frame 7-9 ft-lbs Dash panel mounting screw (front & rear) 5 ft-lbs Floorboard retaining nut 22 in-lbs...
Page 250: Engine Specifications & Torque Values
SPECIFICATIONS INDIAN CHIEF SERVICE MANUAL ENGINE SPECIFICATIONS General GENERAL DATA Item Description/Speciﬁcation Engine type 4-cycle, 45-degree V Number of cylinders Bore and stroke 3.875 in. x 4.25 in. Displacement 100 cu-in Compression ratio Pre #1800 engine Post #1800 Engine 9.5:1 9.2:1 Horsepower 67 bhp at 4750 rpm...
Page 251 INDIAN CHIEF SERVICE MANUAL SPECIFICATIONS Cylinder Head and Valves Item Standard Fit Wear Limits Cylinder head displacement range • Pre #1800 engine 82–83 cc — • Post #1800 engine 86–87 cc — Cylinder head ﬂatness (gasket surface) 0.003 in. 0.005 in. Valve guide-to-cylinder head (press ﬁt) 0.0028–0.0018 in.
Page 252 SPECIFICATIONS INDIAN CHIEF SERVICE MANUAL Oil Pump Assembly Item Description/Speciﬁcation Oil pressure (at normal operating temperature and 2000 rpm) 12–35 psi Crankcase Item Standard Fit Wear Limits Breather valve gear end play 0.008–0.032 in. Exceeds 0.037 in. Camshaft bearing race-to-crankcase (press ﬁt) 0.0005–0.0010 in.
Page 253: Fastener Torque Values
INDIAN CHIEF SERVICE MANUAL SPECIFICATIONS Engine Fastener Torque Values Part Torque Value Air ﬁlter front plate screws 19–24 in-lbs Air ﬁlter back plate screws 19–24 in-lbs Airbox-to-bracket nuts 17–19 ft-lbs Airbox evaporator door retaining screws (to shaft) 17–19 ft-lbs Airbox housing cover retaining screws 19–24 in-lbs Airbox housing retaining nuts 5 ft-lbs...
Page 254 SPECIFICATIONS INDIAN CHIEF SERVICE MANUAL Part Torque Value Pinion gear nut 40 ft-lbs Pinion shaft nut 170 ft-lbs Plug (in rocker cover) 8–12 ft-lbs Rocker base mounting screws 8–12 ft-lbs Rocker shaft support bracket screws 16–20 ft-lbs Spark plugs 18 ft-lbs Sprocket shaft nut 320 ft-lbs Stator mounting screws...
Page 255: Drivetrain Specifications & Torque Values
INDIAN CHIEF SERVICE MANUAL SPECIFICATIONS DRIVETRAIN SPECIFICATIONS & TORQUE VALUES Primary, Clutch and Final Drive GENERAL DATA Item Description/Speciﬁcation Primary drive Chain drive with a wet clutch; 1.54:1 ratio Engine sprocket 24 teeth Clutch sprocket 37 teeth Chain slack 9/16˝-5/8˝ Final drive Belt drive;...
Page 256: Transmission
SPECIFICATIONS INDIAN CHIEF SERVICE MANUAL Transmission Speciﬁcations & Torque Values GENERAL DATA Reference Mainshaft Countershaft Ratio 1st gear 18 teeth 31 teeth 3.24:1 2nd gear 23 teeth 27 teeth 2.21:1 3rd gear 27 teeth 23 teeth 1.60:1 4th gear 19 teeth 29 teeth 1.23:1 5th gear...
Page 257: Electrical Component Fastener Specifications & Torque Values
INDIAN CHIEF SERVICE MANUAL SPECIFICATIONS ELECTRICAL COMPONENT FASTENER SPECIFICATIONS FASTENER TORQUE Item Torque Value Battery box bracket screws 17–19 ft-lbs Battery box screws 17–19 ft-lbs Battery terminal screws 60 in-lbs Circuit breaker stud nut 18–20 in-lbs Coil/cover mounting screws 12–14 ft-lbs Coil harness to coil nuts 15 in-lbs Ground cable terminal screw (to frame)
Page 258: Lubricants And Sealants
SPECIFICATIONS INDIAN CHIEF SERVICE MANUAL LUBRICANTS AND SEALANTS Engine Assembly Part Speciﬁed Lubricant or Sealant Breather valve housing assembly screw threads Blue threadlock Camshaft cover screw threads Blue threadlock Crank pin threads Red threadlock Crankcase bolt threads Blue threadlock ® Crankcase drain plug threads Teﬂon pipe dope...
Page 259 INDIAN CHIEF SERVICE MANUAL SPECIFICATIONS Part Speciﬁed Lubricant or Sealant Engine upper mounting bracket screw threads (to engine) Blue threadlock Evaporator door shaft link retaining screw threads Blue threadlock Floorboard screws Bllue threadlock Fork cover screw threads Blue threadlock Front end alignment bolt threads Blue threadlock Front end alignment screw threads Blue threadlock...
Page 260: Schematics
SCHEMATICS INDIAN CHIEF SERVICE MANUAL CHASSIS WIRING DIAGRAMS Figure 1 — Front chassis harness diagram...
Page 261 INDIAN CHIEF SERVICE MANUAL SCHEMATICS Figure 2 — Rear chassis harness diagram...
Page 262 SCHEMATICS INDIAN CHIEF SERVICE MANUAL IGNITION SYSTEM DIAGRAM Figure 3 — POWERPLUS™ 100 engine ignition system...
Page 263: Ignition System Diagram
INDIAN CHIEF SERVICE MANUAL SCHEMATICS LUBRICATION FLOW DIAGRAM Figure 4 — POWERPLUS™ 100 engine lubrication system ™ In the POWERPLUS 100 engine lubrication system, From the breather valve, the oil is sprayed into the cam the pump draws oil from the tank and supplies the oil gearcase to lubricate the cam and pinion gears.
Page 264: Transmission Power Flow Diagrams
SCHEMATICS INDIAN CHIEF SERVICE MANUAL TRANSMISSION POWER FLOW DIAGRAMS Indian 5-Speed Transmission The 5-speed is a single-countershaft transmission with an output drive gear that rotates freely on the mainshaft input. Both the mainshaft and countershaft incorporate free-rotating gears that are engaged or disengaged by sliding gears splined to the shafts.
Page 265 INDIAN CHIEF SERVICE MANUAL SCHEMATICS 3rd gear — In 3rd gear, the countershaft sliding 3rd 5th gear — On the mainshaft, the sliding 1st gear is gear is disengaged from other countershaft gears. disengaged from the 4th gear and the sliding 2nd gear However, on the mainshaft, the sliding 2nd gear is is moved into engagement with the output drive gear moved into engagement with the 3rd gear, allowing...
Page 266 NOTES: INDIAN CHIEF SERVICE MANUAL...
Page 267: Assembly Drawings
INDIAN CHIEF SERVICE MANUAL ASSEMBLY DRAWINGS ENGINE PART AND ASSEMBLY DRAWINGS Figure 546 — Intake manifold Item Part Number Part Description Qty. 01-396 Intake manifold 01-212 Flange, intake 01-213 D-ring, intake 96-142 Screw, socket head, 5/16”-18 x 7/8” 01-217 Mounting ﬂange 96-822 Bolt, hex head, 5/16”-18 x 1-1/4”...
Page 268 ASSEMBLY DRAWINGS INDIAN CHIEF SERVICE MANUAL Figure 547 — Intake manifold Item Part Number Part Description Qty. 02-284 Nut, 1/4”-20, 12 pt...
Page 269 INDIAN CHIEF SERVICE MANUAL ASSEMBLY DRAWINGS Figure 548 — Crankcase Item Part Number Part Description Qty. 01-001 Engine case Race, right case 01-017 Plug, case drain 29-101 Hose ﬁtting, 90˚ 01-189 Oil ﬁlter bung 01-106 Bearing cam, inner 01-060 Dowel pin, 1/4” x 3/4” 01-161 Dowel pin, hollow 01-010...
Page 270 ASSEMBLY DRAWINGS INDIAN CHIEF SERVICE MANUAL Item Part Number Part Description Qty. 01-282 Bolt, 1/4”-28 x 5.38” 01-285 Bolt, 5/16”-24 x 5.07” 01-283 Nut, 5/16”-24 96-894 Washer, ﬂat 1/4” 96-394 Nut, 1/4”-28 01-090 Switch, oil pressure 01-085 Screen, tappet 01-086 Spring, tappet screen 01-087 Plug, tappet spring...
Page 271 INDIAN CHIEF SERVICE MANUAL ASSEMBLY DRAWINGS Figure 549 — Crankcase Item Part Number Part Description Qty. 01-003 Cylinder stud, 3/8”-16 x 6” 94-033 Rotor, alternator 94-035 Stator, alternator 96-965 Screw, socket head, 10-24 x 1”...
Page 272 ASSEMBLY DRAWINGS INDIAN CHIEF SERVICE MANUAL Figure 550 — Crankcase Item Part Number Part Description Qty. 29-101 Hose ﬁtting, 90˚ 01-280 Bolt, 5/16”-24 x 5.63” 01-282 Bolt, 1/4”-28 x 5.38” 01-285 Bolt, 5/16”-24 x 5.07”...
Page 273 INDIAN CHIEF SERVICE MANUAL ASSEMBLY DRAWINGS Figure 551 — Flywheel assembly Item Part Number Part Description Qty. 01-030 Flywheel set 01-031 Shaft, left side (output) 01-033 Nut, sprocket shaft 01-034 Nut, pinion shaft 01-035 Key, right shaft and crank pin 01-036 Key, shaft (left ﬂywheel) 01-912...
Page 274 ASSEMBLY DRAWINGS INDIAN CHIEF SERVICE MANUAL Figure 552 — Camshaft gearcase cover Item Part Number Part Description Qty. 01-252 Gasket, cam cover 97-121 Screw, socket head, 1/4”-20 x 3/4” 97-120 Screw, socket head, 1/4”-20 x 1-1/4” 01-254 Gasket, ignition cover 00-033 Ignition rotor 96-290...
Page 275 INDIAN CHIEF SERVICE MANUAL ASSEMBLY DRAWINGS Figure 553 — Camshaft and breather valve Item Part Number Part Description Qty. 01-081 Key, gear case 01-048 Gear, oil pump 01-049 Spacer, oil pump drive gear 01-068 Gear, pinion (red) 01-064 Nut, pinion gear 01-097-01 Cam shim (.050˝) 01-097-02...
Page 276 ASSEMBLY DRAWINGS INDIAN CHIEF SERVICE MANUAL Figure 554 — Camshaft gearcase cover Item Part Number Part Description Qty. 01-905 Base assembly, cam cover 01-134 Cam cover, outer 01-251 Seal, cam cover 01-056 Form ring, bottom 01-057 Form ring, middle 01-058 Form ring, top 01-141 Dowel pin, inner, 1/4”...
Page 277 INDIAN CHIEF SERVICE MANUAL ASSEMBLY DRAWINGS Figure 555 — Oil pump Item Part Number Part Description Qty. 01-262 Gasket, oil pump 29-101 Hose ﬁtting, 90˚ 96-879 Screw, socket head, 1/4”-20 x 1-3/4” 96-828 Elbow, barbed hose...
Page 278 ASSEMBLY DRAWINGS INDIAN CHIEF SERVICE MANUAL Figure 556 — Oil pump and ﬁlter mounting Item Part Number Part Description Qty. 96-021 Oil ﬁlter...
Page 279 INDIAN CHIEF SERVICE MANUAL ASSEMBLY DRAWINGS Figure 557 — Front lifter block assembly Item Part Number Part Description Qty. 01-926 Lifter block, front 01-179 Gasket, lifter block (front) 01-180 Lifter 96-013 Screw, socket head, 1/4”-20 x 7/8” 01-167 Pushrod cover assembly 01-191 Clip, pushrod cover...
Page 280 ASSEMBLY DRAWINGS INDIAN CHIEF SERVICE MANUAL Figure 558 — Rear lifter block assembly Item Part Number Part Description Qty. 01-925 Lifter block, rear 01-178 Gasket, lifter block (rear) 01-180 Lifter 96-013 Screw, socket head, 1/4”-20 x 7/8” 01-167 Pushrod cover assembly...
Page 281 INDIAN CHIEF SERVICE MANUAL ASSEMBLY DRAWINGS Figure 559 — Front cylinder head assembly Item Part Number Part Description Qty. 01-236 Front head assembly 01-145 Intake valve, 1.940” 01-150 Exhaust valve, 1.610” 01-165 Stud, exhaust port 01-256 Gasket, head 01-261 Valve seal 01-160 Valve spring set 05-002...
Page 282 ASSEMBLY DRAWINGS INDIAN CHIEF SERVICE MANUAL Figure 560 — Rear cylinder head assembly Item Part Number Part Description Qty. 01-237 Rear head, assembly 01-150 Exhaust valve, 1.610” 01-165 Stud, exhaust port 01-256 Gasket, head 01-160 Valve spring set 05-002 Spark plug 01-159 Keepers...
Page 283 INDIAN CHIEF SERVICE MANUAL ASSEMBLY DRAWINGS Figure 561 — Cylinder head installation Item Part Number Part Description Qty. 01-170 Head bolt, long 01-171 Head bolt, short...
Page 284 ASSEMBLY DRAWINGS INDIAN CHIEF SERVICE MANUAL Figure 562 — Front cylinder rocker assembly Item Part Number Part Description Qty. 01-257 Gasket, lower right 01-258 Gasket, lower left 01-260 O-ring, small 96-296 Screw, socket head, 1/4”-20 x 7/8” 96-297 Screw, socket head, 5/16” x 18 x 1-3/4” 01-259 O-ring, large 97-121...
Page 285 INDIAN CHIEF SERVICE MANUAL ASSEMBLY DRAWINGS Figure 563 — Rear cylinder rocker assembly Item Part Number Part Description Qty. 01-257 Gasket, lower right 01-258 Gasket, lower left 01-260 O-ring, small 96-296 Screw, socket head, 1/4”-20 x 7/8” 96-297 Screw, socket head, 5/16”-18 x 1-3/4” 01-259 O-ring, large 97-121...
Page 286 ASSEMBLY DRAWINGS INDIAN CHIEF SERVICE MANUAL Figure 564 — Rocker shafts Item Part Number Part Description Qty. 01-151 Rocker arm assembly (front cylinder exhaust, rear cylinder intake) 01-152 Rocker arm assembly (front cylinder intake, rear cylinder exhaust) 96-298 Screw, socket head, 5/16”-18 x 2” 96-297 Screw, socket head, 5/16”-18 x 1-3/4”...
Page 287 INDIAN CHIEF SERVICE MANUAL ASSEMBLY DRAWINGS Figure 565 — Rocker covers Item Part Number Part Description Qty. 01-290 Gasket, breather housing 01-321 Seal, O-ring 01-325 Plug, stainless 01-318 Valve umbrella 96-965 Screw, socket head, 10-24 x 1”...
Page 288 ASSEMBLY DRAWINGS INDIAN CHIEF SERVICE MANUAL Figure 566 — Engine assembly...
Page 289: Tools And Equipment
INDIAN CHIEF SERVICE MANUAL TOOLS AND EQUIPMENT SPECIAL TOOLS ® JIMS Tool No. Description (unless speciﬁed otherwise) Cam bearing tool (use with 33416-80-1) 97272-60 Cam cover puller (Fabricate locally) Crank disassembly removing tool 1047-TP Engine stand 1006T Flywheel rebuilding jig 1071 (Rowe HD 09-1194) Ignition diagnostic kit with software and cable IMC No.
Page 290: Tool Drawings
TOOLS AND EQUIPMENT INDIAN CHIEF SERVICE MANUAL ® JIMS Tool No. Description (unless speciﬁed otherwise) Valve spring tester 1090 Tool Drawings The following drawings provide dimensions for ® fabricating a cam cover puller and modifying JIMS piston lock ring tools. Figure 567 —...
Page 291 INDIAN CHIEF SERVICE MANUAL TOOLS AND EQUIPMENT ® Figure 568 — Modiﬁcation to JIMS piston lock ring tools 96780-58A-2 and 96781-72-2...
Page 292 NOTES: INDIAN CHIEF SERVICE MANUAL...
Page 293 ACCELERATOR PUMP ..... 108 CHARGING SYSTEM SERVICE ....225 ACCELERATOR PUMP NOZZLE .
Page 294 ELECTRICAL COMPONENT FASTENER FORK TUBE REMOVAL ..... . 33 SPECIFICATIONS ..... . 247 FRAME AND ACCESSORIES .
Page 295 IGNITION COVER HOUSING/ROTOR REMOVAL MIRROR ASSEMBLY REMOVAL, INSTALLATION AND INSTALLATION ....118 AND ADJUSTMENT ..... . 92 IGNITION COVER HOUSING/ROTOR REMOVAL MOTORCYCLE IDENTIFICATION .
Page 296 REMOVAL AND INSTALLATION ....229 SPROCKET INSTALLATION ....219 REMOVING CHASSIS COMPONENTS AND STARTER CURRENT-DRAW TEST .
Page 297 TRANSMISSION MAINTENANCE ... . . 189 TRANSMISSION OIL CHANGE ....191 TRANSMISSION OVERHAUL ....198 TRANSMISSION POWER FLOW DIAGRAMS .

This manual is also suitable for:

Deluxe 2003 Springfield 2003 Roadmaster 2003

Indian Motorcycle Chief 2003 Service Manual

Maintenance

Troubleshooting

Front Suspension

Steering Components

Rear Suspension

Wheels and Tires

Brake System

Frame and Accessories

Air Cleaner

Fuel System

Ignition System

Lubrication System

Emission Control System

Exhaust System

Engine

Primary Drive

Rear Drive

Clutch

Transmission

Starting System

Charging System

Chassis Electrical

Specifications

Schematics

Assembly Drawings

Tools and Equipment

Quick Links

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for Indian Motorcycle Chief 2003